Space optimisation for hazardous material storage – solution strategies for warehouse managers
The rental and operating costs for storage space are often high. In addition to building maintenance, energy consumption for lighting and air conditioning also incurs considerable expenses. Warehouse managers face the challenge of minimising these costs by using space as efficiently as possible. Space-saving storage also creates more room for manufacturing activities and work processes.
However, if the stored goods are hazardous materials, additional requirements apply: safety distances and regulations on co-storage, for example, make space-saving storage organisation more difficult. Below, you will learn which safety measures and legal requirements are important – and which strategies you can use to implement efficient and space-saving hazardous materials storage.
Hazardous materials: a particular challenge for warehouse managers
As with regular warehousing, the aim of those responsible for storing hazardous materials is to reduce costs by saving space. However, it is important to balance efficiency criteria with the necessary safety measures and legal requirements. Proper storage of hazardous materials is essential to minimise the risk of fires, chemical reactions or other accidents, thereby protecting both employees and facilities. Accordingly, the storage of hazardous materials is subject to strict legal regulations which, compared to non-hazardous stored goods, impose additional restrictions on the design of the warehouse:
As a general rule, only approved storage facilities specifically designed for hazardous substances may be used. This includes, in particular, compliance with the legally prescribed collection volume by means of a suitable and sufficiently dimensioned collection tray.
For hazardous substances with fire hazard potential, such as flammable liquids, special structural requirements for fire protection apply. These substances must be stored separately from fire loads in order to minimise fire risks. Separation can be achieved either by structural barriers or by safety distances.
There are storage prohibitions for hazardous materials with different hazard properties where storage together would lead to an increased risk. To reduce hazards, it is necessary to either store these substances separately within a storage section, taking safety distances into account, or to store them in separate storage sections.
In addition, hazardous materials may not be stored in unlimited quantities without further ado. For many substances, there are specified quantity thresholds above which stricter safety measures are required. These regulations must also be taken into account when planning storage.
All these requirements make it difficult to achieve the goal of space-saving storage. Alternative procurement strategies such as the just-in-time method, which aims to minimise stock levels through smaller batches and demand-driven delivery, are also only of limited use for hazardous substances. This is because high transport costs due to hazardous goods surcharges can quickly negate potential savings in storage space.
Despite these challenges, space-saving storage of hazardous materials is not impossible – but it does require a well-thought-out approach. Through the intelligent use of suitable storage solutions, hazardous material storage can be implemented that is not only safe, but also extremely efficient and cost-optimised. As a developer and manufacturer, DENIOS offers the widest variety of systems for optimally implementing individual storage concepts.
Optimising utilisation of space in the building
The optimal storage solution depends on the spatial conditions in the company as well as the quantity and properties of the hazardous materials to be stored. From an intralogistics perspective, it is often advantageous to set up the warehouse in the company building in order to shorten transport routes and optimise logistical processes.
Hazardous substance racks are ideal for space-saving indoor storage of large quantities. By making efficient use of vertical space, they enable the safe storage of large quantities of hazardous materials in a small area. The racks are equipped with a drip tray that guarantees the collection volume required by water law. Similar to conventional drip trays, they are made of different materials that are suitable for different types of hazardous materials.
Hazardous material racks are available in different versions, which vary in load capacity and size. They range from small container racks for storing smaller containers to drum racks and pallet racks that can hold IBC containers and drums on pallets. Thanks to base and add-on sections, many hazardous material racks can be expanded as required. The stacking rack model series also allows canisters and drums to be stored horizontally, enabling direct use as a filling station. These racks are available in two module sizes and can be stacked up to three high. Stacking racks of the same size can be flexibly combined with each other and are available either as ready-made sets or can be put together individually (stacking racks can be stacked in height but cannot be extended with extension units).
Like conventional storage racks, hazardous material racks also offer a high degree of clarity and good accessibility. Thanks to a well-thought-out arrangement of the containers, hazardous materials can be sorted according to their importance – for example, frequently used materials can be placed at an ergonomically favourable height to enable quick and safe removal.
To ensure optimum safety, a few additional measures should be observed when storing hazardous materials on shelves: Careful handling during storage and removal is essential to prevent containers from falling. Before storage, it should be checked whether the storage containers are suitable for the respective shelf height and have an appropriate test drop height. To prevent damage from forklifts or other industrial trucks, the shelves should be secured with collision protection.
Another important point is the regular inspection of the drip trays. A weekly check is required by law to determine whether liquids have collected in the tray. DENIOS offers an efficient solution here: the specially developed SpillGuard leakage warning system. This can be placed in the collection tray and reliably reports as soon as a leak is detected – a smart solution for greater safety and less effort.
Strategies for dealing with structural requirements and storage prohibitions
When storing certain hazardous substances, additional protective measures such as fire protection, access restrictions or storage prohibitions must be observed. If only small quantities of these substances are to be stored in the same room as other hazardous materials, a fireproof hazardous materials cabinet is recommended, which can be set up in the warehouse and serve as a separate storage section. Hazardous material cabinets are primarily designed for the storage of small containers – however, there are also models that offer space for up to two drums. Depending on other operational processes, it may also be an option to transfer substances delivered in large containers into smaller containers or to have them delivered directly in smaller containers to facilitate storage in hazardous material cabinets. In some cases, it is also sufficient to create additional storage space through the targeted use of hazardous material racks and to store smaller quantities of flammable substances on spill pallets with safety distances.
However, if larger quantities of hazardous materials with special safety requirements need to be stored, it must first be checked whether the existing indoor premises meet the legal requirements or can be retrofitted accordingly. In many cases, relocating the storage area to the outdoor area is an economically sensible alternative – especially if extensive and costly retrofitting would be necessary indoors.
Space and fire protection advantages through external storage
Fire safety requirements are often easier to implement outdoors due to safety distances. Potential hazards are completely removed from the company building, fire brigades benefit from better access in the event of a fire, and the risk of firefighting water damage to company facilities is reduced. However, moving hazardous material storage to the outdoor area can also be a sensible solution if space in the company building is limited and should be used primarily for value-adding activities.
Water regulations must also be complied with in outdoor areas, and hazardous materials must always be stored on a suitable collection tray. However, conventional collection trays are unsuitable for this purpose: on the one hand, precipitation can enter the collection device, and on the other hand, there is a risk of unauthorised access.
Instead, hazardous material depots offer a solution for the safe storage of small quantities of hazardous materials outdoors. These consist of a collection tray that meets all water law requirements and are additionally equipped with a protective structure consisting of walls, a roof and lockable doors or roller shutters. This protects the stored goods from the effects of weather and unauthorised access. Hazardous material depots are available in both plastic* and steel and offer space for small containers, up to eight drums or two IBCs.
* Our plastic hazardous material storage containers may only be set up in outdoor areas that are not exposed to direct sunlight (suitable shade), heavy rain or storms (suitable rain/wind protection).
Maximum storage capacity without safety distances
Since hazardous material storage facilities do not have integrated fire protection equipment, safety distances from buildings must be maintained when flammable substances are stored in them. If there is limited space available outdoors for this purpose, walkways should be reduced as much as possible or larger quantities of hazardous materials should be stored. Hazardous material containers offer a solution. With capacities for up to 72 drums or 18 IBCs, they enable space-saving storage of larger quantities. Their great advantage is the wide range of equipment options that allow them to be specifically adapted to operational requirements.
Fire-protected versions have certified F 90 fire protection and are considered a separate fire compartment. This means they can also be placed directly against the exterior walls of buildings – a logistical advantage that optimises routes and makes processes more efficient. The RFP SD fire protection storage unit is ideal for maximum storage quantities: thanks to its large sliding doors, it offers maximum storage capacity even for locations where hinged doors cannot be opened.
Climatic conditions also play a role in the outdoor storage of hazardous materials: substances that are sensitive to frost or heat must be protected from extreme temperatures. Hazardous material containers can therefore be equipped with thermal insulation, heating or air conditioning technology.
Numerous options are also available for optimal product handling: flexible shelving systems, conveyor and rail systems, pull-out shelf supports or roller conveyors facilitate the safe and efficient transport of drums and pallets within the container.
How can you store hazardous materials safely while also saving space and keeping costs down? The answer depends on various factors: the type and quantity of hazardous materials, the applicable safety regulations and the individual circumstances in your company.
Take advantage of DENIOS' free expert advice – by telephone, digitally or directly on site. Whether you have simple questions or complex challenges, with our many years of experience and a broad portfolio of solutions, we will work with you to find the optimal storage strategy for your requirements.
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