As manufactures of lift trucks develop more sophisticated products that lift full pallet loads higher and faster than previous designs allowed, buyers need to be aware of restrictive building codes that may come into play negating some of the advertised benefits of going higher.

Recently, Distribution Digest conducted research into fire sprinkler systems from the relatively narrow perspective of how high product can be stored in a warehousing or distribution facility equipped with an Early Suppression Fast Response (ESFR) system.

Here’s what we found:

ESFR systems, introduced in the early 90s, quickly became common place throughout the U.S.A., especially for “Spec” buildings with ceiling heights of 40 feet or less. This relatively rapid acceptance of the ceiling supported ESFR system is driven by two major benefits:

1. ESFR deployment in a new facility can be completed during building construction and generally costs 30% to 50% less than the alternative in-rack sprinkler system.
2. Storage systems can be configured and re-configured independent of the ESFR system.

For general merchandise and most consumer goods, ESFR systems can be used in storage areas where the stacked product height does not exceed 35 feet, and the ceiling height is 40 feet or less. This regulation, established by the National Fire Protection Association (www.nfpa.org ) is a “suggestion”. The actual code is established for each municipality by the local fire marshal. Companies must also check with their insurance carrier, as well as other local fire and building inspectors that may be involved.

Example of how Fire Code can Limit Benefit of High Bay Lift Truck Operations

A. ESFR Equipped Storage Area:

Based on the above code – if your pallet load is 56″ high (including the pallet) and the vertical space between the pallet rack load supporting beams (top of beam to top of beam) is 64″, then the top of product at (6) loads high will be 31 ft 10 inches. Going up one more level (to 7 loads high) would put the top of product at 37 ft 2 inches, which exceeds the 35 ft code limit for ESFR and would probably require the installation of in-rack sprinklers in the flue space of the selective rack modules.

 

In this example – (6) pallets high is within the approved ESFR regulation. Therefore, any lift truck that can service a top of beam elevation of 326″ would be acceptable.

 

Another way of looking at it using this same 56″ high load example - there would be no additional storage benefit to be gained with a lift truck capable of servicing a top of beam height greater than 364″ as this would put the top of product above the maximum 35 ft height. The point being that in this example, it may be difficult to justify going higher than (6) loads.

 

We did find one provider of ESFR systems offering a sprinkler for 48 foot high ceilings with a maximum product height of 43 feet. This would allow for (8) loads high putting the top of product at 42 ft 6 inches. However, this is an industry first, designed for specific applications, and as far as we can tell is available only from the Reliable Sprinkler Company (www.reliablesprinkler.com/new_products.php).

B. In-Rack Sprinkler Equipped Storage System:

In-rack systems consist of a conventional ceiling system, and in-rack sprinklers. They are typically installed in buildings with ceiling heights above 40 ft and in high rise rack supported buildings equipped with Automatic Storage & Retrieval Systems (AS/RS).

 

Besides being more expensive, in-rack sprinkler systems can cause product losses resulting from water damage caused by accidentally breaking sprinkler heads. They may also inhibit future changes to storage rack configurations because water must be shutoff and the system drained before the racks can be dismantled and re-arranged. Once the racks have been relocated, the pipes and sprinkler heads must be reinstalled and tested. While all of this is going on – the area is left without fire protection.

 

However, if the existing pallet rack storage system is equipped with in-rack sprinklers, then it may be possible to increase storage capacity by going higher. One newly designed lift truck can reach a top of beam height of 505″ with a full pallet load (see - Distribution Digest Top Stories).

 

In our example - with a 505″ vertical lift capability, by reducing the top of beam to top of beam vertical distance from 64″ to 63″, (9) loads could be stored. In this case, the ability to go higher could yield a substantial reduction in the construction cost of either a new or expanded building.

Final Thoughts

In order to stay competitive company’s naturally want to take full advantage of the latest features and benefits being offered by material handling equipment providers. However, it is important to understand how local building code regulations impact on the use of the equipment. These codes can and do vary considerably from area to area. It is the user’s responsibility to comply with all applicable regulations.

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