The Forgotten Part of Warehouse Design
When businesses consider improving warehouse efficiency, attention often turns to the space inside the building. Racking layouts, storage capacity, picking routes and material handling equipment are carefully considered to maximise productivity. However, the yard outside the warehouse can be just as important to the overall operation. For many businesses, particularly those handling bulky materials, palletised goods or high volumes of deliveries, the external yard is a critical operational space. Yet its layout is sometimes developed around immediate storage requirements rather than a longer-term strategy.
Over time, additional stock, increased vehicle movements and changing operational requirements can result in congested yards, restricted access and unnecessary interaction between pedestrians and vehicles. A well-designed yard should do more than provide space for deliveries and storage. It should support the safe and efficient movement of people, vehicles and materials, while allowing the operation to adapt as the business grows.
Making Better Use of Available Space
One of the first considerations when planning a yard is understanding how the available space is currently being used. External storage is often associated with materials placed directly onto the ground. While this can be appropriate for certain products, it can also create inefficient use of space, particularly where materials are spread across large areas or stacked without clearly defined storage locations.
Purpose-designed outdoor racking systems can offer an alternative. Depending on the products being stored, pallet racking or cantilever racking can allow materials to be organised vertically, potentially freeing up valuable ground space for vehicle movements, loading operations and pedestrian routes. Cantilever racking, for example, can be particularly effective for long or bulky materials such as timber, steel sections and pipework, while appropriately designed pallet racking may be suitable for goods capable of being safely stored externally.
However, outdoor racking requires additional engineering considerations compared with internal installations. Wind loading, corrosion protection, ground conditions, anchoring arrangements and the suitability of the stored materials must all be considered.
Racking designed for an internal warehouse should not simply be relocated outside without confirmation that it is suitable for the external environment. The objective should never be to maximise storage capacity at the expense of safety. Instead, the storage layout should complement the wider movement of vehicles and personnel throughout the yard.
Designing Around Vehicle Movements
An effective yard layout starts with understanding the vehicles that use it. Articulated lorries, rigid vehicles, delivery vans and forklift trucks all have different operating requirements. Their turning circles, maneuvering space, visibility and loading arrangements need to be considered before storage locations are established.
One common mistake is positioning storage too close to vehicle routes, creating restricted turning areas or forcing forklift trucks and delivery vehicles to share congested spaces. Where practical, introducing a one-way traffic system can significantly simplify vehicle movements. Reducing the need for reversing and limiting conflicting traffic movements can improve both safety and operational efficiency. Dedicated loading, unloading and storage zones can also reduce unnecessary journeys across the yard.
For example, locating frequently accessed materials close to appropriate loading areas can minimise forklift travel distances. Separating incoming goods from outgoing dispatch operations may also help prevent congestion during busy periods. Importantly, the layout must accommodate the largest vehicles expected on site, not simply those used during normal day-to-day operations. Allowing sufficient clearance around storage equipment is equally important. Racking should be positioned so that vehicles can manoeuvre safely without exposing uprights and other structural components to repeated impact.
Pedestrian Segregation: A Fundamental Design Principle
Perhaps the most important consideration in any yard is how pedestrians and vehicles interact. A busy logistics yard may involve forklift operators, delivery drivers, warehouse employees, visiting contractors and office personnel, often moving through the same areas. Without clearly defined routes, the potential for collisions increases considerably.
The Health and Safety Executive’s workplace transport guidance emphasises separating pedestrians and vehicles wherever reasonably practicable. Physical segregation should therefore be considered at the initial design stage, rather than introduced as an afterthought. Suitable barriers, designated walkways, controlled crossing points and clear signage can help establish safer routes throughout the site.
Where possible, pedestrian routes should follow natural walking paths between buildings, welfare facilities, parking areas and operational locations. A walkway that requires a significant detour may encourage people to take shortcuts through vehicle operating areas. Particular consideration should be given to areas around warehouse entrances, loading bays and external storage racks, where visibility may be restricted by vehicles or stored goods.
Pedestrian crossings should be positioned where both drivers and pedestrians have sufficient visibility, rather than immediately behind parked trailers or alongside blind corners. Painted lines can support a traffic management strategy, but they should not be relied upon as the sole means of protection in higher-risk areas. Physical separation, where reasonably practicable, provides a more robust solution.
Storage Layouts That Support Safety
The arrangement of external storage can have a direct influence on traffic management. Poorly positioned racking can obstruct visibility, create blind corners or encourage vehicles to operate in areas where pedestrians are present. Conversely, carefully planned storage zones can help establish clear boundaries between different yard activities.
For example, locating bulk storage along suitable yard perimeters may preserve central areas for vehicle circulation, provided that emergency access, structural protection and maneuvering requirements are maintained.
Racking aisles should be designed around the handling equipment being used, with sufficient operating clearances to allow loads to be placed and retrieved safely. The stability and condition of stored materials are equally important. Damaged pallets, unsecured goods and poorly positioned loads can present significant risks, particularly in external environments where wind and weather conditions may affect load stability. Storage equipment must also remain accessible for routine inspections and maintenance. A layout that makes damage difficult to identify or prevents safe access for repairs can create problems over time.
Planning for Growth and Changing Operations
A yard layout that works today may not remain suitable as a business expands. Additional deliveries, changing stock profiles or the introduction of new handling equipment can all influence how space is used. Businesses should therefore periodically review their yard arrangements rather than waiting until congestion or safety concerns become apparent. Observing vehicle movements during peak operating periods can highlight bottlenecks that may not be obvious during quieter times.
Engaging with forklift operators, warehouse personnel and delivery drivers can also provide valuable insight into practical difficulties within the existing layout. Sometimes relatively straightforward changes, such as relocating storage locations, improving pedestrian routes or adjusting traffic flow, can deliver meaningful operational improvements without major investment.
Safety and Efficiency Should Work Together
Yard management is often viewed as a balance between maximising operational capacity and maintaining a safe working environment. In reality, the two should support one another. Clearly organised storage reduces unnecessary handling. Well-planned vehicle routes reduce congestion. Effective pedestrian segregation limits potentially dangerous interactions while giving employees and visiting drivers greater clarity about where they should move. Ultimately, the most efficient yard is not necessarily the one that holds the greatest volume of stock.
It is the one where people, vehicles and materials can move safely, predictably and with minimal unnecessary handling. By considering storage design and traffic management together, businesses can transform their yards from underutilised or congested spaces into safer, more productive extensions of their warehouse operations.
