Planning an automated warehouse involves the building, foundations, high-bay racking and stacker cranes. This guide draws on completed projects and explains preparation, installation, adjustment and acceptance.
Building and foundation preparation
For the steel-framed buildings discussed in the original projects, a clearance of 350–500 mm was left between the racking top and the underside of structural beams, and between the outside of the racking or handling equipment and the internal walls. Floor level deviation in the receiving and dispatch equipment area was limited to ±10 mm.
Foundations must carry the static and dynamic equipment loads. The examples specify differential settlement below 1/1000, a suggested distance of at least 150 mm from the floor surface to reinforcing steel, and concrete of at least grade C30. These are project reference values; foundation loads, reinforcement and tolerances belong in the project design.
High-bay racking installation
Assembled steel racking may use expansion or chemical anchors, or adjustable steel base plates. Base-plate installations require embedded parts prepared during civil works and secondary grouting after installation. Inspect foundations, embedded parts and drilled holes before installing the racking. The example base-plate arrangement places all top surfaces on the same datum, with a height deviation no greater than ±1 mm.
Check and adjust the racking throughout installation. Horizontal and vertical rail alignment, rack upright verticality and beam levels must meet the applicable drawings and inspection requirements. The guide gives the following additional reference tolerances:
- Distance deviation between the lower running rail and upper guide rail: ±10 mm; horizontal misalignment: no more than 5 mm.
- The beam end facing the stacker crane should not be lower than the opposite end; the height difference should be no more than 4 mm.
- Centre distance between the bases of adjacent rack uprights: ±2 mm.
- Dimensions on either side of the rail centreline across the aisle: ±2 mm.
- Displacement between rack frames in the same row and aisle: no more than 5 mm.
Running-rail butt joints use a gap of 10–20 mm, with 16 mm suggested in the guide. Welding consumables must suit the parent metal. Preheat before welding, retain heat afterwards and grind the joint smooth. Welds must be free of cracks, slag inclusions and unacceptable porosity.
Prepare the stacker crane installation site
A stacker crane consists of its base and travelling mechanism, one-piece or sectional mast, lifting mechanism, load platform, maintenance platform and accessories. Mechanical installation provides the foundation for subsequent electrical installation and commissioning.
- Doors or reserved openings must admit delivery trucks, a mobile crane of more than 16 tonnes and a forklift of more than 3 tonnes, as required by the example installation.
- The unloading area must allow these vehicles to work and lift loads safely.
- Allow storage space for every crane. The example base storage area is (base length + 2 m) × (width + 2 m). Mast storage is (section length + 1 m) × (width + 2 m), multiplied by the number of sections.
- The floor must be level, support the crane and rack loads, and meet the required elevation tolerances.
- Review component weights, dimensions, drawings and technical documents before selecting lifting tools and installation methods. Protect motors and other sensitive components, and choose lifting points that keep the base and mast balanced.
Install the crane and accessories
Position components in the work area, choose the mobile crane position and confirm safe access. Lift the base onto the running rail at the end of the aisle, adjust its position and secure it. A sectional mast may be assembled on the ground before lifting, or installed from bottom to top. Locate bolted mast joints with positioning pins. Before welding lifting-guide joints, adjust mast verticality and straightness to the drawings; grind the three working faces smooth afterwards.
Once the main structure is stable, fit the upper horizontal guide wheels, maintenance platform, ladder, flat-cable suspension, lifting wire rope, conductor rail and remaining electrical equipment in sequence.
Adjustment and functional checks
- Centre the base in the aisle and adjust the gap between the lower horizontal wheels and the running rail.
- Adjust the upper horizontal wheels to achieve crane verticality across the aisle.
- Adjust the passive wheel axle for verticality along the aisle; use mast flange shims where necessary.
- Adjust load-platform guide wheels so the anti-fall device works, the safety-clamp gaps are balanced and the fork surface remains level.
- Set the fork torque limiter so rated loads start and stop normally and the limiter slips under overload.
- After the crane can operate electrically, adjust slack-rope and overload switches to respond correctly under the specified test conditions.
Inspect the completed installation, then carry out subsystem tests, integrated tests, trial operation, capacity tests and availability tests. Use the agreed acceptance programme, technical documents and applicable standards to define the test items and methods.
Installation personnel and work controls
- Riggers, fitters, welders and electricians must hold the qualifications required for their work and complete installation training.
- Measurement and inspection tools must comply with applicable metrology requirements and provide the accuracy needed for the installation.
- Have concealed work inspected and accepted before it is covered.
- Use helmets, protective footwear and other required protection; work at height also requires the appropriate fall protection.
- Plan the lifting and assembly sequence for the actual site to avoid unnecessary repeated lifts.
Coordinating civil works, racking and crane installation early helps the project move from preparation to commissioning with clear responsibilities and acceptance criteria.