Estimated reading time: 8 minutes
Kirby Group Engineering's off-site manufacturing facility in Portlaoise, Co. Laois, is a great example of what's possible when you tailor storage solutions to a complex workspace. We designed, supplied and installed a multi-product storage system to meet the diverse requirements of this project.
Project Overview
| Detail | Information |
|---|---|
| Client | Kirby Group Engineering |
| Location | Portlaoise, Co. Laois, Ireland |
| Industry | Off-Site Manufacturing |
| Project Completed | April 2024 |
| Solutions Installed | Pallet Racking, Cantilever Racking, Longspan Shelving, 3m Mesh Partitioning, Wire Mesh Decking |
| Key Benefits | Maximised vertical space, secure tool storage, streamlined workflows, future scalability |
What Are the Best Racking Systems for Engineering and Fabrication Businesses?
Kirby Group Engineering needed a storage setup that could handle the demands of a busy manufacturing environment. As a mechanical and electrical engineering contractor operating across multiple sectors, they required storage infrastructure that could keep pace with high-output operations.
Here's what the project called for:
- Pallet racking for bulk storage: The facility handles large quantities of palletised materials that need organised, accessible storage
- Cantilever storage for long and irregular items: Steel beams, pipes and profiles don't fit on standard racking
- Secure mesh partitioning: High-value tools and sensitive components needed protection
- Flexibility for future expansion: The layout had to allow for changes as operations evolve
- Safety compliance: All installations needed to meet EU regulations
How Do You Design a Safe Storage Layout for an Engineering Site?
Kirby Group Engineering required a setup that could support everything from heavy palletised goods to secure tool and parts storage. Several factors shaped our final solution.
Mixed-use requirements: The Portlaoise facility serves multiple functions. Storage zones needed to accommodate raw materials, fabricated components, packaging supplies and finished goods ready for dispatch.
Making the most of available space: Kirby needed to use the building's full height without compromising accessibility or safety.
Built to last: Engineering and fabrication work is demanding. All storage equipment had to withstand heavy daily use and maintain its structural integrity over many years.
Supporting operational flow: Where you put storage matters. We positioned everything to reduce handling time and support lean operations.
Keeping valuable items secure: Tools, precision equipment and sensitive inventory all needed dedicated secure zones with controlled access.
What's the Best Way to Combine Pallet Racking and Cantilever Racking in a Manufacturing Facility?
We designed a multi-product solution that addressed every aspect of Kirby Group Engineering's storage requirements.
Pallet Racking for Manufacturing Warehouse Storage
The backbone of the storage system is heavy-duty pallet racking configured to maximise vertical space. This selective racking system provides direct access to every pallet position, so workers can retrieve materials quickly when they need them on the production floor.
We positioned the pallet racking to create clear traffic lanes for forklift operations. Load capacities were calculated for Kirby's specific requirements, with appropriate safety margins built in.
Cantilever Racking for Long Materials Like Steel Beams
Engineering operations involve plenty of long materials: steel sections, aluminium profiles, conduit and piping. Standard racking simply can't handle these items efficiently. That's where cantilever racking comes in.
We configured the cantilever arms at the right intervals to support various lengths without sagging or damage. Both single-sided and double-sided options were used depending on location.
Longspan Shelving for Manufacturing Workflows
For hand-loaded items, smaller components and medium-weight goods, longspan shelving was the right choice. These units offer good accessibility and you can adjust them to fit items of varying sizes.
We positioned the longspan shelving to create efficient picking stations. Workers can quickly grab frequently used components without wasting time. And because the shelf heights are adjustable, the system can adapt as needs change.
Wire Mesh Decking for Enhanced Safety
Wire mesh decking was integrated throughout the pallet racking system. It supports non-standard pallet sizes and loose items that might otherwise fall through beam gaps.
But there's more to it than that. The open mesh design lets sprinkler water pass through, which improves fire safety compliance. It also allows better visibility of stored items from below and promotes air circulation to prevent moisture build-up.
Secure Mesh Partitioning with Lockable Storage
One of the standout features is the 3-metre high mesh partitioning system with lockable access. This creates defined secure zones for:
- High-value tools and specialist equipment
- Precision instruments requiring controlled access
- Sensitive inventory and components
- Items with specific security requirements
Professional Installation and Layout Design
We positioned each storage system to align with Kirby Group Engineering's operational flow. Our installation team worked to minimise disruption and ensure every component met safety and quality standards. The layout supports smooth material handling routes and reduces unnecessary movement.
Project Outcomes: Streamlined Manufacturing and Secure Tool Storage
The completed installation has transformed Kirby Group Engineering's Portlaoise facility into a clean, efficient and secure working environment.
Clearly defined storage zones: Materials, components and equipment now have designated locations. No more time wasted searching for items.
Improved accessibility: Workers can retrieve materials quickly with direct access to all pallet positions and well-organised shelving.
Less clutter: The storage solution has eliminated the mess that can build up in busy manufacturing environments. The workspace is safer and more professional as a result.
Better security: The secure mesh partitions protect valuable tools and stock effectively.
Room to grow: The modular nature of the systems means you can add extra bays as the business expands. That protects your investment for years to come.
It was a pleasure to support Kirby Engineering on this project. Their forward-thinking approach to off-site manufacturing called for a storage system that was just as innovative and future-ready. By combining multiple racking types with secure partitioning, we delivered a solution that meets both their current operational needs and long-term goals.
— Ciaran Duffy, Director, RackZone
"Related Storage Solutions for Engineering Facilities
RackZone offers a range of products suitable for engineering workshops, manufacturing facilities and industrial environments across Ireland:
Transform Your Industrial Storage
Whether you're fitting out a new manufacturing facility or looking to improve storage capacity in an existing warehouse, we can design, supply and install storage solutions tailored to your exact requirements. We offer next business day delivery across Ireland and Northern Ireland, expert installation services and a commitment to quality that's earned us an "Excellent" Trustpilot rating. Get in touch today on +353 (0)90 9673261 to discuss your project
Frequently Asked Questions (FAQs)
What storage systems are best for engineering workshops?
The best storage systems for engineering workshops are a combination of pallet racking for bulk materials, cantilever racking for long items like steel and pipes, and longspan shelving for smaller components. Secure mesh partitioning is also recommended for protecting valuable tools and equipment.
How do I organise a manufacturing facility?
Effective organisation is achieved by creating defined storage zones for different material types, implementing vertical storage solutions and positioning systems to support efficient workflows. Clear labelling and accessible layouts reduce handling time.
What type of racking is used for long materials like steel beams?
Cantilever racking is the ideal solution for storing long materials like steel beams, pipes, timber and profiles. This system features horizontal arms extending from vertical columns, providing unobstructed support for lengthy items that standard shelving can't accommodate.
How do you design a safe storage layout for an engineering site?
Safe storage layout design is based on load capacity calculations, clear traffic lanes for forklifts, adequate aisle widths and proper anchoring of all racking systems. Upright protectors, wire mesh decking and compliance with EU safety regulations are essential.
What's the best way to combine pallet racking and cantilever racking?
The best approach is to position pallet racking in central warehouse areas for palletised goods and locate cantilever racking along walls or in dedicated zones for long materials. This combination maximises space and keeps different material types organised.
How do I secure tools and equipment in a warehouse?
Securing tools and equipment is best achieved through mesh partitioning systems with lockable access points. These create dedicated secure zones within your facility, allowing visibility but preventing unauthorised access to valuable or sensitive items.
What's the most efficient storage setup for manufacturing workflows?
The most efficient setup is one that aligns storage locations with production sequences, minimises material handling distances and provides direct access to frequently used items. Combining pallet racking, longspan shelving and dedicated workstations supports lean manufacturing.
How do mesh partitions improve warehouse security?
Mesh partitions are effective because they create physical barriers with controlled access points, yet they maintain visibility into secure areas. The robust construction deters unauthorised entry and lockable gates ensure only authorised personnel can access valuable inventory.
How do I reduce clutter in a busy production facility?
Reducing clutter is accomplished by implementing storage systems with designated locations for all materials, maintaining clear floor areas and using vertical space effectively. Regular housekeeping routines and defined storage zones prevent disorganised items from piling up.
