Warehouse Fieldbook

Modern warehouse with pallet racking and open material handling space

WAREHOUSE EQUIPMENT · COSTS · CAPACITY

Warehouse decisions,measured properly.

Practical cost guides, equipment comparisons and capacity resources for U.S. warehouses and distribution centers.

100 guides23 planning toolsU.S. market

THE FIELDBOOK

100 warehouse guides

Large pallet racking installation inside a modern U.S. warehouse

Storage Systems

How Much Does Pallet Racking Cost?

Selective pallet racking with individually accessible pallet positions

Storage Systems

Selective Pallet Racking Cost

Forklift operating inside a deep drive-in pallet racking lane

Storage Systems

Drive-In Pallet Racking Cost

Push-back pallet racking with multi-deep pallet rails and carts

Storage Systems

Push-Back Pallet Racking Cost

Pallet flow racking with gravity roller lanes for FIFO storage

Storage Systems

Pallet Flow Racking Cost

Cantilever warehouse racking storing long steel tubes and timber

Storage Systems

Cantilever Racking Cost

Automated pallet shuttle operating inside high-density warehouse racking

Storage Systems

Pallet Shuttle System Cost

Warehouse technicians installing pallet rack uprights and beams

Storage Systems

Pallet Rack Installation Cost

New pallet racking compared with older used warehouse racking

Storage Systems

New vs Used Pallet Racking

Selective pallet racking compared with drive-in warehouse storage

Storage Systems

Selective vs Drive-In Pallet Racking

Push-back pallet racking compared with drive-in pallet racking in a warehouse

Storage Systems

Push-Back vs Drive-In Racking

Industrial shelving for smaller inventory compared with full-height pallet racking

Storage Systems

Industrial Shelving vs Pallet Racking

High-density warehouse storage compared with selective pallet racking

Storage Systems

High-Density vs Selective Pallet Racking

Warehouse safety inspector examining pallet rack uprights, beams and anchors

Storage Systems

Pallet Rack Inspection Cost

Technicians repairing a damaged pallet rack upright inside a warehouse

Storage Systems

Pallet Rack Repair Cost

Wire mesh, steel and wood pallet rack decking types in warehouse racking

Storage Systems

Pallet Rack Decking Types Compared

Rack guards, bollards and end-of-aisle protection installed in a warehouse

Storage Systems

Pallet Rack Protection Systems: Costs & Options

Multi-level warehouse pick module with conveyors, shelving and order picking stations

Storage Systems

Warehouse Pick Module Cost & Design Factors

Modern counterbalance forklift inside a warehouse

Forklifts

How Much Does a Forklift Cost?

Technician inspecting a used forklift before purchase

Forklifts

Used Forklift Cost: What to Pay and What to Check

Warehouse manager evaluating a forklift for a lease-versus-purchase decision

Forklifts

Forklift Lease vs Buy

Forklift rental fleet being inspected at an industrial equipment facility

Forklifts

Forklift Rental Cost

Electric forklift and propane forklift shown side by side inside a warehouse

Forklifts

Electric vs Propane Forklift: Cost & Ownership

Electric warehouse forklift compared with a diesel forklift operating outdoors

Forklifts

Electric vs Diesel Forklift

Reach truck in a narrow rack aisle compared with a counterbalance forklift

Forklifts

Reach Truck vs Counterbalance Forklift

Narrow-aisle reach forklift lifting a pallet between high warehouse racks

Forklifts

Narrow-Aisle Forklift Cost

Warehouse order picker operating an elevated order-picking forklift

Forklifts

Order Picker Cost

Forklift operator working while a warehouse supervisor monitors equipment utilization

Forklifts

Forklift Operating Cost Per Hour

Forklift technician performing scheduled maintenance on industrial equipment

Forklifts

Forklift Maintenance Cost

Technician assessing a heavily used forklift before deciding whether to repair or replace it

Forklifts

Forklift Repair Cost: Repair or Replace?

Used forklift showing normal wear inside a maintenance facility, illustrating forklift lifespan and replacement timing

Forklifts

Forklift Lifespan: How Long Does a Forklift Last?

Multiple forklifts operating across a large warehouse floor, illustrating forklift fleet sizing

Forklifts

How Many Forklifts Does a Warehouse Need?

Three-wheel and four-wheel electric forklifts compared side by side inside a warehouse

Forklifts

3-Wheel vs 4-Wheel Electric Forklift

Order picker and reach truck compared inside a high-bay warehouse

Forklifts

Order Picker vs Reach Truck

Forklift using a specialized load handling attachment on palletized cartons

Forklifts

Forklift Attachment Costs & When They Pay Off

Large warehouse conveyor network transporting cartons through a distribution center

Conveyors

Warehouse Conveyor System Cost

Industrial roller conveyor carrying cardboard boxes through a warehouse

Conveyors

Roller Conveyor Cost

Powered belt conveyor transporting cartons through an industrial warehouse

Conveyors

Belt Conveyor Cost

Heavy duty pallet conveyor transporting a fully loaded pallet

Conveyors

Pallet Conveyor Cost

Automated warehouse sortation system routing cartons through multiple conveyor lanes

Conveyors

Sortation System Cost

Gravity roller conveyor compared with a powered roller conveyor carrying cartons in a warehouse

Conveyors

Gravity vs Powered Roller Conveyor

Belt conveyor compared with roller conveyor systems transporting cartons inside a warehouse

Conveyors

Belt vs Roller Conveyor

Technicians installing an industrial warehouse conveyor system

Conveyors

Conveyor Installation Cost

Maintenance technician servicing motors and rollers on a warehouse conveyor system

Conveyors

Conveyor Maintenance Cost

Damaged industrial conveyor being repaired beside a newer replacement conveyor section

Conveyors

Conveyor Repair vs Replacement

Accumulation conveyor compared with a standard powered conveyor moving warehouse cartons

Conveyors

Accumulation vs Standard Powered Conveyor

Warehouse manager reviewing conveyor performance and return on investment data beside an operating system

Conveyors

How to Calculate Conveyor ROI

Highly automated warehouse with conveyors, robotic handling equipment and pallet storage

Automation

Warehouse Automation Cost

High-bay automated storage and retrieval system operating inside a distribution center

Automation

AS/RS Cost: What a System Really Costs

Warehouse manager reviewing performance data overlooking an automated storage and retrieval system

Automation

AS/RS ROI & Payback Period

Automated storage and retrieval system compared with conventional pallet racking inside a warehouse

Automation

AS/RS vs Conventional Pallet Racking

Unit-load pallet ASRS compared with mini-load automated storage for totes and smaller inventory

Automation

Unit-Load vs Mini-Load AS/RS

Autonomous mobile robots transporting storage totes through a warehouse picking area

Automation

Autonomous Mobile Robot Cost

Automated guided vehicle transporting a pallet along a defined warehouse route

Automation

Automated Guided Vehicle Cost

Autonomous mobile robot compared with an automated guided vehicle inside a warehouse

Automation

AMR vs AGV

Goods-to-person automated storage system delivering inventory totes to a warehouse operator

Automation

Goods-to-Person System Cost

Industrial robotic palletizing system stacking cartons onto pallets inside a warehouse

Automation

Automated Palletizing System Cost

Pallet shuttle storage system compared with a high-bay automated storage and retrieval system

Automation

Pallet Shuttle vs AS/RS

Warehouse robotics deployment illustrating Robotics-as-a-Service compared with owning robot equipment

Automation

Robotics-as-a-Service vs Buying Warehouse Robots

Warehouse pallet racking and floor storage illustrating usable warehouse storage capacity

Layout & Capacity

How to Calculate Warehouse Storage Capacity

Forklift traveling through a warehouse aisle between pallet racks, illustrating aisle width planning

Layout & Capacity

Warehouse Aisle Width Guide

High-density pallet racking filled with inventory, illustrating pallet positions per square foot

Layout & Capacity

How Many Pallet Positions Fit Per Square Foot?

Dense high-bay warehouse storage with narrow aisles and pallet racking

Layout & Capacity

How to Calculate Warehouse Storage Density

Tall pallet racking using warehouse clear height for additional vertical storage capacity

Layout & Capacity

How to Use Warehouse Clear Height

Warehouse planner reviewing a pallet rack layout while standing inside the storage area

Layout & Capacity

How to Plan a Pallet Rack Layout

Forklift maneuvering through a marked turning area between warehouse pallet racks

Layout & Capacity

Forklift Turning Radius & Aisle Planning

Warehouse manager evaluating open floor area and pallet storage to estimate required warehouse space

Layout & Capacity

How Much Warehouse Space Do You Need?

Warehouse combining upper reserve pallet storage with lower forward picking locations

Layout & Capacity

Reserve Storage vs Forward Picking

Warehouse worker scanning inventory at organized picking locations during a slotting operation

Layout & Capacity

Warehouse Slotting: How to Plan Product Locations

Warehouse planning team reviewing a facility layout to compare expansion with internal space optimization

Layout & Capacity

Warehouse Expansion vs Space Optimization

Congested warehouse storage layout with blocked floor space and inefficient pallet placement

Layout & Capacity

Warehouse Layout Mistakes That Reduce Capacity

Modern warehouse loading dock with dock levelers, shelters, trailers and safety equipment

Loading Docks

Loading Dock Equipment Cost

Industrial dock leveler bridging the warehouse loading dock and trailer floor

Loading Docks

Dock Leveler Cost

Technician replacing a large commercial loading dock overhead door

Loading Docks

Commercial Loading Dock Door Replacement Cost

Warehouse loading docks showing dock seal and dock shelter configurations around trailers

Loading Docks

Dock Seal vs Dock Shelter

Trailer secured at a warehouse loading dock by a mechanical vehicle restraint system

Loading Docks

Vehicle Restraint System Cost

Hydraulic loading dock lift raising a pallet between ground and dock height

Loading Docks

Loading Dock Lift Cost

Maintenance technician servicing loading dock equipment at a warehouse

Loading Docks

Loading Dock Maintenance Cost

Large distribution center with multiple active loading dock doors and trailers

Loading Docks

How Many Loading Docks Does a Warehouse Need?

Large structural steel warehouse mezzanine providing a second level of usable storage space

Mezzanines

Warehouse Mezzanine Cost Per Square Foot

Warehouse mezzanine compared with an external building expansion for adding usable facility space

Mezzanines

Warehouse Mezzanine vs Building Expansion

Structural steel mezzanine compared with a rack-supported mezzanine inside a warehouse

Mezzanines

Structural vs Rack-Supported Mezzanine

Construction crew installing a structural steel mezzanine inside an operating warehouse

Mezzanines

Warehouse Mezzanine Installation Cost

Busy warehouse operating on two levels beneath and above a storage mezzanine

Mezzanines

Warehouse Mezzanine ROI & Payback

Warehouse mezzanine displaying different industrial decking surfaces including steel grating and panel decking

Mezzanines

Mezzanine Decking Options & Costs

Warehouse mezzanine construction project with structural steel, access equipment and installation work in progress

Mezzanines

Hidden Costs in a Warehouse Mezzanine Project

Technician replacing and servicing a large industrial forklift battery

Power & Charging

Forklift Battery Replacement Cost

Modern lithium-ion forklift battery compared with a traditional lead-acid industrial forklift battery

Power & Charging

Lithium-Ion vs Lead-Acid Forklift Batteries

Industrial forklift connected to a dedicated warehouse battery charging unit

Power & Charging

Forklift Battery Charger Cost

Electric forklifts using conventional, fast and opportunity charging stations inside a warehouse

Power & Charging

Forklift Charging: Conventional, Fast & Opportunity

Traditional forklift battery room compared with a modern lithium-ion forklift charging area

Power & Charging

Forklift Battery Room vs Lithium Conversion

Warehouse maintenance manager reviewing equipment service records beside forklifts and material handling equipment

Equipment Ownership

How Much Should a Warehouse Budget for Equipment Maintenance?

Preventive forklift maintenance compared with emergency reactive repair inside an industrial workshop

Equipment Ownership

Preventive vs Reactive Warehouse Equipment Maintenance

Technician inspecting a used forklift before the purchase of material handling equipment

Equipment Ownership

Used Material Handling Equipment: When Is It Worth Buying?

Warehouse manager and service technician reviewing a material handling equipment maintenance contract

Equipment Ownership

Full-Service vs Preventive Maintenance Contracts

Warehouse managers evaluating equipment ownership and leasing options beside industrial forklifts

Equipment Ownership

Lease vs Buy Warehouse Equipment

Safety inspector examining pallet racking damaged after a forklift impact in a warehouse

Warehouse Safety

What to Do After a Forklift Hits a Pallet Rack

Warehouse pedestrian walkway physically separated from forklift traffic by industrial safety barriers

Warehouse Safety

Forklift-Pedestrian Separation Systems

Warehouse loading dock equipped with trailer restraint, dock barrier and visual safety communication systems

Warehouse Safety

Loading Dock Safety Equipment Guide

Warehouse aisle with clearly marked pedestrian routes, equipment clearances and industrial floor safety markings

Warehouse Safety

Warehouse Aisle Clearance & Marking: OSHA Basics