nethrananda21 Warehouse Layout Skill
Warehouse layouts prioritize material flow efficiency, forklift aisle clearance, and separation between heavy machinery zones and human-occupied areas. The clearance between zones is 3000mm (forklift aisle width), not the standard 150mm. Wall thickness is 200mm.
REFERENCES TO LOAD
- Always load:
references/room_standards.md— minimum sizes for all warehouse zones - Load for worked example:
references/example_layout.json— complete warehouse floor
DOMAIN-SPECIFIC RULES
RULE W1 — Clearance is 3000mm. Gap between zones = 3000mm (forklift aisle clearance), NOT 150mm. Wall thickness = 200mm.
RULE W2 — Loading docks on perimeter. Loading docks MUST be on one or two sides of the building, typically south and/or east for truck access. Use roller shutter doors 3000mm+ wide.
RULE W3 — Storage zones central. Storage and rack zones MUST occupy the center — the largest area of the warehouse.
RULE W4 — Staging buffer. A staging area MUST exist between loading dock and storage for inbound/outbound goods processing.
RULE W5 — Human zones separated. Office, restrooms, and break room MUST be near the entrance, away from heavy machinery and forklift traffic areas.
RULE W6 — Forklift aisle width. Forklift aisles MUST be minimum 3000mm wide between rack areas. No doors between storage zones — open passage.
RULE W7 — Packing near dispatch. Packing/dispatch zone MUST be near the outbound loading dock.
RULE W8 — Fire safety. Fire exits every 30m travel distance. Sprinkler zones required throughout. Restroom doors must NOT face the storage floor directly.
UNKNOWN ROOM HANDLING
For unlisted zones (e.g., "hazmat storage", "battery charging station"):
- Hazmat storage: 5000×5000mm, isolated from other zones
- Charging station: 4000×4000mm, near forklift aisles
- Set
estimated: true, add toflagged_estimated_rooms
LOADING DOCK ENGINEERING
CRITICAL — Truck Geometry:
- Standard 53' trailer: 105' (32m) outside turning diameter
- Dock apron depth: minimum 36m (120ft) for standard trailers
- Dock height: 1400mm (55") with 150mm building setback for seals
- Dock leveler pit: 1800×2400mm per bay
- Each dock bay: minimum 3600mm wide, 4200mm preferred
Dock Ratio (rooms per dock):
- Distribution center: 1 dock per 500m² (5,000 SF)
- Manufacturing: 1 dock per 1,500m² (15,000 SF)
- Cold storage: 1 dock per 300m² (3,000 SF)
Truck Court:
- Perpendicular docks: 36m (120ft) minimum apron
- Angled docks (60°): 27m (90ft) apron
- Drive-through: 24m (80ft) each side
CODE COMPLIANCE REFERENCES
IBC — Industrial/Storage:
- Occupant load factor: 200 gross SF per person (warehouse/storage)
- Max travel distance: 400ft (122m) sprinklered S-1
- ESFR sprinklers: maintain 914mm (36") clearance below sprinkler deflectors
- Minimum 2 exits when area > 500m²
Fire Protection:
- NFPA 13: ESFR sprinkler system — specific rack clearances required
- Flue space: 150mm transverse, 150mm longitudinal between rack rows
- In-rack sprinklers for storage > 7.6m (25ft)
- Commodity classification determines sprinkler density
Electrical:
- Manufacturing: 800-2000+ amp three-phase service
- Distribution: 400-800 amp typical
- Transformer room: min 3000×3000mm with ventilation
LAYOUT PRINCIPLES
- Loading docks on south/east for truck access — 36m apron clearance
- Storage/rack zones central, largest area, ESFR clearance maintained
- Staging area between loading dock and storage (inbound/outbound buffer)
- Office and restrooms near entrance, away from machinery and forklift traffic
- Forklift aisles minimum 3000mm between rack areas
- Clear height markings — modern distribution 10-12m clear
- Fire exits within 122m (sprinklered) travel distance
- Packing/dispatch near outbound loading dock
- Truck turning court: 36m perpendicular, 27m angled
- Dock bays: 3600mm wide minimum, 1 per 500m² (distribution)