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Wa r e h o u s e
s pa c e c a lc u l at i o n s

Introduction
For those companies who do not have access to warehouse design programs
there are a number of simple ways to calculate the space required for specific
operations. In this tool we have included a calculation for dock space and
racked pallet storage.

How to do it
1) Calculation of dock space requirements
The formula for this is relatively simple as follows:
Dock Space = Roundup

{Number of loads received Hours/load}

length of shift

(size of load space/pallet)

Data
receiving 20 loads per day
each load is 26 pallets
each pallet is 1m 1.2m
45 minutes per load to unload vehicle
30 minutes per load to stage prior to put-away
8 hours per day work shift

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Warehouse Space Calculations

Calculation
{Roundup (20 1.25)/8} (26 (1.2 1.0))
= 3.125 31.2
= 4 31.2
= 124.8 square metres
Dock space = 124.80 sq. metres
Add double the space for working and travel area = 249.60 square metres
Total space required = 374.40 square metres

2) Pallet storage calculation

This tool enables operators to calculate the number of pallets which can be
stored within a particular cubic area.
It works on the basis of calculating width, length and height modules within
the warehouse.
A module width is calculated as follows:
Module Width = width of aisle + 2 pallet lengths (short side) + 100 mm
For example, given the following data
Aisle =
2,500mm (variable with type of Mechanical Handling Equipment used)
Pallet size = 1200mm 1000mm
Two pallets short side = = 2 1,000mm = 2,000mm
Clearance = 100mm between back to back pallets
Therefore:
Width of module =
4,600 mm (the sequence is pallet aisle pallet clearance)

Warehouse Space Calculations

A module length is calculated as follows:

Module Length = width of upright + clearance + 2 pallets (long side)
Rack upright plus clearance = 420mm (120mm + 3 100mm)
Two pallets (long side) = 2 1,200mm = 2,400mm
Therefore:
Length of module =
2,820mm (the sequence is upright/clearance/pallet/clearance/pallet/clearance)

Module Height = Height of pallet + 150mm

Pallet height = 1,350mm
Clearance above pallet = 150mm
APR beam width of 140mm
Therefore:
Height of module =
1,640mm (sequence is pallet and goods clearance beam height)

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Warehouse Space Calculations

Total pallets stored within cubic capacity of a warehouse section, excluding

receiving and despatch areas, gangways and other areas
(No. of width modules pallets in module width)
(No. of length modules pallets in module length)
(No. of height modules) = No. of pallets into cube volume of warehouse
So for a warehouse section with a width of 48 metres, a length of 120 metres
and a height of 10 metres.
Width calculation = 48m/4.6m = 10 pallets
Length calculation = 120m/2.82m = 42 pallets
Height calculation = 10m/1.64m = 6 pallets
Therefore total number of pallets = (10 2) (42 2) (6) = 10,080 pallet
locations in this warehouse storage area.
There are a number of free resources which can also calculate the number of
pallets that can be stored within a specific area.
These are supplied, in the main, by the material handling and storage equipment companies.
USA example http://webtools.cisco-eagle.com/rack/
UK example http://www.redirack.co.uk/palletcalc.php
A simple pallet calculation sheet using Excel can be downloaded from
http://www.appriseconsulting.co.uk/logisticstools