Design & Layout
Know Your Layout Will Work Before You Break Ground
We visit your facility, measure the real space, and deliver code-compliant CAD drawings before a single rack is ordered, so there are no surprises during installation or inspection.
Warehouse design and layout services involve professional assessment of a facility's physical space, operational workflows, and code requirements to produce engineered rack layout drawings. These services typically include on-site measurement, PE-stamped CAD drawings, permit-ready documentation, and fire code compliance review.
The Challenge
Most Layout Problems Show Up After Install, When It's Too Late
Designs built from photos or phone calls often miss critical details: column spacing, low sprinkler heads, uneven floors, forklift turning radii. By the time you discover the issue, racks are already on-site and your installation window is half over. Rework is expensive, delays are costly, and failed inspections create risk you can't afford.
We visit your facility before we quote, so the design reflects your actual space, not an assumption.
What You Get
Everything Included, No Surprises
On-Site Assessment & CAD Drawings
We physically measure your facility (columns, ceiling height, dock doors, sprinkler drops, forklift clearance paths) then produce professional AutoCAD layouts showing rack locations, aisle widths, beam elevations, and equipment clearances. Plan views, elevations, and installation details all included.
Engineering Calculations & Specifications
Our PE-licensed engineers produce stamped structural calculations, load capacity tables, seismic design parameters, and foundation requirements. Documentation meets ANSI MH16.1, IBC, and local code requirements, and provides liability protection for your organization.
Permit-Ready Documentation & ROI Analysis
We prepare complete permit packages formatted for your local jurisdiction, navigate the approval process, and respond to plan review comments. You also get capacity calculations and before/after comparisons to support capital investment decisions.
How It Works
A Clear Process, Start to Finish
Site Assessment & Data Collection
We conduct a comprehensive facility walkthrough, measuring building dimensions, column locations, ceiling heights, floor conditions, and documenting obstructions. We also collect operational data: SKU count, pallet dimensions, inventory turnover, order profiles, forklift specs, and growth projections.
Needs Analysis & Requirements Planning
We analyze your data to understand storage requirements, operational workflows, and business objectives, determining optimal storage type, required pallet positions, pick path strategies, staging areas, and special requirements like FIFO or temperature zones.
Conceptual Layout Development
Our CAD specialists develop 2–3 layout options addressing your requirements. Each design includes rack configurations, aisle layouts, equipment access paths, dock utilization, and staging areas, with tradeoffs clearly explained so you can make an informed decision.
Engineering & Permit Documentation
Once you approve a design, our engineers develop full construction documents: rack type, beam levels, load capacities, anchoring requirements, seismic calculations, and permit packages meeting local jurisdiction requirements.
Implementation Support
We don't disappear after the drawings are approved. We provide installation oversight, answer field questions, conduct site visits during installation, and perform final verification to ensure the as-built system matches engineered plans.
Scope of Work
Installations We Handle
Selective Pallet Racking
The most common and versatile racking type, providing direct access to every pallet. We optimize bay spacing, beam heights, and aisle widths for your specific forklift and pallet dimensions, maximizing density without sacrificing accessibility.
Drive-In, Push-Back & Pallet Flow
High-density systems for facilities with limited SKU variety or specific FIFO/LIFO requirements. We engineer rail systems, cart mechanics, slope requirements, and brake systems to ensure smooth operation and structural integrity.
Multi-Tier & Mezzanine Structures
When vertical space exceeds 24 feet, multi-tier systems can double or triple storage capacity. We design engineered platforms with integrated conveyors, stairs, safety gates, and pick modules that fully utilize cube.
Cantilever & Specialized Systems
For long materials, sheet goods, or non-palletized products, we design cantilever racks, lumber storage, and custom solutions that provide safe, accessible storage for challenging inventory types.
The Difference
Why Facilities Teams Choose Hammerhead
40–60% More Storage Capacity
The average professionally designed layout increases storage capacity by 40–60% over ad-hoc arrangements. We analyze SKU velocity, pallet dimensions, and picking patterns to maximize cube utilization while maintaining accessibility.
Designs That Pass Inspection
We know what inspectors look for: clearances, load ratings, seismic anchoring. We design to those standards before the first anchor is drilled. Our permit-ready documentation means you're not scrambling after racks are already in the ground.
20–30% Improvement in Pick Rates
Strategic layout design reduces picker travel distance, minimizes congestion, and creates logical flow patterns. Many clients see 20–30% improvement in pick rates after implementing optimized layouts, meaning faster fulfillment and lower labor costs.
One Point of Contact: Start to Finish
The designer who walks your facility is the same person who produces your drawings and answers questions through installation. We're not tied to any single manufacturer, so our recommendations prioritize your operational needs, not product margins. Over 500 warehouse layouts delivered across North America, from 10,000 to 1,000,000+ sq ft.
Common Questions
Frequently Asked Questions
How long does the design process take?
Typical projects move from initial site visit to permit-ready drawings in 3–4 weeks. Rush services are available for time-sensitive projects. Permit approval timelines depend on your local jurisdiction (typically 2–8 weeks), and we manage that process for you.
What information do you need to get started?
To begin, it helps to have building dimensions or CAD files (if available), current inventory data (SKU count, pallet dimensions, turnover rates), material handling equipment specifications, and operational goals. The site visit fills in what we can't get from documents.
Can you design around our existing racking?
Yes. If you have usable existing racking, we incorporate it into the design to reduce costs. We assess structural condition, determine remaining capacity, and integrate existing systems with any new installations for an optimized combined layout.
Do you handle the permit submission?
Absolutely. We prepare complete permit packages, submit to local building departments, respond to plan review comments, and coordinate revisions until approval. We handle the bureaucracy so you can focus on operations.
What if our needs change after the design is complete?
We build flexibility into designs wherever possible. For significant scope changes, we offer revision services to update drawings and engineering. Minor field adjustments can often be addressed during installation without formal revisions.
Common Challenges
Design Challenges We Solve Every Day
Limited Ceiling Height
Low-ceiling buildings require creative solutions. We optimize beam spacing, specify shorter uprights, and design staging areas that maximize usable height without compromising safety clearances, squeezing every inch of vertical storage out of constrained spaces.
Irregular Building Footprints
Older buildings with non-standard column grids, odd angles, or obstructions require custom layouts. We work around every constraint to create functional designs that utilize every available square foot rather than leaving awkward pockets of wasted space.
Mixed Inventory Types
Facilities storing pallets, loose cases, and long materials need integrated solutions, not separate systems bolted together. We design hybrid layouts combining selective racks, carton flow shelving, and cantilever sections within a single cohesive flow.
Seismic Requirements
High seismic zones (California, Pacific Northwest, Alaska) impose stringent engineering requirements. Our PE-licensed engineers perform site-specific seismic calculations, specify appropriate base connections and bracing, and design to SDC D and E requirements while maintaining operational efficiency.
Every project starts with understanding the space. We walk the floor, measure what's actually there, and design around the realities of the building, not just a spec sheet. That's the difference between a layout that looks good on paper and one that passes inspection on the first try.
Jeff Andrews
CEO, Hammerhead Warehouse Systems
Related Services
Installation & PM
From delivery coordination to final bolt-down, we manage the full installation process with minimal disruption to your operations.
Learn More →
Permits & Compliance
We coordinate permitting with local jurisdictions and design to fire marshal and OSHA requirements from the start.
Learn More →
Safety Inspections
Annual or as-needed inspections to identify rack damage, clearance issues, and code compliance risks before they become problems.
Learn More →Ready to Design a Layout That Actually Fits?
Stop leaving capacity on the table. Schedule a free site visit and we'll show you what's possible. No obligation, no sales pressure.
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