Client: Midlands-Based Manufacturing & Distribution Company

Product: 300kg UDL 4-Tier Longspan Shelving (2000L × 600W × 2000H mm)

Executive Summary

This comprehensive case study outlines the end-to-end delivery of a custom heavy-duty longspan shelving solution for a leading manufacturing and distribution company based in the West Midlands, United Kingdom. The project addressed critical warehouse storage inefficiencies, inventory management challenges, and compliance risks within the client's 2,500m² industrial facility.

Over a 12-week engagement, we delivered a fully optimized storage system featuring 120 units of our 300kg uniform distributed load (UDL) 4-tier longspan shelving (dimensions: 2000mm × 600mm × 2000mm). The solution has since delivered measurable improvements across key operational metrics, including a 45% increase in usable storage capacity, a 30% reduction in order picking times, and full compliance with UK HSE (Health and Safety Executive) and SEMA (Storage Equipment Manufacturers' Association) standards.

This case study details the project lifecycle, from initial consultation and design engineering through installation, commissioning, and post-implementation support, highlighting our commitment to delivering scalable, safety-first storage solutions tailored to the unique needs of UK industrial operations.

◆  Client Background & Business Context

1.1 Client Profile

The client is a mid-sized manufacturing and distribution firm specializing in industrial components for the construction and automotive sectors. With over 20 years of operation in the UK market, the company serves a national network of contractors, retailers, and original equipment manufacturers (OEMs) from its purpose-built warehouse facility in the West Midlands. The facility operates as a central hub for receiving raw materials, storing finished goods, and fulfilling customer orders, with an average of 500 order lines processed daily.

The company's rapid growth in 2023-2024, driven by increased demand for its core product lines, exposed significant gaps in its existing storage infrastructure. Prior to our engagement, the warehouse relied on a mix of outdated pallet racking, ad-hoc shelving, and floor-stored inventory, leading to chronic disorganization, inefficient workflows, and growing compliance concerns. The client identified the need for a scalable, cost-effective storage solution that could accommodate both fast-moving small parts and bulkier, slower-moving inventory while aligning with its strategic goal of streamlining supply chain operations.

1.2 Core Business Challenges

Through initial consultations and on-site audits, our team identified several interconnected pain points that were impacting the client's operational performance

• Storage Capacity Constraints: The existing warehouse layout utilized only 60% of its available vertical space, with most inventory stored on the floor or in low-capacity shelving units. This resulted in a 30% overstock situation, with excess inventory stored in temporary off-site facilities at a monthly cost of £1,500.

• Inventory Management Inefficiencies: Disorganized storage practices made it difficult for staff to locate parts quickly, leading to an average order picking time of 12 minutes per line item. This resulted in late order fulfillments, increased labor costs, and customer dissatisfaction, with 8% of orders experiencing delivery delays due to picking errors.

• Compliance & Safety Risks: The client's current storage setup did not meet SEMA guidelines or HSE workplace safety standards. Issues included overloaded shelving units, unstable floor-stored inventory, and obstructed emergency egress paths, exposing the company to potential fines, insurance claims, and workplace accidents.

• Lack of Scalability: The client's outdated shelving systems were non-modular, making it impossible to reconfigure layouts or expand capacity as inventory levels grew. This lack of flexibility created a bottleneck for the company's projected 25% annual growth rate over the next three years.

• Inventory Damage & Loss: Poorly organized storage, particularly for small, high-value components, led to an average of £12,000 per year in inventory loss due to damage, misplacement, or theft.

1.3 Project Objectives

Working collaboratively with the client's warehouse operations and facilities management teams, we established clear, measurable objectives for the project:

• Primary Objective:  Increase usable warehouse storage capacity by 40% or more, eliminating the need for off-site inventory storage.

• Secondary Objectives:

1. Reduce order picking time by a minimum of 25% through improved inventory organization and layout design.

2. Achieve full compliance with UK HSE and SEMA storage equipment standards, eliminating all safety risks associated with the previous setup.

3. Implement a scalable, modular shelving system that can adapt to future inventory growth and changing operational needs.

4. Reduce inventory damage and loss by 70% or more through secure, organized storage solutions.

5. Complete the project with minimal disruption to the client’s daily operations, avoiding costly downtime.

◆ Initial Consultation & Site Audit

2.1 Stakeholder Engagement

The project kicked off with a multi-stakeholder consultation involving our account management, engineering, and installation teams, alongside the client's warehouse manager, facilities director, and health and safety officer. This initial meeting allowed us to align on project goals, timelines, and key success metrics, while gaining a holistic understanding of the client's operational workflows, inventory profiles, and compliance requirements.

Key discussion points included:

• The client's inventory mix, including part sizes, weights, turnover rates, and storage requirements (e.g., hazardous materials, fragile components, high-value items).

• Daily warehouse operations, including forklift routes, pedestrian traffic patterns, order picking processes, and shift schedules.

• Current pain points, including bottlenecks in receiving, storage, and dispatch processes.

• Compliance priorities, including adherence to HSE, SEMA, and insurance provider requirements.

• Budget constraints and return on investment (ROI) expectations, with the client targeting a payback period of under 24 months.

2.2 On-Site Warehouse Audit

Following the consultation, our engineering team conducted a full day on-site audit of the client's warehouse facility. The audit included detailed assessments of:

1. Facility Layout & Dimensions: The warehouse measured 50m × 50m (2,500m²) with a clear internal height of 6.5m. The floor slab was rated for 5kN/m², suitable for supporting heavy-duty shelving systems. The audit identified key operational zones, including receiving, bulk storage, small parts picking, and dispatch areas, as well as emergency egress paths, fire safety equipment, and overhead obstructions (e.g., lighting, sprinklers, and ventilation systems).

2. Inventory Analysis: Our team conducted a full inventory sampling to categorize items by size, weight, turnover rate, and value. The analysis revealed that 60% of inventory consisted of small to medium-sized parts (0.1–20kg), 30% were medium-sized bulk items (20–100kg), and 10% were large, heavy components (100–300kg). This breakdown confirmed that our 300kg UDL longspan shelving (2000mm × 600mm × 2000mm) would be ideal for storing the majority of the client's inventory, with the ability to accommodate both light and heavy items across its four tiers.

3. Safety & Compliance Review: The audit identified several critical compliance issues, including:

• Overloaded, damaged, or unstable shelving units that did not meet SEMA guidelines.

• Obstructed fire exits and emergency egress paths due to floor-stored inventory.

• Lack of clear pedestrian walkways and forklift/pedestrian segregation.

• Absence of safety signage, load capacity labels, and risk assessments for storage equipment.

• Operational Workflow Mapping: Our team mapped the client's current order picking and inventory movement processes, identifying bottlenecks such as excessive travel time between storage zones, inefficient part retrieval methods, and lack of clear inventory labeling systems.

2.3 Post-Audit Consultation & Solution Alignment

Following the on-site audit, our team presented a detailed report to the client, summarizing our findings, highlighting key pain points, and proposing a preliminary solution framework. We walked the client through our analysis of their inventory and operational workflows, explaining how a tailored longspan shelving solution could address each of their core challenges.

Key recommendations from the preliminary report included:

• A modular, scalable longspan shelving system to maximize vertical and horizontal storage space.

• elayout, with fast-moving inventory stored on easily accessible shelving units and slow-moving items allocated to higher tiers.

• Integration of clear pedestrian walkways and safety barriers to comply with HSE requirements.

• Installation of safety signage, load capacity labels, and training for staff on safe use of the new shelving system.

The client expressed strong alignment with our recommendations, approving the next phase of the project: detailed design engineering and solution development.

◆ Design & Engineering Phase

3.1 Solution Design Principles

Our design process was guided by three core principles, tailored to the client's specific needs:

1. Safety First: All designs fully complied with UK HSE and SEMA standards, prioritizing structural stability, load capacity, and workplace safety.

2. Operational Efficiency: The layout was designed to streamline workflows, reduce travel time, and improve order picking accuracy.

3. Scalability & Flexibility: The modular shelving system allowed for easy reconfiguration and expansion to accommodate future inventory growth.

3.2 Shelving System Selection: 300kg UDL 4-Tier Longspan Shelving (2000L × 600W × 2000H mm)

Based on the inventory analysis and facility requirements, our engineering team selected our heavy-duty longspan shelving system as the core of the solution. The key specifications and benefits of the shelving units are detailed below:

3.2.1 Technical Specifications

Parameter Specification Compliance Standard 

Dimensions 2000mm (L) × 600mm (W) × 2000mm (H) SEMA FEM 10.2.02 

Load Capacity 300kg Uniform Distributed Load (UDL) per tier, 1200kg total per unit BS EN 15512:2020 

Tier Configuration 4 adjustable tiers (height adjustable in 50mm increments) HSE L113 

Frame Construction Heavy-duty blue powder-coated steel uprights with reinforced base plates, anti-collapse locking mechanism SEMA 

Beam Construction Orange powder-coated box section beams with safety locking pins, rated for 300kg UDL per tier BS EN 15512:2020 

Decking Options Steel decking panels (anti-slip finish) for heavy items, or chipboard decking for lighter inventory HSE 

Finish Powder-coated blue uprights (RAL 5005) and orange beams (RAL 3020), providing corrosion resistance in industrial environments ISO 12944-6 

Assembly Bolt-free, modular design for quick, tool-free assembly and reconfiguration SEMA 

3.2.2 Key Benefits for the Client

• Versatile Load Capacity: The 300kg UDL per tier rating allowed the client to store both light, small parts and heavier bulk items on the same shelving units, eliminating the need for multiple storage solutions.

• Adjustable Tier Heights: The 50mm incremental height adjustment enabled the client to customize each tier to fit different product sizes, maximizing space utilization.

• Durable Construction: The heavy-duty steel frames and beams, combined with the powder-coated finish, ensured long-term durability and resistance to wear and tear in the busy warehouse environment.

• Modular Scalability: The bolt-free design allowed for easy expansion, reconfiguration, or relocation of units as the client's inventory needs changed over time.

• Safety-Forward Design: The anti-collapse locking mechanism, reinforced base plates, and load-rated construction fully complied with UK safety standards, reducing the risk of accidents or structural failure.

3.3 Warehouse Layout Design

Our engineering team developed a full warehouse layout plan, optimizing the placement of the 120 shelving units to maximize storage capacity while maintaining efficient workflows and compliance with safety standards. The key design elements included:

1. Zoned Storage Layout: The warehouse was divided into three primary zones based on inventory turnover rates:

• Fast-Moving Zone (Front of Warehouse): Shelving units located closest to the dispatch area, housing high-turnover items for quick access.

• Medium-Turnover Zone (Mid-Warehouse): Shelving units for items with moderate turnover rates, balanced between accessibility and storage density.

• Slow-Moving Zone (Rear of Warehouse): Shelving units for low-turnover, bulkier items, maximizing storage density in less frequently accessed areas.

2. Walkway Design: Clear, marked pedestrian walkways (1.2m minimum width) were incorporated between shelving rows, complying with HSE requirements for safe movement and emergency egress. Forklift access routes (3m minimum width) were also designated to avoid conflicts between pedestrian and vehicle traffic.

3. Aisle & Bay Spacing: Shelving units were arranged in rows with 1.5m wide access aisles, allowing staff to easily access all tiers with standard picking equipment. The 2000mm length and 600mm depth of the shelving units were optimized to fit the warehouse's column grid, minimizing wasted space around structural supports.

4. Safety Features: The layout included clear signage for emergency exits, fire equipment, and pedestrian/forklift routes. All shelving units were placed at least 500mm away from sprinkler heads and overhead obstructions to maintain compliance with fire safety regulations.

5. Integration with Existing Systems: The shelving layout was designed to complement the client's remaining pallet racking and bulk storage areas, creating a cohesive, integrated storage ecosystem that eliminated operational silos.

3.4 Engineering Validation & Compliance

Before finalizing the design, our engineering team conducted a full structural analysis and compliance review to ensure the solution met all relevant UK standards:

1. Structural Load Testing: Finite element analysis (FEA) was performed on the shelving design to verify that each unit could safely support the rated 300kg UDL per tier, with a 1.5x safety factor (450kg UDL per tier) as required by SEMA guidelines. The analysis confirmed no deflection or structural failure under the test load, even at maximum capacity.

2. Stability & Upright Design: The reinforced base plates and anti-collapse locking mechanism were tested to ensure the shelving units remained stable under uneven loading conditions, preventing tipping or collapse.

3. Fire Safety Compliance: The layout was reviewed to ensure all shelving units were placed in compliance with UK fire safety regulations, including maintaining clear access to sprinklers, fire exits, and fire equipment.

4. SEMA & HSE Alignment: The full design was cross-referenced against SEMA's Code of Practice for the Design, Installation and Use of Static Storage Equipment and HSE's L113 guidance on storage at work, confirming full compliance with all requirements.

Once the design was validated, we presented the final layout plan, engineering drawings, and compliance documentation to the client for approval. The client's facilities management and health and safety teams reviewed the plans in detail, raising no concerns and formally approving the solution.

◆ Project Planning & Logistics

4.1 Project Timeline & Milestones

Working with the client, we developed a detailed project timeline to ensure the solution was delivered on schedule with minimal disruption to warehouse operations. The 12-week project timeline was structured as follows:

Phase Timeline Key Milestones 

• Consultation & Audit Weeks 1-2 On-site audit, stakeholder alignment, problem identification 

• Design & Engineering Weeks 3-5 Layout design, engineering validation, client approval 

• Manufacturing & Preparation Weeks 6-7 Shelving production, quality control, packaging 

• Pre-Installation Preparation Week 8 Client inventory relocation, site preparation 

• Installation & Commissioning Weeks 9-10 Shelving assembly, safety testing, staff training 

• Post-Project Support & Review Weeks 11-12 Final inspection, performance review, handover 

4.2 Logistics & Delivery Planning

To ensure a smooth installation, we developed a comprehensive logistics plan for the delivery of the 120 shelving units:

• Manufacturing & Quality Control: All shelving units were manufactured at our ISO 9001-certified facility, with rigorous quality control checks at every stage of production. Each unit was fully assembled and tested in the factory to verify fit, finish, and load capacity before being disassembled and packaged for transport.

• Packaging & Transport: The shelving components were carefully packaged in protective materials to prevent damage during transit. We arranged for dedicated delivery to the client's warehouse using our fleet of UK-based vehicles, with delivery scheduled to coincide with the client's pre-installation preparation phase to avoid storage delays.

• Delivery Coordination: Our logistics team worked closely with the client to coordinate delivery times, ensuring access to the warehouse loading dock and clear pathways for transporting components to the installation zone. All deliveries were scheduled during off-peak hours to avoid disrupting daily operations.

4.3 Pre-Installation Preparation

To minimize downtime during installation, we collaborated with the client to complete critical pre-installation tasks in advance:

1. Inventory Relocation: The client's team relocated existing inventory from the installation zone to temporary storage areas, including the newly designated bulk storage zones and the off-site facility (phased out as the new shelving was installed).

2. Site Preparation: The warehouse floor was cleared and cleaned, with all obstructions (e.g., old shelving, debris, electrical cables) removed from the installation area.

3. Team Briefing: Our installation team held a pre-project briefing with the client's warehouse staff to review the installation schedule, safety protocols, and any operational requirements during the installation phase.

◆ Installation & Commissioning Phase

5.1 Installation Team & Safety Protocols

The installation was carried out by our in-house team of fully trained, SEMA-certified installers, led by a dedicated project manager with over 10 years of experience in UK warehouse storage solutions. Prior to the installation, all team members completed the client's site-specific safety induction, including training on warehouse hazards, fire safety procedures, and the use of PPE.

Key safety protocols followed during installation included:

• Daily toolbox talks to review safety procedures and identify potential hazards.

• Use of appropriate PPE (hard hats, safety boots, high-visibility vests, gloves) at all times.

• Barriers and signage to cordon off the installation zone and prevent unauthorized access.

• Coordination with the client's team to manage forklift and pedestrian traffic during installation.

5.2 Phased Installation Process

To minimize disruption to the client's daily operations, the installation was completed in phases over 2 weeks, with work scheduled during evening and weekend shifts to avoid peak warehouse hours:

Phase 1: Site Marking & Frame Installation

The installation team began by marking the exact positions of each shelving unit on the warehouse floor using the approved layout plan. The blue steel upright frames were then installed and anchored to the floor using base plates and expansion bolts, ensuring each frame was plumb and level to within ±3mm tolerance. The team worked systematically from the rear of the warehouse forward, installing rows of frames in blocks to maintain clear access paths for ongoing warehouse operations.

Phase 2: Beam & Tier Assembly

Once the frames were installed, the team began fitting the orange box section beams to the uprights. Each beam was secured with safety locking pins to prevent accidental dislodgement, with tier heights adjusted according to the client's inventory requirements. For each shelving unit, the team installed four tiers, with heights calibrated to accommodate different product sizes. Steel decking panels were then laid on the beams, creating a flat, stable surface for storing inventory.

Phase 3: Safety & Compliance Checks

After completing each block of shelving units, the installation team conducted a series of safety and compliance checks:

• Verifying all beams were securely locked into place and uprights were plumb.

• Checking that base plates were properly anchored to the floor.

• Ensuring all load capacity labels were affixed to each shelving unit, clearly displaying the 300kg UDL per tier rating.

• Confirming that walkways, fire exits, and sprinkler access were not obstructed.

Phase 4: Final Commissioning & Testing

Once all 120 shelving units were installed, our project manager conducted a full walkthrough of the warehouse to inspect the entire system. The team performed a series of load tests on sample shelving units, applying 110% of the rated load (330kg UDL per tier) to verify structural stability and compliance with safety standards. No deflection or structural issues were identified during testing, confirming the integrity of the installation.

Following the physical inspection, we coordinated with the client's health and safety officer to conduct a formal compliance review, confirming the installation fully met all HSE and SEMA requirements. A detailed installation report, including as-built drawings, load test results, and compliance documentation, was provided to the client for their records.

5.3 Staff Training & Handover

To ensure the client's team could safely and effectively use the new shelving system, we conducted a comprehensive training session for all warehouse staff:

1. Safe Use of Shelving: Training on load capacity limits, correct loading/unloading procedures, and the risks of overloading or misusing the shelving units.

2. Maintenance & Inspection: Guidance on basic maintenance tasks, including checking beam locks, upright stability, and floor anchors, as well as how to identify signs of damage or wear.

3. Emergency Procedures: Review of safety protocols in the event of an accident or structural issue, including who to contact and how to evacuate the area safely.

4. Inventory Organization: Tips for maximizing the efficiency of the new layout, including how to assign inventory to the different zones based on turnover rates.

The training session included a Q&A with our project manager and installation team, ensuring all staff felt confident using the new system. We also provided the client with a detailed user manual and maintenance schedule to support ongoing safe use of the shelving.

◆ Post-Installation Results & Operational Impact

6.1 Quantitative Performance Improvements

Within three months of completing the installation, the client reported significant improvements in their warehouse operations, aligned with the project's initial objectives:

1. Increased Storage Capacity: The new shelving system added 960m² of usable storage space, a 48% increase from the previous setup. This eliminated the need for off-site inventory storage, saving the client £18,000 per year in rental costs. The total storage capacity of the warehouse increased to 1,920 cubic meters, supporting the client's projected growth for the next three years.

2. Reduced Order Picking Time: The zoned layout and organized shelving reduced average order picking time from 12 minutes to 8 minutes per line item, a 33% improvement. This allowed the warehouse team to process an additional 150 orders per day without increasing staffing levels, improving order fulfillment rates and customer satisfaction.

3. Improved Inventory Accuracy: The clear, labeled shelving units reduced picking errors from 8% to 1%, eliminating costly order corrections and returns. Inventory accuracy rates improved to 99.5%, reducing the risk of stockouts and overstock situations.

4. Reduced Inventory Damage & Loss: Secure, organized storage reduced inventory damage and loss by 80%, saving the client an estimated £9,600 per year in replacement costs.

5. Compliance & Safety: The installation resolved all previous safety and compliance issues, eliminating the risk of HSE fines or insurance claims. The client also reported a 0% rate of workplace accidents related to storage equipment in the six months following the installation, compared to two minor incidents in the previous year.

6.2 Qualitative Benefits

Beyond the measurable operational improvements, the client also reported several qualitative benefits from the new shelving system:

• Improved Employee Morale: The safer, more organized working environment boosted staff morale, with the warehouse team reporting reduced stress and improved job satisfaction.

• Enhanced Professional Image: The clean, structured warehouse layout improved the client's image during customer and supplier visits, supporting their reputation as a reliable, professional partner.

• Future-Proof Flexibility: The modular design of the shelving system allowed the client to easily reconfigure layouts to accommodate new product lines or changing inventory needs, providing long-term flexibility for their growing business.

• Streamlined Workflows: The zoned storage layout aligned with the client's order picking processes, creating a more logical, efficient workflow that reduced unnecessary movement and improved overall productivity

6.3 Client Testimonial

Following the project's successful completion, the client's Warehouse Operations Director provided the following testimonial:

“Partnering with your team on this shelving solution has been a game-changer for our warehouse operations. From the initial consultation to the final installation, your team demonstrated a deep understanding of our business needs and a commitment to delivering a solution that works for us. The new longspan shelving has not only doubled our storage capacity but also streamlined our workflows, reduced picking times, and eliminated our safety concerns. The team's attention to detail, compliance with UK standards, and minimal disruption during installation exceeded our expectations. We now have a warehouse that is safe, organized, and scalable, supporting our growth for years to come. I would highly recommend your storage solutions to any UK industrial business looking to optimize their warehouse operations.”

◆ Post-Project Support & Ongoing Partnership

7.1 Warranty & Maintenance Services

As part of our commitment to customer satisfaction, we provided the client with a comprehensive after-sales support package, including:

• 5-Year Structural Warranty: All shelving components are covered by a 5-year warranty against manufacturing defects, ensuring long-term reliability.

• Annual SEMA-Compliant Inspections: Our team conducts annual inspections of the shelving system to check for wear, damage, or compliance issues, providing the client with a detailed report and recommendations for maintenance or repairs.

• On-Call Technical Support: Our UK-based support team is available 24/7 to answer any questions or address issues related to the shelving system, with a guaranteed 48-hour response time for urgent on-site support.

• Spare Parts Availability: We maintain a stock of replacement parts for the shelving system at our UK warehouse, ensuring fast delivery of any components needed for repairs or modifications.

7.2 Future Collaboration & Expansion

The successful completion of this project has laid the foundation for an ongoing partnership with the client. The client has already expressed interest in expanding the shelving system to accommodate additional product lines and exploring other storage solutions, including mezzanine flooring and pallet racking, as part of their long-term warehouse optimization plans. Our team remains engaged with the client, providing ongoing advice and support to help them maximize the value of their storage infrastructure.

◆ Conclusion

This case study demonstrates how a tailored, safety-first longspan shelving solution can address the unique challenges faced by UK industrial warehouses, delivering measurable improvements in storage capacity, operational efficiency, and compliance. For our Midlands-based manufacturing and distribution client, the installation of 120 units of our 300kg UDL 4-tier longspan shelving (2000mm × 600mm × 2000mm) has transformed their warehouse operations, eliminating off-site storage costs, reducing order picking times, and creating a safer, more organized working environment.

Key takeaways from the project include:

• A deep understanding of the client's business and operational needs is critical to designing a solution that delivers real value.

• Compliance with UK HSE and SEMA standards is non-negotiable, both for safety and for avoiding costly fines or insurance issues.

• Modular, scalable storage solutions provide long-term flexibility, supporting businesses through periods of growth and change.

• A collaborative, client-centric approach—from initial consultation through installation and post-project support—ensures a successful outcome that aligns with the client's strategic goals.