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Example warehouse floor plan of a larger warehouse operation:

Zonal Storage

Irrespective of the structure type or the size, space planners should consider planning the physical location of stored items relative to the amount of effort required to move or load them, including:


An exception to storing infrequently used cargo in the rear of a facility is planning on storing extremely heavy or difficult to move items near the front of a warehouse or storage facility, even if they are used only rarely. Items like machine parts or generators might be cumbersome or even dangerous to move around inside of a storage site, and keeping them closest to the exit is an advisable strategy. This is especially true for storage locations that are entirely managed by hand - planners should think of the physical capabilities and safety of loaders.

Storage Space Zonal Plan
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Storage Solutions

The ways in which cargo is physically stored in a warehouse can dramatically increase usable storage space, increase efficiency, and impact safety. Generally, there a few main categories through which cargo is physically stored and handled.


There are multiple varieties of alternatives for stacking loose cartons and irregular shapes. The configuration will depend on the commodity itself, the space requirements of the warehouse, and the speed and skill of the warehouse staff. Some possible configurations might include:

Block StackBrick StackPinwheel StackIrregular Stacks with Separators 

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Many ground stacking operations also utilize what is called "pyramid stacking." Pyramid stacks are useful for durable, bulky items and in contexts when high volumes of uniform items need to be stored in a relatively small space. Pyramid stacks - sometimes also called "stair stacking" have interlocking lairs with reduced diameters the further up the stack goes. The pyramid shape prevents dangerous items from falling, and may make accessing the top layer easier for hand loaders. 

Pyramid Stack

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No matter what the stacking configuration looks like, stacks should not be stored above an unsafe height.