SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

STANDARD OPERATING PROCEDURE FOR GOODS HANDLING

CARING ABOUT WAREHOUSE RACKING AND BLOCK STACKING

Name: SOP4GH
Subject: Caring about Warehouse Racking and Block Stacking
Valid for: Central & Store Fulfilment Units
Area of Work: Customer Fulfilment
Issued By: Fulfilment Operations Manager - CFF Group
Content Owner: Central & Store Fulfilment Operations Managers - CFF Group
Verifier: Fulfilment Operations Leaders
Latest review: October 5, 2021
Version: 5.2.3
Contact: [email protected]

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 1
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Contents

1 Overview --------------------------------------------------------------------------------------------------- 5
1.1 Purpose ----------------------------------------------------------------------------------------------------- 5
1.2 Scope --------------------------------------------------------------------------------------------------------- 5
1.3 Roles & Responsibilities ------------------------------------------------------------------------------- 5
1.4 INGKA Group / Business Rules --------------------------------------------------------------------- 5
1.5 References ------------------------------------------------------------------------------------------------- 6
1.6 Definitions-------------------------------------------------------------------------------------------------- 6
2 Process Map ---------------------------------------------------------------------------------------------- 9
3 Description of the SOP activities --------------------------------------------------------------- 10
3.1 Naming and recognizing the main parts ------------------------------------------------------- 11
3.2 Structure build-up, part replacement, and maintenance -------------------------------- 12
3.3 Requirements --------------------------------------------------------------------------------------------- 12
3.4 Objects and elements not belonging to the structure ------------------------------------ 13
3.5 Standard types (1)(2) -------------------------------------------------------------------------------------- 14
3.6 Standard dimensions (1)(2) ----------------------------------------------------------------------------- 16
3.6.1 Frame depth (1)(2) ------------------------------------------------------------------------------------------ 16
3.6.2 Compartment width (1)(2) ------------------------------------------------------------------------------- 16
3.6.3 Beam spacing (1)(2) ---------------------------------------------------------------------------------------- 17
3.6.4 Upright buckling length (1)(2)-------------------------------------------------------------------------- 17
3.6.5 Configurations (1)(2) --------------------------------------------------------------------------------------- 18
3.7 Location types (2) ----------------------------------------------------------------------------------------- 19
3.8 Storage Profiles (1)(2) ------------------------------------------------------------------------------------- 22
3.8.1 Storage Profiles, width of 880mm and 730mm, on 2.0m and 3.0m beams (1)(2) -- 22
3.8.2 Storage Profiles, width of 880mm and 730mm, on 1.9m and 2.9m beams (1)(2) --- 23
3.8.3 Storage Profiles, width of 800mm and 650mm, on 2.0m and 3.0m beams (1)(2) -- 24
3.8.4 Storage Profiles, width of 800mm and 650mm, on 1.9m and 2.9m beams (1)(2)--- 25
3.9 Risk mitigation (2)----------------------------------------------------------------------------------------- 27
3.9.1 Upright anchoring (2) ----------------------------------------------------------------------------------- 27
3.9.2 Upright protection (2) ----------------------------------------------------------------------------------- 27
3.9.3 Securing beams (2) --------------------------------------------------------------------------------------- 28
3.9.4 Securing Storage Profiles (2)-------------------------------------------------------------------------- 28
3.9.5 Extended end frames (2) ------------------------------------------------------------------------------- 29
3.9.6 Drive- and walk-through clearances ------------------------------------------------------------- 29
3.9.7 Back mesh (2) ----------------------------------------------------------------------------------------------- 30
3.9.8 Backstops--------------------------------------------------------------------------------------------------- 30
3.9.9 Fall through protections (2) --------------------------------------------------------------------------- 30
3.9.10 Warehouse accessibility------------------------------------------------------------------------------- 31

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 2
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.9.11 Capacity and load sign --------------------------------------------------------------------------------- 32

3.9.12 Storage Profile protection (2) ------------------------------------------------------------------------- 32
3.9.13 Climbing----------------------------------------------------------------------------------------------------- 32
3.10 Clearances-------------------------------------------------------------------------------------------------- 33
3.10.1 Horizontal and vertical clearances ---------------------------------------------------------------- 33
3.10.2 Minimum clearances ----------------------------------------------------------------------------------- 34
3.10.3 Multifunctional role of vertical clearances ----------------------------------------------------- 34
3.10.4 Vertical clearances at storage locations --------------------------------------------------------- 35
3.10.5 Vertical clearances at picking locations with only ceiling sprinkler heads --------- 36
3.10.6 Vertical clearances at picking locations with ceiling & in-rack sprinkler heads -- 37
3.10.7 Vertical clearance alignment with in-rack sprinkler heads ------------------------------- 38
3.10.8 Vertical clearances at the back --------------------------------------------------------------------- 38
3.11 Width and depth of locations ----------------------------------------------------------------------- 39
3.11.1 Theoretical maximum depth based on standard Warehouse Racking (1)(2) --------- 39
3.11.2 Usable maximum width and depth based on aisle width and Forklift --------------- 41
3.11.3 Limitations for multiple Unit Loads in a single storage location ----------------------- 42
3.12 Unit Load placement ----------------------------------------------------------------------------------- 43
3.12.1 Placement of Unit Loads with Paper Pallet on Storage Profiles ------------------------ 43
3.12.2 Placement of ULs with Paper Pallet at EURO sized Storage Profiles ----------------- 43
3.12.3 Placement of ULs with Paper Pallet at IKEA sized Storage Profiles ------------------- 44
3.12.4 Placement of ULs with Wooden Pallets at EURO sized locations ---------------------- 46
3.12.5 Placement of ULs with Wooden Pallets at EURO sized locations with mesh ------ 47
3.12.6 Placement of ULs with Wooden Pallets at IKEA sized locations ------------------------ 47
3.12.7 Placement of ULs with Wooden Pallets at IKEA sized (2-leg) locations -------------- 49
3.12.8 Placement of ULs at picking locations ----------------------------------------------------------- 50
3.13 Inspection -------------------------------------------------------------------------------------------------- 52
3.13.1 Visual check ------------------------------------------------------------------------------------------------ 52
3.13.2 Frequency (2) ----------------------------------------------------------------------------------------------- 52
3.13.3 Tolerances -------------------------------------------------------------------------------------------------- 54
3.13.4 Inspectors -------------------------------------------------------------------------------------------------- 54
3.13.5 Assessment tools (2) ------------------------------------------------------------------------------------- 54
3.13.6 Upright and cross brace assessment ------------------------------------------------------------ 55
3.13.7 Twisted upright assessment (2)---------------------------------------------------------------------- 56
3.13.8 Beam assessment --------------------------------------------------------------------------------------- 57
3.13.9 Locking pins/bolts assessment (2) ------------------------------------------------------------------ 58
3.13.10 Storage Profile assessment (2) ----------------------------------------------------------------------- 59

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 3
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.13.11 Upright protection assessment (2)------------------------------------------------------------------ 60

3.13.12 Floor anchoring assessment (2) --------------------------------------------------------------------- 61
3.13.13 Mesh assessment (2)------------------------------------------------------------------------------------- 61
3.13.14 Stored Unit Loads assessment (2) ------------------------------------------------------------------ 62
3.14 Block stacking --------------------------------------------------------------------------------------------- 63
3.14.1 Stacking Unit Loads with Paper Pallets ---------------------------------------------------------- 63
3.14.2 Stacking white goods (appliances) ---------------------------------------------------------------- 65
3.14.3 Stacking Handling Material -------------------------------------------------------------------------- 66
4 Revision history ----------------------------------------------------------------------------------------- 67
5 Index --------------------------------------------------------------------------------------------------------- 68

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 4
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

1 Overview

1.1 Purpose

The purpose of this Standard Operating Procedure (SOP) is to describe the basic Warehouse Racking require-
ments in line with the operational needs forthcoming from our Forklift equipment space needs, the goods
handling sub processes taking place in the area, the requirements for setting up the WMS from a capacity
perspective, the inspection of Warehouse Racking, and the use of block stacking. It is the basis for Excellence
in Operation and service to customer in all sub processes from inbound handling to outbound handling.

Critical requirements are marked with an exclamation mark symbol:

1.2 Scope

This SOP explains the situational setup of stock bearing areas, either in Warehouse Racking or block stack are-
as, contributing to Excellence in Operation at every touch point in the storing and retrieval goods handling
sub processes. In order to harvest all benefits of the procedures in this SOP, aside their application, handled
Unit Loads must be compliant to SOP: Caring about Unit Loads.

Described requirements are valid for all individuals handling IKEA Products in all IKEA branded, and INGKA
owned, leased or operated Fulfilment Units. In case specific requirements are only valid in a Central or Store
Fulfilment Unit, this is then marked with a colored background:

… …
(CENTRAL FULFILMENT UNITS) (STORE FULFILMENT UNITS)

Some requirements are not valid, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased,
or operated units. These requirements are marked ‘(2)’.

Both managers and co-workers are target groups, acting according to their respective responsibilities.

1.3 Roles & Responsibilities

Who is accountable: Fulfilment Unit Manager

Who is responsible: Fulfilment Warehouse Manager / Store Logistics Manager
Who contributes: All involved co-workers

1.4 INGKA Group / Business Rules

Group / Business Rule No. and Name Specific Rule No. and Name
Ingka Group Rule on Health, Safety & Security

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 5
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

1.5 References

EN 15.629 (Steel static storage systems - Specification of storage equipment)

EN 15.635 (Steel static storage systems - Application and maintenance of storage equipment)
EN 15.620 (Steel static storage systems - Tolerances, deformations and clearances)
EN 15.512 (Steel static storage systems - Principles for structural design)
EN 16.681 (Steel static storage systems - Principles for seismic design)
INGKA preferred Handling Equipment supplier operating manuals

1.6 Definitions

Aisle The free space between Warehouse Racking runs, between a Warehouse Racking
run and walls, areas, and/or other obstacles.
ASTRO Warehouse Management System software package.
Bay The space in between 2 uprights, from floor to the top of the upright.
Back mesh An intertwined structure, placed behind a Warehouse Racking run.
Backstop A structure at the rear of or behind the storage location, acting as a barrier.
Back-to-back The space in between two adjacent Warehouse Racking runs.
Bar in/out To block locations for storing/retrieving goods.
Beam A metal bar, manufactured for carrying Handling Material.
Beam level The height where a beam is placed within a bay, measured at the top of the beam.
Beam connector The part of the beam that connects and locks into the upright.
Bolt A threaded fastener with an external male thread for a nut.
Buckling length Determines the maximum span a column can support with load before it collapses.
Cable tie A plastic strip with serrations on one end that lock inside an opening on the other
end, used to bind things together.
Capacity and load sign Signs which tell end users how to use and how not to use Warehouse Racking.
CEA European insurance and reinsurance federation.
CEN European Committee for Standardization
Chimney The flue space within the back-to-back space of two Warehouse Racking runs.
Clearance The distance between two objects, an amount of clear space.
Compartment The entire storage space on top of a single beam, in between the 2 uprights.
Cross brace The metal parts between uprights to form a frame.
Deflection Bending, turn from a true course or straight line. We use the “L/200” limit for Ware-
house Racking, where “L” stands for the length, or span, and dividing this by 200
gives the maximum bending limit.
Deformation Changing the original form.
Dent A hollow or depression in a surface.
Display shelve Space in the Warehouse Racking dedicated to present a selection of best-selling
products in the location below.
Drive-through Dedicated place where Forklifts can drive-through the Warehouse Racking into ad-
jacent aisles.
Dynamic forces Forces that occur due to motion.
(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 6
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Elevated location All locations above the floor.

End cap Plastic protection that fits into Storage Profile elements.
End frame First/last frame at Warehouse Racking run, or near drive/walk-through.
End frame protector Protective shields installed around the base of an end frame to minimise damage.
End podia Space at the beginning of a Warehouse Racking run to help customers navigate,
showing an example of the type of products that are stored in the aisle behind.
Exposed area The place where individuals are not protected against potential falling items.
Fall through protection A safety mesh to prevent items or Unit Loads stored above from falling through the
Warehouse Racking structure.
Flange The outer edge of the backside of an upright which is attached to cross braces.
Flue space Flue space allows, in case of fire, heat and smoke to go upwards. This delays the
spread of fire, and allows the fire sprinkler systems to extinguish the fire or keep it
away from spreading.
Flush Even with another surface or component.
FM An American mutual insurance company (FM Global) that specializes in loss preven-
tion services.
Frame Combination of 2 or 3 uprights, with cross braces.
Gross-row-spacer-share Total available space behind a Warehouse Racking frame, for storage and clear-
ance/flue space) together.
Handling Equipment (HE) Refers to normal Forklifts, pallet jacks, and mono forks used to handle Unit Loads.
Heavy duty mesh An intertwined structure, placed inside a storage location, developed to carry half
EURO sized Wooden Pallets.
High-level picking area Picking area built under the ceiling inside Warehouse Racking.
Honeycomb A rugged, cost-effective, custom engineered paper material that is stronger than
corrugated cardboard and less expensive than wood.
Hybrid Storage Profile Storage Profile (decking) with wooden (timber) elements to store Unit Loads on.
Inside protector Protective shields installed around the base of an entire frame, at all sides, to mini-
mize damage to Warehouse Racking, Unit Loads, and/or IKEA Products.
Inspection Look carefully, closely and critically.
Leg Row of combined uprights and beams.
Loading Unit Vehicle type to move cargo: Container types, Trailers, Box-Trailers, Box-Vans, etc.
Locking pin/bolt A small metal device that is placed to lock the beam and upright together to avoid
that beams get accidentally, and unintendedly, dislodged.
Mapping The process of identifying, dimensioning, and naming of all locations, work areas,
and travel paths, within the Fulfilment Unit.
MDF Medium-density fibreboard, a wood-substitute material.
Mesh An intertwined structure, most often made out of metal.
Module Low Unit Loads, designed for optimized minimum delivery quantity per article.
NFPA National Fire Protection Association.
OSB Oriented strand board, similar to particle board.
Picking location Location where individuals take and collect articles in a specified quantity.
Profile element for ready Type of Storage Profile, formerly known as OPUL profiles.
-to-sell Unit Load
(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 7
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Row spacer Are mounted between adjacent Warehouse Racking runs to ensure that they are
kept straight and to give the Warehouse Racking even more strength and steadi-
ness.
Run Row of interconnected bays.
Seismic activity Movements caused by an earthquake or vibration of the earth, whether due to nat-
ural or artificial causes.
SGF Store Goods Flow - WMS software package
Showcase A dedicated space in the Warehouse Racking to present a combination of best-
selling IKEA Products.
Silo Warehouse with high bay racking in which Unit Loads are handled by a crane, auto-
mated or semi-automated (operator on board)
Sprinkler head The component of a fire sprinkler system that discharges water when the effects of
a fire have been detected, such as when a predetermined temperature has been
exceeded.
Sprinkler system A fire sprinkler system is an active fire protection method, consisting of a water
supply system, providing adequate pressure and flowrate to a water distribution
piping system onto which fire sprinklers are connected.
Sprinkler zone The area covered by the discharge water spray from the sprinkler heads.
Stack Orderly pile of Unit Loads.
Static forces A constant force applied to a stationary object.
Storage location Location where Forklift operators store Unit Loads until they need to be sent to
other Fulfilment Units or to be replenished at picking locations.
Storage Profile A construction placed into a storage location to carry Unit Loads, especially de-
signed for Paper Pallets with low tunnel heights, but which can also be used with
Wooden Pallets.
Storage Profile element The parts of the Storage Profile where the Unit Load is placed on.
Tolerance The permissible range of variation in a dimension of an object.
Unit Load (UL) A manageable unit consisting of one or several consumer packages or several mul-
ti-pack packages, fixated to a Handling Material, designed to be handled at the
IKEA supply chain.
Unit Load Label (ULL) Provide clear and concise logistical information about the Unit Load to which it is
affixed.
Unit Load The Unit Load Stacking Capacity defines the maximum weight (in kg) that can be
stacking capacity stacked on top of the Unit Load.
Upright A metal column or post, produced into a modified "C" shape, containing holes or
slots at which to connect beams and cross braces.
Upright protector Protective shields installed around the base, floorplate, and anchors of an upright
to minimize damage.
Walk-through Dedicated place where pedestrians can walk through the Warehouse Racking into
adjacent aisles.
Warehouse A software application to control and manage the day-to-day operations in a ware-
Management house. WMS software guides inventory, receiving and storing, optimizes picking
System (WMS) and shipping of orders, and advises on inventory replenishment.
Warehouse Racking Material handling storage aid system designed to store materials on Handling Ma-
terial.
(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 8
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

2 Process Map

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 9
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3 Description of the SOP activities

Important note:

All dimensions mentioned in the below paragraphs are based on the INGKA
standards for Warehouse Racking and aisles. Actual Warehouse Racking and
aisle sizes within your Fulfilment Unit might deviate. In order to apply all proce-
dures, standard and requirements, all Warehouse Racking and aisles must be
measured, and the given standard dimensions in this SOP adapted accordingly.

3.5 Standard types

3.6 Standard dimensions
(3.6.1 Frame depth, 3.6.2 Compartment width, 3.6.3 Beam spacing, 3.6.4 Upright
buckling length, 3.6.5 Configurations)
3.8 Storage Profiles
(3.8.1 Storage Profiles width of 880mm and 730mm, on 2.0m and 3.0m beams, 3.8.2
Storage Profiles width of 880mm and 730mm, on 1.9m and 2.9m beams, 3.8.3 Stor-
age Profiles width of 800mm and 650mm, on 2.0m and 3.0m beams, 3.8.4 Storage
Profiles width of 800mm and 650mm, on 1.9m and 2.9m beams)
3.11.1 Theoretical maximum depth based on standard Warehouse Racking

The described procedures, standard and requirements in this document are

applicable for all type of Fulfilment Units without taking any specific require-
ments into consideration related to seismic activity.

Warehouse Racking structures in the Fulfilment Unit can meet older require-
ments and therefore have differences with the current described procedures,
standard and requirements. Always refer to the supplier handover package for
further details. Any changes to the Warehouse Racking configuration will have
an impact on the total load capacity of the Warehouse Racking structure and
structural integrity.

Changes to the Warehouse Racking structure must:

 only be made after formal written approval of the Warehouse Racking

supplier for all changes to the Warehouse Racking on top of the first
buckling length above the floor,
 be executed according to the relevant technical requirements,
 be executed by qualified, trained, and certified individuals,
 include an update of the Warehouse Racking information package,
 include updated or new load signs when needed.

Changes in Warehouse Racking configuration might require changes in the fire

sprinkler system setup to secure compliancy with NFPA, FM, CEN or CEA stand-
ards and meet INGKA’s intended protection level.

Where local authorities require local standards only and do not recognize NFPA,
FM, CEN or CEA standards, the automatic fire sprinkler system must be individu-
ally verified, as acceptable by an authorized fire specialist, who has been ap-
proved by Group Risk Management.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 10
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.1 Naming and recognizing the main parts

Upright

Row spacer

Beam

Cross brace

Storage Profile

Capacity and load sign

Mesh

End frame protector

Upright protector

Cable tie

Locking pin

Special demands for Fulfilment Units in seismic areas can lead to different specifications/dimensions of com-
ponents like e.g.: higher beams, additional reinforcements and/or alternative component placement.
Built-in high-level picking areas, or automatic picking and storage solutions, can also lead to different specifi-
cations/dimensions of components.
(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 11
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.2 Structure build-up, part replacement, and maintenance

Qualified, trained, and certified individuals, working for the Warehouse Racking supplier or appointed
contractors, must erect new Warehouse Racking structures in the unit.

Qualified, trained, and certified individuals, must replace all damaged Warehouse Racking parts.

Appointed INGKA co-workers, with a strong passion for safety, can:

 place or replace parts below 2000mm, limited to all in-rack accessories and their respective fixation ma-
terials (no cross braces, uprights, spliced uprights),
 place any relevant accessories on end frames/podia,
 place show models, customer communication, tools, lighting, safety equipment, etc.

Trained operators of order pickers and mobile elevated work platforms can replace aisle side locking pins/
bolts for beams and/or Storage Profile cable ties on all elevated levels.

Splicing of uprights is not an INGKA approved replacement method. Only if the original solution is a spliced
upright, the damaged part can be replaced separately. An exception applies for end frame extensions since,
on these components, no vertical forces are acting.

3.3 Requirements

Once the Warehouse Racking structure has been handed over from the supplier to the Fulfilment Unit, the
Fulfilment Unit has to map the storage locations in the Warehouse Management System (ASTRO/SGF), in-
spect, assess, maintain, and use the Warehouse Racking according to the relevant specifications. This docu-
ment will explain the different components to inspect and assess, and will describe the necessary corrective
actions required to be initiated.

The Warehouse Racking supplier must hand over all relevant information related to the erected Warehouse
Racking. The package must include information such as:

 static/dynamic calculations,
 (dis-)assembly and service instructions,
 operating instructions,
 spare parts list,
 number and types of anchors used to firmly fix the Warehouse Racking and its protection to the floor,
 the configuration of all the sections as they’ve been erected,
 configuration changes made after the Fulfilment Unit has accepted the handover,
 layouts in English,
 operating instructions on demand in national language/languages,
 capacity and load signs in national language/languages.

This package must be available to the Fulfilment Unit and kept up to date when changes are made.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 12
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.4 Objects and elements not belonging to the structure

It is not allowed to puncture or drill into any of the Warehouse Racking compo-
nents as this can weaken the structure. Lighting, fire extinguishers, and other
necessary equipment or facilities are fixed to the structure using existing holes,
hanging on the structure, or installed on a standalone solution, according to the
supplier handbook. They are always installed by qualified individuals while re-
specting all codes.

Total weight capacity and static construction of the Warehouse Racking has to be
monitored when adding additional elements.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 13
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.5 Standard types (1)(2)

There are 2 standard types of Warehouse Racking for Unit Load storage in the INGKA Central Fulfilment Unit:

EURO sized 2-leg IKEA sized 3-leg

6300 9450

1050 700 1050 3500 1050 700 1050 1050 800 900 800 1050 4850 1050 800 900 800 1050

EURO sized IKEA sized

number of legs 2 3

minimum aisle width 3500mm 4850mm

EURO - EURO 700mm

minimum row spacer
IKEA - IKEA 900mm
length
IKEA - EURO 800mm

Fulfilment Units with ESFR (Early Suppression, Fast Response) sprinkler heads and fire baffles cannot have
back-to-back IKEA and/or IKEA XL Warehouse Racking due to the fact that two combined bays exceed the max-
imum surface of 11,5 m2.
IKEA sized 2-leg

Older Central Fulfilment Units might have 2-legged

Warehouse Racking designed for storing IKEA sized
Unit Loads with Wooden Pallets. Applying the princi-
ples described in this document allow these installa-
tions to be used safely.

There are no goods picking operations allowed in

this Warehouse Racking type, unless loaded with EU-
RO sized Unit Loads only.
550 550

1050 1100 1050

(CENTRAL FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 14
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

There are 3 standard types of Warehouse Racking for Unit Load storage in the INGKA Store Fulfilment Unit:

EURO sized 2-leg IKEA sized 3-leg

5700 8300

1050 600 1050 3000 1050 600 1050 1050 800 600 800 1050 1050 800 600 800 1050
4000

IKEA XL sized 3-leg

9200

1050 1000 800 1050 1050 800 1000 1050

4500

Fulfilment Units with ESFR (Early Suppression, Fast Response) sprinkler heads and fire baffles cannot have
back-to-back IKEA and/or IKEA XL Warehouse Racking due to the fact that two combined bays exceed the max-
imum surface of 11,5 m2.

EURO sized IKEA sized IKEA XL sized

number of legs 2 3 3

minimum aisle width 3000mm 4000mm 4500mm

minimum row spacer EURO - EURO / EURO - IKEA / IKEA - IKEA 600mm
length EURO - IKEA XL / IKEA - IKEA XL 1000mm

(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 15
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.6 Standard dimensions (1)(2)

3.6.1 Frame depth (1)(2)

INGKA has agreed on a

Warehouse Racking
standard that is in line EURO IKEA
with our supply chain
needs and that meets all Hej,

relevant safety criteria. Im

Aisle
50mm 50mm 50mm 50mm 50mm

950mm 950mm
750mm

1050mm 1850mm

3.6.2 Compartment width (1)(2)

The standard compartment widths in Central Fulfil- 3000mm

ment Units are 3000mm and 2000mm. Only compart-
ments with a drive-through can be wider.
2000mm

(CENTRAL FULFILMENT UNITS)

The standard compartment widths in Store Fulfilment 2900mm

Units are 2900mm and 1900mm. Only compartments
with a drive-through can be wider.

1900mm

(STORE FULFILMENT UNITS)

There may be examples where compartments deviate from the standard, e.g. in seismic active areas or above
drive-throughs. It’s important to know, and verify with the Warehouse Racking supplier if needed, what the
exact weight bearing capacity of storage locations in these compartments is.
(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 16
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.6.3 Beam spacing (1)(2)

A standard compartment
height is set to 1400mm, Level 70
8450m m
and 1450mm for beams Level 60
7950mm
above 6500mm.
Level 60
7000m m
Below 3500mm, an addi- Level 50
6500mm
tional beam can be add-
ed in order to create Level 50
5600m m Level 40
700mm gross high stor-
5100mm
age locations for Mod- Level 35*
Level 40
ules and backflow Unit 4200m m
4400mm
Level 30
Loads. The maximum Level 35 3700mm
bay weight must never 3500m m Level 25
Level 30 3000mm
be exceeded. 2800m m Level 20
Level 25
2300mm
2100m m
A beam level is measured Level 20 Level 10
at the top of the beam, a 1400m m 1400mm
compartment is meas- Level 5
750mm
ured between both beam Level 10 Level 0
tops.
* only allowed above drive-through´s

(CENTRAL FULFILMENT UNITS) (STORE FULFILMENT UNITS)

3.6.4 Upright buckling length (1)(2)

The buckling length for The buckling length for

uprights in Central Fulfil- uprights in all Store Ful-
ment Units is 2800mm filment Units is 2300mm
on any level, and measured from the floor
2850mm when creating a up. The next upright
2800mm

high location at level 50. buckling length, above

2300mm for the same
2800mm

upright, is 2800mm, and

2850mm when creating a
high location at level 40.
2300mm

(CENTRAL FULFILMENT UNITS) (STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 17
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.6.5 Configurations (1)(2)

Within the given Warehouse Rack-

ing standard, many different config-
urations can be made based on lo-
cal facts and needs like e.g.: capaci- 1450
ty, volumes, range, etc.
2850

1400

1400

2800

1400

2300
2300 /
/ 2800
2800

Example

Non-standard bays are bays with an

atypical configuration, aiming to
create:

1450
 a drive-through,
 an extra high picking location,
 a range presentation solution,
 or a communication solution. 1400

The adjoining bays of non-standard

bay configurations must have all 1400
beams installed at standard Show case
heights, except the beam at
1400mm. Non-standard bays can 1400
never be the first, nor the last bay of Drive-through
a Warehouse Racking run. or
extra high
2300
location Show case
/
2800

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 18
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.7 Location types (2)

Different storage location types can be created within Warehouse Racking compartments. Each of the follow-
ing storage location types have maximum load bearing capacities. These maximum capacities must be se-
cured within the Warehouse Management System mapping process. It must be ensured that the maximum
compartment load is never exceeded. Mapping additional compartments must be done in a way which en-
sures that the maximum bay load is never exceeded. Consult the Warehouse Racking package details, or the
capacity and load signs on the Warehouse Racking itself, for more details on the allowed loads.

Paying special attention to load bearing capacity and clearances is required for mapping 4 narrow Unit Loads
in one 3000mm compartment.

Hybrid Storage Profile

Storage location with a hybrid Storage Profile for a
Unit Load with Paper Pallet, equal to, or wider than
720mm. They can also be used for Unit Loads with a
Wooden Pallet, respecting all required clearances.
Weight restriction of the storage location: 750Kg,
minus weight of the Storage Profile = Unit Load:

 EURO sized Warehouse Racking, max. 719Kg

 IKEA sized Warehouse Racking, max. 713Kg

Narrow hybrid Storage Profile

Storage location with a hybrid Storage Profile for a
narrow Unit Load with Paper Pallet less than 720mm
wide.
Weight restriction of the storage location: 750Kg,
minus weight of the Storage Profile = Unit Load:

 EURO sized Warehouse Racking, max. 719Kg

 IKEA sized Warehouse Racking, max. 713Kg

Heavy duty mesh

Storage location with a heavy duty mesh for half EU-
RO sized Wooden Pallets, not for Paper Pallets, only
allowed to be used on storage level 20 and 30.
Weight restriction of the storage location: 750Kg,
minus weight of the heavy duty mesh = Unit Load:

 EURO sized Warehouse Racking, max. 728Kg

(CENTRAL FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 19
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Wooden Pallet location

Storage location for Unit Load with Wooden Pallet.
Weight restrictions towards the storage location:

 EURO sized Warehouse Racking, max. 750Kg

 IKEA sized Warehouse Racking, max. 750Kg

Metal Storage Profile

Storage location with a metal Storage Profile for a
Unit Load with Paper Pallet, equal to, or wider than
720mm. They can also be used for Unit Loads with a
Wooden Pallet, respecting all required clearances.
Weight restriction of the storage location: 750Kg,
minus weight of the Storage Profile = Unit Load:

 EURO sized Warehouse Racking, max. 719Kg

 IKEA sized Warehouse Racking, max. 713Kg

Narrow metal Storage Profile

Storage location with a metal Storage Profile for a
narrow Unit Load with Paper Pallet less than 720mm
wide.
Weight restriction of the storage location: 750Kg,
minus weight of the Storage Profile = Unit Load:

 EURO sized Warehouse Racking, max. 719Kg

 IKEA sized Warehouse Racking, max. 713Kg

Profile elements for ready-to-sell Unit Loads

Picking location with profile elements for ready-to-
sell Unit Loads with Paper Pallet.
Weight restriction of the storage location: 750Kg,
minus weight of the profile elements = Unit Load:

 EURO sized Warehouse Racking, max. 727Kg

 IKEA sized Warehouse Racking, max. 713Kg

(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 20
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Unit Loads can be both

double and deep stacked
on floor level inside the
Warehouse Racking
structure.

All criteria for block

stacking apply.

The height of the stacked Front

Unit Loads must ensure view

a minimum of 75mm
clearance towards the
upper beam.

Side views

Range presentations can

be integrated into the
Warehouse Racking.

Presented show models

on e.g. showcases, end
podia and/or display
shelves must be firmly
fixed to the Warehouse
Racking.

(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 21
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.8 Storage Profiles (1)(2)

Mapping storage locations with the Warehouse Management System must be done with one of the following
standard configurations, valid for the specific type of Storage Profile, length of beam, and type of Fulfilment
Unit. Each configuration shows the maximum width dimension that must be mapped.

Storage Profiles with a width of 880mm and 730mm have been produced until the beginning of 2020. An im-
proved Storage Profile design with a reduced with of 800mm and 650mm became available in 2019. Both can
be used in the same Fulfilment Unit, as long as they are not mixed in the same compartment.

3.8.1 Storage Profiles, width of 880mm and 730mm, on 2.0m and 3.0m beams (1)(2)

Configuration 1 - Can be placed above exposed areas Configuration 2 - Can be placed above exposed areas
 3000mm →  3000mm →

<
880mm 940mm 880mm 980mm 980mm
720mm

75 105 105 75 130 125 125 130

3000mm

Configuration 3 - Can be placed above exposed areas Configuration 4

 3000mm →  3000mm →

900mm 900mm 900mm 1450mm 1320mm

85 95 95 85 360 590 300

3000mm 3000mm

Configuration 5 Configuration 6
 3000mm →  3000mm →

< < < < <

1240mm
720mm 720mm 720mm 720mm 720mm

75 255 255 75 203 202 202 203

3000mm

(CENTRAL FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 22
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Configuration 7 Conf. 8 - Can be placed above exp. areas Configuration 9

 2000mm →  2000mm →  2000mm →

< < <

1040mm 880mm 880mm
720mm 720mm 720mm

75 160 155 75 90 75 180 180 180

(CENTRAL FULFILMENT UNITS)

3.8.2 Storage Profiles, width of 880mm and 730mm, on 1.9m and 2.9m beams (1)(2)

Configuration 1 - Can be placed above exposed areas Configuration 2 - Can be placed above exposed areas
 2900mm →  2900mm →

<
840mm 880mm 840mm 940mm 940mm
720mm

5 5
75 75 110 95 95 110
5 5

Configuration 3 Configuration 4
 2900mm →  2900mm →

< < < < <

1160mm
720mm 720mm 720mm 720mm 720mm

65 215 215 65 180 175 175 180

Configuration 5 Configuration 6
 2900mm →  1900mm →

<
1330mm 1330mm 950mm
720mm

300 540 300 115 100 75

(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 23
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.8.3 Storage Profiles, width of 800mm and 650mm, on 2.0m and 3.0m beams (1)(2)

Configuration 1 - Can be placed above exposed areas Configuration 2 - Can be placed above exposed areas

 3000mm →  3000mm →

650mm 650mm 650mm 650mm 950mm 800mm 950mm

80 80 80 80 80 150 150 150 150

3000mm 3000mm

Configuration 3 - Can be placed above exposed areas Configuration 4

 3000mm →  3000mm →

800mm 950mm 800mm 900mm 900mm 900mm

150 150 150 150 125 175 175 125

3000mm 3000mm

Configuration 5 Configuration 6

 3000mm →  3000mm →

< <
650mm 1400mm 650mm 1260mm
720mm 720mm

75 375 375 75 110 340 340 110

3000mm 3000mm

Configuration 7 Configuration 8

 3000mm →  3000mm →

1020mm 650mm 1020mm 800mm 1100mm 800mm

190 185 185 190 75 225 225 75

3000mm 3000mm

(CENTRAL FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 24
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Configuration 9
 3000mm →

1450mm 1320mm

400 660 340

3000mm

Configuration 10 Configuration 11
 2000mm →  2000mm →

<
1050mm 880mm 880mm
720mm

110 240 200 115 170 115

(CENTRAL FULFILMENT UNITS)

3.8.4 Storage Profiles, width of 800mm and 650mm, on 1.9m and 2.9m beams (1)(2)

Configuration 1 - Can be placed above exposed areas Configuration 2

 2900mm →  2900mm →

<
850mm 900mm 850mm 940mm 940mm
720mm

100 150 150 100 145 180 180 145

Configuration 3 Configuration 4
 2900mm →  2900mm →

< <
1160mm 650mm 1300mm 650mm
720mm 720mm

145 255 255 145 75 325 325 75

(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 25
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Configuration 5 Configuration 6

 2900mm →  2900mm →

< < <

1330mm 1330mm
720mm 720mm 720mm

340 620 340 240 235 235 240

Configuration 7
 2900mm →

970mm 650mm 970mm

160 165 165 160

Configuration 8 Configuration 9
 1900mm →  1900mm →

<
950mm 1020mm 650mm
720mm

150 190 110 185 190 75

(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 26
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.9 Risk mitigation (2)

3.9.1 Upright anchoring (2)

The Warehouse Racking must be firmly fixed to the floor. The minimum require-
ment is 2 anchors in the base plate of the front upright, 1 anchor for the middle
(IKEA size Warehouse Racking) and back upright base plates. The handover infor-
mation package holds the information needed to check the correct anchoring of
the Warehouse Racking in the Fulfilment Unit.

3.9.2 Upright protection (2)

The Warehouse Racking

must be protected from
handling damages by
the use of:

 aisle side upright

protectors (a),
 inside protectors (b),
 or end frame protec-
tors (c).
(a) (b) (c)

These protectors must

be firmly fixed to the
floor.

End frame protectors are

required at the begin-
ning and end of the run,
inside drive-throughs,
and inside walk-
throughs.
End frame protector End frame protector Inside protector

Aisle side upright protec-

tors are a minimum of
300mm high. Inside and
end frame protectors are
a minimum of 400mm
high.

End frame protectors

can be partly made with End frame protector Inside protector Upright protector
wooden beams.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 27
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.9.3 Securing beams (2)

Beams must be se-

cured to the up-
rights by certified
locking pins, or cer-
tified bolts, in order
to prevent beams
being accidentally
dislodged.

3.9.4 Securing Storage Profiles (2)

Storage Profiles must be

fixed to the front beam
with 2 approved cable Min. 30mm
ties. These cable ties se- Hej,

cure that the Storage Im

Aisle
Profile cannot fall out of
the Warehouse Racking
when coincidently
touched or lifted during
storing/retrieving of Unit
Loads. Aisle side beam, 2 cable ties and ‘gripped’ by L-profiles on both sides,
plus L-profile in front of the middle and last beam.

To ensure we can check the position of the Storage

Profile in its respective location, a magnetic strip of
the same size as 2 Storage Profile elements and the
space between them, can be placed on the beam
aligned with the Storage Profile elements. They must
be consistently placed, left or right, of each Storage
Profile. The drawing shows the magnetic strip on the
left side of the storage profile, as seen from the side
of the aisle.

Use the Forklift, without load on the fork arms or on

the Storage Profile, to gently slide the profile back
into its intended position.

Profile elements for

ready-to-sell Unit Loads
in picking locations must
be fixed to the aisle side
beam with a front clip
and to the mesh in the
back, with a back clip.
(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 28
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.9.5 Extended end frames (2)

Extended end frames (b)

prevent items falling
sideways into main
aisles.
(a) (b)

A standard upright (a)

can extend above the
highest beam, but this is
not required.
(a) (b)
Uprights at the begin-
ning and the end of a
run must extend at least
1100mm above the high-
est beam, to be allowed
to store a Unit Load with
a maximum height of
2150mm in the storage
locations next to end
frame.

The maximum height of

a Unit Load mapped next
to an end frame is twice
the length of the frame
extending over the high-
est positioned beam.

Example: If the frame

extends 500mm, the Unit
Load must be maximum
1000mm high.

3.9.6 Drive-through and walk-through clearances

In-rack drive-through
clearance between Ware-
MI NI MUM 250m m

house Racking and Fork-

lift must be at least
250mm.

In-rack walk-throughs
Minim um
2100m m

must be at least 2100mm

high.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 29
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.9.7 Back mesh (2)

Single sided free stand-

ing Warehouse Racking
requires netting or mesh
to make sure items or
Unit Loads cannot fall
out of the back of the
Warehouse Racking.
Items or Unit Loads can
still fall, but the point of
impact is contained with-
in the footprint of the
Warehouse Racking.

3.9.8 Backstops

Backstops, intended to
stop Unit Loads from
  
being pushed too deep
into the location, are for-
bidden for any type of
Warehouse Racking.

3.9.9 Fall through protections (2)

Fall through protections are needed above all Warehouse Racking locations, in between the beams, where
individuals need to get inside the Warehouse Racking structure with head and torso. The exposed areas must
not have gaps exceeding a width of 150mm.

Examples
1 2 3 4 5 6

Level 70

Level 60

Level 50

Level 40

Level 30
HAND STACKED PICKING ITEMS OF A
STORAGE UNIT LOAD LIFTED BY DRIVE
LOCATION GOODS AN ORDER PICKER HIGH PICKING THROUGH
PICKING
Level 20 LOCATION LOCATION

PICKING PICKING PICKING WALK WALK

LOCATION LOCATION LOCATION THROUGH THROUGH
Level 10

Fall through protection required

(CENTRAL FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 30
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Examples
1 2 3 4 5 6

Level 60

Level 50

Level 40

Level 30
DISPLAY SHELF

Level 20 PICKING HAND STACKED DRIVE

HIGH
LOCATION GOODS THROUGH
PICKING
Level 10 LOCATION SHOW CASE
PICKING PICKING WALK
WALK
LOCATION LOCATION THROUGH
THROUGH

Fall through protection required

(STORE FULFILMENT UNITS)

Walk-through locations
in Warehouse Racking
next to a wall need to
have fall through protec-
tion installed between
the Warehouse Racking
and the wall. This protec-
tion can be mesh, net-
ting, or any other suppli-
er approved and INGKA
Procurement offered
solution.

3.9.10 Warehouse accessibility

During trading hours,

the warehouse area has
to be closed off for our
customers and visitors,
as in this area heavy
equipment can be in use.

(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 31
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.9.11 Capacity and load sign

Sufficient capacity and load signs, provided by the

Warehouse Racking supplier, must be available and
clearly visible.

The content of the sign must include relevant infor-

mation for all types of INGKA approved handling ma-
terial suitable for storage in the different types of
storage locations.

(E.g. Warehouse Racking type, max. weight per stor-

age and picking location, max. weight per compart-
ment, max. weight per bay, etc)

3.9.12 Storage Profile protection (2)

(CENTRAL FULFILMENT UNITS)

Metal Storage Profiles are, in essence, made for stor-
age locations and not for picking locations.
By attaching end caps at the aisle side and in each
Storage Profile element, we are able to use them in
picking locations below 2800mm (level 30) as well.
With adding these end caps we protect individuals
from potential bodily harm.
Given the fact that Storage Profiles stick out 75mm
into the aisle, they can not be used in picking loca-
tions at Store Fulfilment Units.

All individual profile elements for ready-to-sell Unit

Loads with Paper Pallet must have an attached end
cap in order to protect individuals from potential
bodily harm. These type of profile elements are espe-
cially designed for Store Fulfilment Units.

(STORE FULFILMENT UNITS)

3.9.13 Climbing

Appointed individuals must have had a specific train-

ing and use fall protection equipment when climbing
in Warehouse Racking cannot be avoided.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 32
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.10 Clearances

3.10.1 Horizontal and vertical clearances

To facilitate the handling and storage activity, clearances must be ensured when setting up the Ware-
house Management System (ASTRO/SGF).

Clearances apply for all storage and picking locations defined within the Warehouse Racking structure,
from the floor up to the highest storage location.

X Y (CENTRAL FULFILMENT UNITS) X Y (STORE FULFILMENT UNITS)

X: The minimum clearance between Unit Loads and uprights, and adjacent Unit Loads.
Y: The minimum clearances measured from the top of the Unit Load and the bottom of the beam above it.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 33
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.10.2 Minimum clearances

When beams are placed at a height between 0mm and 3000mm above the floor, the Y clearance for the load
placed on them is minimum = 75mm, between 3000mm and 6000mm the minimum is 100mm, and 125mm
when beams are placed at a height between 6000mm and 9000mm above the floor.

Beam Beam Y clearance

Level Level X clearance
height height Standard handling clearance In-rack sprinkler heads
(CENTRAL (STORE
Clearances between goods and/or beam/sprinkler heads must be bigger or equal to:
FULFILMENT UNITS) FULFILMENT UNITS)

8450mm 70 7950mm 60
125mm
7000mm 60 6500mm 50
5600mm 50 5100mm 40
4200mm 40 3700mm 30 100mm
3500mm 35
150mm 75mm
3000mm 25
2800mm 30 2300mm 20
2100mm 25 1400mm 10 75mm
1400mm 20 750mm 5
Floor 10 Floor 0

A support template to calculate the maximum usable height of a location is available. If the outcome of the
value to register cannot be set in the Warehouse Management System (ASTRO/SGF), round down to the first
value that can be registered.

3.10.3 Multifunctional role of vertical clearances

Vertical clearances secure sufficient handling space

when storing goods. The same space is needed for
fire protection, named flue space. Flue space:

 enables heat to have an unobstructed way up,

to activate the sprinkler heads, and evacuate
via the ceiling hatches,
 enables sprinkler water to reach the detected
fire in an unobstructed way,
 keeps away fire from spreading.

Warehouse Racking equipped with in-rack sprinkler

heads impacts the Y clearance and require more
space than needed for handling purposes only.

The Y clearance between the top of Unit Loads,

stored on the highest elevated storage level, and the
ceiling sprinkler heads must be at least:

 1000mm, when storage height is > 2500mm,

 500mm, when storage height is < 2500mm.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 34
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.10.4 Vertical clearances at storage locations

Warehouse Racking set-

up without in-rack sprin-
kler heads:

Sprinkler zone
 all handling clear-
ances will function
as flue spaces,
 the space between
stored Unit Loads
do not have to be
aligned between all
compartments and

Sprinkler zone
will function as ir-
regular flue space.

Warehouse Racking set-

up with in-rack sprinkler
Sprinkler zone

heads:

 all handling clear-

ances will function

Sprinkler zone
as flue spaces,
 compartments
with in-rack sprin-
kler heads require
planned handling
clearances be-
tween Unit Loads,
perpendicular un-
der the sprinkler
heads,
 the lowest tier of a
Sprinkler zone

sprinkler zone can

have handling
clearances that are
not aligned with
the compartment
above.

CEILING SPRINKLER HEADS ONLY CEILING & IN-RACK SPRINKLER HEADS

(with or without fire baffles)

Planned and required

vertical clearances to
function as flue space

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 35
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.10.5 Vertical clearances at picking locations with only ceiling sprinkler heads

Vertical clearances at ele-

vated picking levels:
 clearances of mini-
mum 75 mm are re-
quired near the up-
rights,
 clearances between

Sprinkler zone
stacks of goods are

Sprinkler zone
not required except
compartments with
mattresses and so-
fas,
 occasional spaces,
planned or un-
planned, will func-
tion as irregular flue
space,
 handling clearances
for Forklifts will func-
tion as flue space,
 matrasses and sofas
require additional
double mesh picking
Sprinkler zone

Sprinkler zone
location dividers.

Vertical clearances at
floor picking level:
 clearances near the
uprights are not re-
quired when replen-
ished with Pallet
Jacks or by hand,
 the space inside and
in between the up-
Sprinkler zone

rights will function as

Sprinkler zone

flue space, and

should therefore
never be blocked
with goods,
 handling clearances
for Forklifts will func-
tion as flue space,
(CENTRAL FULFILMENT UNITS) (STORE FULFILMENT UNITS)
 mattresses and so-
fas require single
mesh picking loca-
tion dividers for high
Planned and required
locations only. vertical clearances to
function as flue space

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 36
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.10.6 Vertical clearances at picking locations with ceiling & in-rack sprinkler heads

Vertical clearances at
multiple elevated picking
levels:
 compartments must
have a minimum of
75mm clearance
space on all levels

Sprinkler zone
between stacked

Sprinkler zone
goods, perpendicular
under the sprinkler
heads, and near the
uprights.

Vertical clearances at sin-

gle elevated picking lev-
els:
 clearances of min. 75
mm are required
near the uprights,
 clearances between
stacks of goods are
not required except
compartments with
Sprinkler zone

Sprinkler zone
mattresses and so-
fas,
 mattresses and sofas
must have a mini-
mum of 75mm clear-
ance space between
stacked goods, se-
cured with double
mesh picking loca-
tion dividers, per-
pendicular under the
sprinkler heads.
Sprinkler zone

Sprinkler zone

 handling clearances
for Forklifts will func-
tion as flue space.

Vertical clearances at
floor picking level:
(CENTRAL FULFILMENT UNITS) (STORE FULFILMENT UNITS)

 clearances near uprights are not required when replenished with Pallet
Jacks or by hand,
 the space inside and in between the uprights will function as flue space, and
Planned and required
should therefore never be blocked with goods, vertical clearances to
function as flue space
 handling clearances for Forklifts will function as irregular flue space,
 mattresses and sofas require single mesh picking location dividers for high
locations only.
(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 37
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.10.7 Vertical clearance alignment with in-rack sprinkler heads

In-rack sprinkler heads

are allowed to have a
maximum of 75mm off-
set from their intended/
ideal location in the flue
space.

The red coloured sprin-

kler heads represent the
intended/ideal location,
the yellow sprinklers rep-
resent the maximum,
offset.

3.10.8 Vertical clearances at the back

Minimum 150mm
Vertical clearance in be-
tween Warehouse Rack-
ing should be minimum
150mm wide, in a
STORAGE LOCATIONS

straight and unobstruct-

Chimney

ed way, from the top of

the lowest tier all the way
up to the ceiling.

This vertical clearance is

often called “the chim-
ney”.

There is no minimum
vertical clearance re-
quired for goods placed
back-to-back on floor
PICKING LOCATIONS

level.

Vertical clearing to obsta-

cles like a wall, pillar, util-
ities, etc. is at least
75mm.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 38
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.11 Width and depth of locations

3.11.1 Theoretical maximum depth based on standard Warehouse Racking (1)(2)

Based on standard Warehouse Racking depth, the use of standard-length row spacers, distances to walls/
objects, handling clearances and flue spaces, the maximum length of a Unit Load that can be handled in Ware-
house Racking, must be calculated.
150mm
Unit Loads being placed
on floor locations and
elevated locations below
2800mm, can stick out-
side the Warehouse
Racking frame inside the
aisle, with max. 75mm.

Chimney
There is no minimum
vertical clearance re-
quired for goods placed
back-to-back on floor
level.
1850mm 900mm 1850mm

The available space be-

tween the outer ends of
the aisle side uprights (a)
can be divided based on
the individual location
space need.
(a) 150mm

Calculation maximum depth floor location:

 EURO sized: 75+1050+700+1050+75= 2950mm

 IKEA sized: 75+1850+900+1850+75= 4750mm
Chimney

Calculation maximum depth storage location:

 EURO sized: 1050+(((700-150)/2)*2)= 1600mm

 IKEA sized: 1850+(((900-150)/2)*2)= 2600mm

Theoretical maximum depth of locations:

Level EURO sized IKEA sized

10 <2950mm <4750mm 1050mm 700mm 1050mm

20-25 1200mm 2000mm

30*-35-40*-50-60-70 1600mm 2600mm
*
Storage locations directly above 700mm high locations (level 25,
level 35) must not have dimensions longer than 1200mm for EURO
sized, and 2000mm for IKEA size Warehouse Racking.

(a)
(CENTRAL FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 39
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING
150mm
Unit Loads being placed
on floor locations and
elevated locations below
2300mm must not stick .

outside the Warehouse

Chimney
Racking frame in order to
maximize storage capaci-
ty.

There is no minimum
vertical clearance re-
quired for goods placed
back-to-back on floor
1850mm 600mm 1850mm
level.

The available space be-

tween the outer ends of
the aisle side uprights (a)
can be divided based on
the individual location
space need. (a) 150mm

Calculation maximum depth floor location:

 EURO sized: 1050+600+1050= 2700mm

Chimney
 IKEA sized: 1850+600+1850= 4300mm
 IKEA XL sized: 1850+1000+1850= 4700mm

Calculation maximum depth storage location:

 EURO sized: 1050+(((600-150)/2)*2)= 1500mm

 IKEA sized: 1850+(((600-150)/2)*2)= 2300mm
 IKEA XL sized: 1850+(((1000-150)/2)*2)= 2700mm#

Theoretical maximum depth of locations: 1050mm 600mm 1050mm

Level EURO sized IKEA sized IKEA XL sized

0 <2700mm <4300mm <4700mm
5-10 1200mm 2000mm 2000mm
20-25-30*-
1500mm 2300mm 2700mm#
40-50-60

*
Storage locations directly above 700mm high locations (level 25) must (a)
not have dimensions longer than 1200mm for EURO sized, and
2000mm for IKEA size Warehouse Racking.

#
Caution, potentially exceeding standard Forklift load bearing capacity.

(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 40
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Storage locations directly above 700mm high loca-

tions must not have dimensions longer than 1200mm
for EURO sized, and 2000mm for IKEA size Ware-
house Racking.

Dimensioning this way will minimise the potential

risk of hitting the Unit Load with the Forklift fork
board while (attempting to) handling the Unit Load
below.

3.11.2 Usable maximum width and depth based on aisle width and Forklift

The usable depth of a storage location is limited to

the used Forklift types and available aisle space. This
means that, even if the standard INKGA aisle dimen-
sions are respected, it’s necessary to make sure the
handling clearances are ensured and updated in the
Warehouse Management System (ASTRO/SGF). This
must be redone when new types of Forklifts are tak-
en into service, or aisles have been changed.

A Manoeuvring clearance
Dp Depth of Unit Load
D 90° turning radius of Forklift and Unit Load
AST Minimum clear aisle width,
between Unit Load or Warehouse Racking at any level
Wp Width of Unit Load

A support template to calculate the maximum usable width and depth of a location is available. If the outcome
of the value to register cannot be set in the Warehouse Management System (ASTRO/SGF), round down to the
first value that can be registered.
(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 41
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.11.3 Limitations for multiple Unit Loads in a single storage location

In order to secure visibility during Unit Load han-

dling, handling multiple Unit Loads on Paper Pallets,
in a single location is only allowed at locations below
3000mm, above the floor.

The maximum combined Unit Load length, for multi-

Max. Max.
ple Unit Loads at a single storage location is limited
per location, dependent on the Warehouse Racking 600 600
type: mm mm
Level EURO sized IKEA sized
<3000mm 1200mm 2000mm

Total max. 1200mm

Max. Max. Max.

Max. Max.
650 650 650
1000mm 1000mm
mm mm mm

Total max. 2000mm Total max. 2000mm

Multiple Unit Loads placed on, and strapped to, a

Wooden Pallets can be considered as a single Unit
Load, and therefore be stored on all elevated storage
levels, respecting all required clearances.

Total max. 2000mm

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 42
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.12 Unit Load placement

3.12.1 Placement of ULs with PP on Storage Profiles

Unit Loads with Paper

Pallets, equal to, or wider
than 720mm, given the
exception, all have mid-
dle feet. These PP feet
must always be placed
100% centrically on the
middle Storage Profile
element.

The outer PP feet must   

be placed on the Storage
Profile by at least 50% of
the width of the PP feet.

3.12.2 Placement of ULs with Paper Pallet at EURO sized Storage Profiles

   
Hej,

Im
Aisle

In order to secure visibility during Unit Load handling, handling multiple Unit Loads in a single location is only
allowed at locations below 3000mm, above the floor.

   
Hej,

Im
Aisle

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 43
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING


Compliant Unit Loads with Paper Pallets, less than
1200mm long, can be placed flush with the front of
the Storage Profile elements at aisle side. This will
ensure that the Forklift operator always has a clear Hej,

view on the handling material tunnels’ entry points. Im

Aisle

IKEA sized Unit Loads are not allowed to be stored in

EURO sized Warehouse Racking.

 
Hej,

Im
Aisle

3.12.3 Placement of ULs with Paper Pallet at IKEA sized Storage Profiles

 
Hej,

Im
Aisle


Hej,
In order to secure visibility during Unit Load han- Im
dling, handling multiple Unit Loads in a single loca- Aisle

tion is only allowed at locations below 3000mm,

above the floor.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 44
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

 
Hej,

Im
Aisle

 
Hej,

Im
Aisle
0

 
Hej,

Im
Aisle

Compliant Unit Loads

with Paper Pallets, less  
than 2000mm long,
can be placed flush
with the front of the
Storage Profile ele- Hej,

ments at aisle side. Im

Aisle
This will ensure that
the Forklift operator
always has a clear
view on the handling
material tunnels’ entry
points.
(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 45
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

 
Hej,

Im
Aisle

3.12.4 Placement of ULs with Wooden Pallets at EURO sized locations

   
Hej,

Im
Aisle

  
Hej,

Im
Aisle


Hej,

IKEA sized Unit Loads are not allowed to be stored in Im

EURO sized Warehouse Racking. Aisle

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 46
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.12.5 Placement of ULs with Wooden Pallets at EURO sized locations with mesh

   
Hej,

Im
Aisle

Heavy Duty Mesh Heavy Duty Mesh Heavy Duty Mesh Heavy Duty Mesh

(CENTRAL FULFILMENT UNITS)

3.12.6 Placement of ULs with Wooden Pallets at IKEA sized locations

 
Hej,
Max. Max. Im
1000mm 1000mm Aisle

Total max. 2000mm

 
Hej,

Im
Aisle

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 47
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

 
Hej,

Im
Aisle

 
Hej,

Im
Aisle

 
Hej,

Im
Aisle

 
Hej,

Im
Aisle

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 48
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.12.7 Placement of ULs with Wooden Pallets at IKEA sized (2-leg) locations

 

Hej,

Im
Aisle

 

Hej,

Im
Aisle

Older Central Fulfilment Units might have 2-legged Warehouse Racking designed for storing IKEA sized Unit
Loads with Wooden Pallets, not to be confused with 2-legged EURO size Warehouse Racking.

(CENTRAL FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 49
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.12.8 Placement of ULs at picking locations

Unit Loads being placed

on floor locations and
elevated locations below
2800mm can stick out-
side the Warehouse
Racking frame, inside the
aisle, with max. 75mm.

This will ensure a maxi-

mum aisle width for han-
dling goods and keeping
handled and already 75mm 75mm

stored goods free from Hej,

damages. Im
Aisle

75mm 75mm

(CENTRAL FULFILMENT UNITS)

Unit Loads being placed

on floor locations and
elevated locations below
2300mm must not stick
outside the Warehouse
Racking frame (flush with
the beam).

This will ensure a maxi-

mum aisle width for han-
dling goods and keeping Hej,

handled and already Im

Aisle

stored goods free from

damages.

Modules and low Unit

Loads in picking locations
have to be placed in such
a way that PP feet are
supported by a profile
element, and all clear-
ance requirements are
secured.
Minimum 2 and maxi-  
mum 5 profile elements
per Module or low Unit
Load must be used.
(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 50
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

When creating additional

picking locations with an
additional beam at
750mm above the floor
(level 5), ensure that the
appropriate beam is
used.

All types of Unit Loads,

placed on elevated pick-
ing location beams, re-
quire the same beams as
for storage locations.

When picking locations

are used for hand
stacked goods only, a
slimmer beam can be
used.

Min. 75mm
 

Unit Loads handled with

Powered Handling Mate-
rial Equipment, such as
Powered Stackers or
Reach Trucks, require a Min. 75mm  
minimum of 75mm clear-
ance between adjacent
Unit Loads and between
Unit Loads and uprights.

Unit Loads handled with Min. 75mm  

a hand pallet jack or elec-
trical hand pallet jack on
floor locations can be
placed as close together
as needed to maximize
capacity, but still handle
No minimum 
the goods with care.

(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 51
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.13 Inspection

3.13.1 Visual check

The inspection of Warehouse Racking is a visual check from

the floor up, with potential stored Unit Loads partially blocking
the view on all components.

Inspection will result in a list of:

 visible damages and deformations that must be subject-

ed to an assessment,
 missing components,
 incorrect placed Unit Loads,
 non-compliant Unit Loads.

The findings must trigger immediate corrective actions to

ensure the safety of every individual in the Fulfilment Unit.

Warehouse Racking must be taken out of service when acceptable tolerances are exceeded. In case of doubt
due to poor visibility high up in the Warehouse Racking, a closer look with a dedicated motorised mobile work
platform, operated by a licensed operator, might be needed. If this is not possible, assume the worst-case sce-
nario and initiate immediate corrective actions.

3.13.2 Frequency (2)

The inspection of all Warehouse Racking components for conventional Warehouse Racking, like anchoring,
fixations, placement, and compliance of Unit Loads must be done systematically, according this frequency:

Daily: Every individual detecting wrong placement, or non-compliant Unit Loads, is obliged to correct
these immediately if possible or to report this immediately to the person overseeing the goods
handling process.
Every individual detecting damages or deformations to conventional Warehouse Racking and any
other potential unsafe situation, is obligated to report this immediately to the responsible person
for Warehouse Racking safety, or the appointed representative. Results are shared with Facility
Management in those Fulfilment Units where a Facility Management Internal Service Agreement is
agreed and in place. These findings must be recorded and archived for a minimum of 2 years.
Both digital and paper-based archives are acceptable.

Weekly: The complete (100%) Warehouse Racking must be thoroughly inspected by appointed inspectors
being the responsible person for Warehouse Racking safety, or the appointed representatives. All
results except placement and compliance of Unit Loads, are shared with Facility Management in
those Fulfilment Units where a Facility Management Internal Service Agreement is agreed and in
place. The findings must be recorded and archived for a minimum of 2 years. Both digital and pa-
per-based archives are acceptable.
(STORE FULFILMENT UNITS)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 52
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Monthly: The complete (100%) Warehouse Racking must be thoroughly inspected by appointed inspectors
being the responsible person for Warehouse Racking safety, or the appointed representatives. In
those Fulfilment Units where a Facility Management Internal Service Agreement is agreed and in
place, except for placement and compliance of Unit Loads, this happens under the responsibility
of Facility Management. The findings must be recorded and archived for a minimum of 2 years.
Both digital and paper-based archives are acceptable.
(CENTRAL FULFILMENT UNITS)

Yearly: The complete Warehouse Racking, including accessories, must be inspected by an experienced
competent person at least once every 12 months. The Fulfilment Unit has the option to have the
inspection carried out by:

 experienced INGKA inspectors, not being part of the daily, weekly, and/or monthly inspec-
tions in that Fulfilment Unit,
 Warehouse Racking supplier,
 experienced, with proven track record, 3rd partner Warehouse Racking specialist.

The findings must be recorded and handed over to the responsible person for Warehouse Rack-
ing equipment safety, or appointed representative for immediate preventative measures whenev-
er required. Facility Management is responsible for the coordination, execution, and outcome of
the yearly inspection. The findings must be archived for a minimum of 2 years. Both digital and
paper-based archives are acceptable.

A support template for paper-based inspections is available.

The inspection of all Warehouse Racking components for semi-automated and full automated high bay/silo
Warehouse Racking, like anchoring, fixations, placement, and compliance of Unit Loads must be done sys-
tematically, according this frequency:

Daily: Every individual detecting wrong placement, or non-compliant Unit Loads, is obliged to correct
these immediately if possible or to report this immediately to the person overseeing the goods
handling process. Every individual detecting damages or deformations to high bay/silo Ware-
house Racking and any other potential unsafe situation, is obligated to report this immediately to
the responsible person for Warehouse Racking safety, or appointed representative. Results are
shared with Facility Management in those Fulfilment Units where a Facility Management Internal
Service Agreement is agreed and in place. The findings must be recorded and archived for mini-
mum 2 years. Both digital and paper-based archives are acceptable.

Yearly: At least 20 % of the complete high bay/silo Warehouse Racking, including accessories, must be
inspected by a certified external company, ensuring a complete installation inspection every roll-
ing 60 months. The inspection must be carried out by certified and authorized individuals
(independent specialists, Warehouse Racking supplier or officially trained Warehouse Racking in-
spectors) in accordance with DIN-EN 15635 (or the relevant local equally high, or higher/stricter
norm/norms). The findings must be recorded and handed over to the responsible person for
Warehouse Racking equipment safety, or appointed representative, for immediate preventative
measures whenever required. Facility Management is responsible for the coordination, execution,
and outcome of the yearly inspection. The findings must be archived for minimum 10 years. Both
digital and paper-based archives are acceptable. If any of the inspections show a significant num-
ber of damages or deformations, the responsible person for Warehouse Racking safety can, to-
gether with the inspector and/or high bay/silo Warehouse Racking supplier, decide if a complete
inspection makes sense to ensure safety and system availability.
(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 53
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.13.3 Tolerances

All Warehouse Racking components have tolerances to allow for inherent variances in construction materials,
workmanship skills, and impact absorption from daily operations. Many of these tolerance are an integral part
of the design and can be related to minimum required safety factors.

With exception of the components highlighted in this document, our company policy remains its zero-
tolerance approach towards damages/deformations.

The tolerances for upright, bracing, and beam deformation are valid for Ware-
house Racking supplied by the Stow Group, Tegometall, and Dexion, and are in
line with EN15635.

Tolerances for any other Warehouse Racking supplier must be checked and veri-
fied, consulting their respective Warehouse Racking operator manuals, or any
other formal communication from/with the supplier.

Some of the deformations can be measured, these are factual and quantifiable. Some other deformations will
rely on a sharp eye and sound, personal judgement. In case of doubt, opt for the worst-case scenario, ask for
a 2nd and 3rd opinion. If no classification consensus is found, classify the assumed deformation/damage as
RED, and initiate and/or take required corrective actions. The principle of “In case of doubt, take it out (of ser-
vice)!” must always be applied.

Regarding US/CA + RMI standards compliance, the tolerances mentioned in this document towards uprights,
beams and bracings do not apply!
The actual tolerances are not handed over by the Warehouse Racking suppliers due to shared liability on
Warehouse Racking safety and integrity.

3.13.4 Inspectors

The responsible for Warehouse Racking safety within the Fulfilment Unit can appoint co-workers with a high
passion for safety to inspect Warehouse Racking on a regular basis. The appointed inspectors must be aware,
and understand, the hazards posed by non-compliance to the Warehouse Racking requirements. Knowledge
transfer towards the appointed inspectors can come from either experienced senior IKEA Warehouse Racking
inspectors, the Warehouse Racking supplier, or an experienced, with proven track record, 3 rd partner Ware-
house Racking specialist.

3.13.5 Assessment tools (2)

Spotted or suspected deformations or damages to

uprights and bracings must be measured to assess
m

whether corrective actions are required or not. For

3m

this the following tools must be used:

 straight metal spirit level, or a straight metal

m
m

ruler, both exact 1000mm long,

10

 the mandatory INGKA tailor made deformation

measurement pen, available via procurement
m

Webshop
5m

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 54
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.13.6 Upright and cross brace assessment

Place the spirit level lengthwise against the side/face of the upright you need to
inspect. Whenever possible the deformation will be approximately largest in the
middle of the spirit level. Measure with the pen the appropriate thickness between
the spirit level and the component to be inspected.

When measuring uprights, and the pen fits the gap, measure again using the next
thickness of the pen. Both measurements together will determine which actions
need to be taken.

Uprights deformed in a corner must be evaluated by inspecting both the face and
the side of the upright. Missing cross braces must be classified RED.

(Upright face assessment)

Evaluation
A s s e s s m e n t t o o l s r e q u i r e d
Upright face 0mm =<3mm >3mm =<5mm >5mm
Upright sides 0mm =<5mm >5mm =<10mm >10mm

Cross brace 0mm =<10mm >10mm =<20mm >20mm

Loading and off- Bar in affected Off-load the

loading the locations in the affected locations
affected locations WMS (ASTRO/ immediately.
is allowed. SGF) ensuring Bar in the affect-
Can be re- that the frame ed locations in
classified as AM- load does not in- the WMS (ASTRO/
BER or RED, if the crease. SGF) ensuring
deformation in- Monitor the de- that none of the
creases. formation weekly locations will be
for a period of 4 loaded. (Upright side assessment)
weeks. If the de- Have the de-
Corrective formation in- formed/damaged
actions creases during component re-
these weeks, re- placed immedi-
classify as RED. ately when the
At the latest 4 severity of the
weeks after de- deformation is
tection of the de- assessed an im-
formation, re- mediate threat
classify as RED. for collapse, oth-
erwise replace at
earliest conven-
ience.

(Cross brace assessment)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 55
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Correct placement of the

< Rear < Rear
spirit level is important
flanges > flanges >
to avoid additional toler-
ances due to the bend-


ing of the spirit level it-
self.

The rear flanges, used to screw upright and cross

Spirit level
1000mm


Spirit level
1000mm
braces together, has no weight bearing support Spirit level

Spirit level
1000mm
1000mm
function, and therefore does not require a defor-
mation assessment as such. However, if damaged,
(Cross-section uprights)
deformations and damages extending into the up-
right must be assessed according to the given meth-
od and tolerances.

3.13.7 Twisted upright assessment (2)

Uprights, especially those that are anchored with one anchor only, can to some
extend twist and stand slightly out of alignment with the other upright/uprights of
the frame.

F o c u s e d v i s u a l i n s p e c t i o n
When placing a virtual ana- Any twist misalignment
logue clock over the cross over ‘1 minute’ must be
sections, the upright can be classified as RED.
Evaluation
at the most ‘1 minute’ (= 6°) Only 1 twisted upright per
out of alignment. frame is allowed and twist-
ed uprights must not oc-
cur in adjacent frames. If
so, all affected bay loca-
tions must be classified as
RED.

Loading and off-loading the Off-load the affected loca-

affected locations is allowed. tions immediately.
Can be re-classified as RED, if Bar in the affected loca-
the deformation increases. tions in the WMS (ASTRO/
SGF) ensuring none of the
locations will be loaded.
Corrective Have the deformed com-
actions ponent replaced immedi-
ately when the severity of
the deformation is as-
sessed an immediate
threat for collapse, other-
wise replace at earliest
convenience.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 56
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.13.8 Beam assessment

F o c u s e d v i s u a l i n s p e c t i o n
Any dents =<5mm deep Any dents >5mm Any dents on the beam
on any of the faces of the =<10mm on any of the edges.
beam. faces of the beam. Any dents >10mm on any
Beam is split open/ of the faces of the beam.
opened seam =< 5mm. Punctured beam.
Any cracked or corroded
welds (not surface corro-
sion).
Beam is split open/
opened seam > 5mm.
Beam connector not, or
Evaluation
not completely, engaged
(not tight against the
upright).
Deformation to beam
connector.
Loaded beams deflection
more than their
span/200: (1900mm -
max. 9mm, 2900mm -
max. 14mm, 2000mm -
max. 10mm, 3000mm -
max. 15mm).
Unloaded beams show-
ing any deflection.

Loading and off-loading Bar in affected locations Off-load the affected lo-
the affected locations is in the WMS (ASTRO/SGF) cations immediately.
allowed. ensuring the frame load Bar in the affected loca-
Can be re-classified as does not increase. tions in the WMS
AMBER or RED, if the de- Monitor the deformation (ASTRO/SGF) ensuring
formation increases. weekly for a period of 4 none of the locations will
weeks. If the defor- be loaded.
Corrective mation increases during Have the deformed/
actions these weeks, re-classify damaged component
as RED. replaced immediately
At the latest 4 weeks af- when the severity of the
ter detection of the de- deformation is assessed
formation, re-classify as an immediate threat for
RED. collapse, otherwise re-
place at earliest conven-
ience.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 57
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Beam connectors

Beam deflection

3.13.9 Locking pins/bolts assessment (2)

Evaluation F o c u s e d v i s u a l i n s p e c t i o n
Beams are locked with certi- Certified locking pins or
fied locking pins or certified certified bolts are de-
bolts. formed or missing.

Loading and off-loading the Place locking pins and/or

affected locations is allowed. bolts immediately.
Off-load the affected loca-
tions if immediate replace-
Corrective ment is not possible.
actions Bar in the affected loca-
tions in the WMS (ASTRO/
SGF) ensuring none of the
locations will be loaded.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 58
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.13.10 Storage Profile assessment (2)

Evaluation
F o c u s e d v i s u a l i n s p e c t i o n
Deformations to the sides, Load bearing surface of
the bottom and the front of any of the Storage Profile
the Storage Profile elements elements is deformed.
that do not extend into the Dislodged Storage Profile
bearing surface of the ele- element.
Metal Storage
ment (top side). Any broken or deformed L-
Profiles
2 approved cable ties are cor- shaped components re-
rectly placed at the front sulting in an uneven load
beam. bearing storage surface.
Missing or broken cable
(Storage location
tie. side view)
Broken off or/and cracked Dislodged Storage Profile
pieces of wood, not thicker element. Storage Profile elements
than a thumb and less than Any visible screw shanks.
90mm long, over the length Over the complete face
of the Storage Profile ele- split Storage Profile ele-
L-shaped component
ment. ments.
Storage Profile element sur- Any broken or deformed L-
Hybrid Storage
face cracks caused by drying. shaped component result-
Profiles
Storage Profile element par- ing in an uneven load
tially split over the front face, bearing storage surface.
less than 90mm long over Missing or broken cable
the length of the element. tie.
2 approved cable ties are cor-
rectly placed at the front
Cable tie Cable tie
beam. (CENTRAL FULFILMENT UNITS)
(Storage location front view)

Loading and off-loading the Replacing the cable tie, or

affected locations is allowed. bar in/out the affected lo- Loading surface
Can be re-classified as RED, if cations in the WMS
the deformation increases. (ASTRO/SGF), if immediate
replacement is not possi-
Sides Sides
ble.
For damages or defor-
(Metal Storage Profile
mations, off-load the element front view)
Corrective affected locations immedi-
actions ately. Bar in the affected
locations in the WMS Loading surface
(ASTRO/SGF) ensuring
none of the locations will
be loaded. Have the de-
Crack Broken off
formed component re-
(Hybrid Storage Profile
placed at earliest conven-
element front view)
ience.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 59
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.13.11 Upright protection assessment (2)

A s s e s s m e n t t o o l s r e q u i r e d
Undamaged upright protec- Deformations which
tion. caused the decrease in the
Evaluation
Clearance between upright intended gap/clearance
protector and upright itself is between the upright pro-
=>10mm. tector and upright itself <
10mm.
Cracked welds. (aisle side upright protector)

Cracked wooden beam.

Collision impact protection Replace the damaged up-

secured, normal fulfilment right protection.
operation can take place. Set a perimeter around
the damaged upright pro-
tector, indicating to opera-
tors of Forklifts to be extra
Corrective careful operating and driv-
actions ing around it, and bar in/
out the affected locations
in the adjacent bays in the (inside protector)
WMS (ASTRO/SGF), if im-
mediate replacement is
not possible.

(end frame protector)

=>10mm =>10mm

=>10mm

(cross-section upright and

upright protector)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 60
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.13.12 Floor anchoring assessment (2)

F o c u s e d v i s u a l i n s p e c t i o n
Superficial surface cracks in Broken, loose from the
Evaluation
the concrete floor . concrete, (partially) un-
screwed, missing anchor.
Deep cracks/broken off
pieces of concrete flooring
(upright floor anchoring)
around anchor.

Floor anchoring in good Have the floor anchoring

shape, normal fulfilment op- damage assessed and re-
eration can take place. paired by a specialist.
Set a perimeter around
the damaged floor anchor-
ing, indicating to opera-
tors of Forklifts to be extra
Corrective careful operating and driv-
actions ing around it, if immediate
repair is not possible.
Off-load the adjacent bays
if necessary, and bar in/
(anchor)
out the affected locations
in the WMS (ASTRO/SGF), if
immediate repair is not
possible.

3.13.13 Mesh assessment (2)

Evaluation F o c u s e d v i s u a l i n s p e c t i o n
Unloaded and loaded mesh Unloaded and loaded
deflection =<5mm. mesh deflection >5mm.

Mesh in good condition, nor- Off-load the affected loca-

(mesh)
mal fulfilment operation can tions.
take place. Replace the mesh.
Corrective Bar in/out the affected lo-
actions cations in the adjacent
bays in the WMS (ASTRO/
SGF), if immediate replace-
ment is not possible.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 61
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.13.14 Stored Unit Loads assessment (2)

F o c u s e d v i s u a l i n s p e c t i o n
Stored Unit Loads are compli- Non-compliant Unit Load.
ant, stable, secure, and un- Incorrect wrapping of
damaged. strapping.
Damaged, incorrect, un-
suitable, or non-compliant
Handling Material.
Severe damaged PP feet.
Potential unstable Unit
Load.
(SOP4GH - Caring about
Wrongly stored Unit Load
Evaluation Unit Loads)
(storage location type,
placement, clearances).
More than 4 collars used.
Non-compliant Unit Load
with non-conforming.
Undone/loose hanging
straps, wrapping material
and/or pieces of card-
board hanging from any
Warehouse Racking com-
ponent, obstructing flue
spaces and/or hindering
the safe use of a storage
location.
(SOP4GH - Caring about
Unit Loads are safe and se- Correct the detected issue Warehouse Racking)
curely stored, normal Fulfil- immediately if required
Corrective ment Unit activities can take from a safety perspective,
actions place. otherwise at the latest 24
hours after detection.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 62
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.14 Block stacking

3.14.1 Stacking Unit Loads with Paper Pallets

Hej,

Im
Aisle

For block stacking of Unit Loads with Paper Pallets,

the following 2 methods are allowed:
Maximum 3150mm
 Column stack: requires tiers to be exact and
properly stacked on top of each other.
The PP feet of the stacked Unit Loads are per-
pendicular above the other,
 Pyramid stack: 3rd tier of Unit Loads are not
perpendicular above the other.
To ensure packaging and/or goods of the 2nd
tier do not potentially get damaged, a solid
board (particle board, OSB, MDF, honeycomb (Column stack)
cardboard, etc.) must be used in between the
2nd and 3rd tier.

Any other kind of stacking method is potentially un-

Hej,

Im
Aisle

safe or can lead to product and/or packaging dam-

ages, and is therefore not allowed.
Maximum 3150mm
The height of the stacked Unit Loads does not ex-
ceed 3150mm in picking areas, or in areas where
pedestrians have access.

(Pyramid stack)

The Unit Load Label, existing at every Unit Load with IKEA Products, indicates the 1840mm
b. 150Kg 555mm
weight of the Unit Load (a), and the maximum weight that can be stacked on top
of it (b), in the understanding that other forces besides gravity will impact the Article number:
007.111.969
stack. Suppli er: XX-XY
Date stamp: 07-04-1969

During transportation amongst static forces, dynamic forces (acceleration, decel-

Quantity: 1
Gross Weigth:

eration, driving over bumps, or potholes), can potentially damage products and/ a. 100Kg
or packaging by crushing them, when the maximum stacking capacity is exceed-
ed.

For mid- and long-term block stacking in the Fulfilment Unit, besides static forc-
es, no other dynamic forces potentially impact the stack and therefore the indi-
cated allowed maximum stacking weight (b), can be multiplied by a factor of 1.5.
For the given ULL example (150Kg x 1,5 = 225Kg), a total of 225Kg can be stacked
on top of this Unit Load. (ULL)

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 63
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Block stacking is an efficient storage method for high volume products, or for
handling goods in transit. Nevertheless, Unit Loads with IKEA Products are made
for storing in Warehouse Racking. Stacking over time can lead to potential prod-
uct and/or packaging damages and therefore requires special attention.

Short-term (<3 days) block stacking prerequisites:


 this kind of block stacking is mainly used during transit handling and con-
sist out Unit Loads with a different length and/or width,
 the weight stacked on the lowest unit load in the stack is never more than
the allowed maximum stacking capacity as mentioned on the ULL,
 given the fact that the strength of Unit Load packaging is in the corners,
Unit Loads stacked in this way must be unstacked within at the most 3
days.

Mid-term (<6 weeks) block stacking prerequisites:

 this kind of block stacking is often used for high turnaround Unit Loads, but
is always demanded by the fulfilment operations responsible,
 only 1 article number will be part of a stack, produced by the same supplier,
 the weight stacked on the lowest unit load in the stack is never more than
1,5 times the allowed maximum stacking capacity as mentioned on the ULL,
 the size of the stacking area (m²/m³) is compliant with the fire regulations,
 the stacked articles fire class is within the allowed fire class of this area,
 clearances are respected (handling and flue space).

Long-term (>6 weeks) block stacking prerequisites:

 this kind of block stacking is a non-preferred and exceptional storage

method often related to capacity limitations and temporary external ware-
houses, but always formally signed off by the Fulfilment Unit responsible,
 weekly Safety & Quality audits must be performed and documented to veri-
fy if Unit Loads, packaging, and/or IKEA Products are not negatively impact-
ed by deformations or damages of any kind,
 all documents must be archived and available in the Fulfilment Unit for a
minimum of 1 year,
 all mid-term (<6 weeks) block stacking prerequisites are also valid.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 64
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.14.2 Stacking white goods (appliances)

Unit Loads with white goods (appliances), different

than Unit Loads with IKEA Products, are designed by
our suppliers for block stacking, no matter if they
contain a Paper Pallet or not. Therefore time re-
strictions are not valid, but the following conditions
must be fulfilled when block stacking as a storage
method is applied:

 only 1 article number will be part of a stack,

produced by the same supplier,
 the number of Unit Loads per stack is smaller
or equal to the maximum height as men-
tioned on the ULL, or supplier label,
 if both ULL and supplier label exist, the ULL
prevails,
 the size of the stacking area (m²/m³) is compli-
ant with the fire regulations,
 the stacked articles’ fire class is within the al-
lowed fire class of this area,
 clearances are respected (handling and flue
space),
 independent from any flue space require-
ments, stacks with appliances must have suffi-
cient space in between them to allow handling
with the proper Handling Equipment (clamps).

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 65
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

3.14.3 Stacking Handling Material

MWPP components that can be reused must be

stacked neatly as per component type and dimen-
sion. These stacks must be strapped for transport,
internally or between different Fulfilment Units.

Lids and collars must be stacked to a maximum of

830mm high, allowing them to be stacked a maxi-
mum of 3 Unit Loads high in the Loading Unit.

Unit Loads with trays can be stacked up to 15 pieces

high. A filler must be used inside the top tray, in or-
der to be able to stack another Unit Load on top of it.

Wooden Pallet or Metal Picking Platform stacks in-

side the Fulfilment Unit must not exceed 17 pieces in
picking areas, or in areas where pedestrians have
access.

In storage areas where no picking activities take

place, and pedestrians do not have access, the stack-
ing height of Wooden Pallets and Metal Picking Plat-
forms is maximized by the used Forklift equipment,
as long as the entire stack stability is secured.

The handling quantity in the Fulfilment Unit depends

on the Forklift equipment and the length of the mast
being used.

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 66
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

4 Revision history

Version Date Major changes Updates coor- Issuer of doc

dinated by
4.0 19/11/2019 New release Richard Smeets Cees de Jong
4.01 10/01/2020 Text corrections Cees de Jong Cees de Jong
5.0 18/05/2020 Remade in DTP software, separate Cees de Jong Cees de Jong
versions SFU and CFU merged into
one, restructured, multiple text and
layout improvements, index added,
Storage Profile strapping rule
changed
5.1 19/05/2020 IKEA instead of INGKA logo Cees de Jong Cees de Jong
5.2 18/12/2020 Added corrective action RED for Cees de Jong Cees de Jong
missing cross braces, awareness on
compartment width deviations, up-
dated clearance and location divid-
ers requirements for picking loca-
tions, replacing damaged parts by
qualified, trained, and certified peo-
ple, sharpening height restriction
block stack areas.
5.2.1 31/3/2021 3.10.5 & 3.10.6: Text added “when Cees de Jong Cees de Jong
replenished with Pallet Jacks or by
hand”, “minimum of 75mm”; page
52: drawings adapted.
5.2.2 31/5/2021 1.6: buckling length definition up- Cees de Jong Cees de Jong
dated; 3.5: added IKEA back-to-back
limitation; 3.7 & 3.13.14: text correc-
tions; 3.9.2: background coloring
correction.
5.2.3 5/10/2021 1.2 – page 5: IGR H, S&S added; Cees de Jong Cees de Jong
3.12.8 - page 51: correction related
to the use of pallet jacks; 3.13.2 -
page 52: clarification on document-
ing daily findings

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 67
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

5 Index Page
Navigator
accessibility, 2, 31 capacity and load sign, 3, 6, 11-12, 19, 32
accountable, 5 cardboard, 7, 62-63
1 2
adjacent, 6, 8, 33, 51, 56, 60-61 ceiling, 3, 7, 34-38 3 4
adjoining, 18 centrically, 14, 43 5 6
aligned, 28, 35 certified, 10, 12, 28, 53, 58, 67
alignment, 3, 38, 56 chimney, 6, 38-40 7 8
anchor, 8, 12, 27, 56, 61 clamps, 65 9 10
anchored, 56 class, 64-65 11 12
anchoring, 2, 4, 27, 52-53, 61 classification, 54
appliances, 4, 65 classified, 55-57, 59 13 14
appoint, 54 classify, 54-55, 57 15 16
appointed, 12, 32, 52-54 clearance, 2-3, 6-7, 14, 19-21, 29, 33-42, 51, 17 18
approval, 10 60, 62, 64-65, 67
approved, 10, 12, 28, 31-32, 59 climbing, 3, 32 19 20
archive, 52-53 clip, 28 21 22
archived, 52-53, 64 clock, 56
23 24
area, 1, 5-8, 11, 16, 22-25, 30-31, 63-67 co-workers, 5, 12, 54
astro, 6, 12, 33-34, 41, 55-61 collapse, 6, 55-57 25 26
authorities, 10 collars, 62, 66 27 28
authorized, 10, 53 collision, 60
29 30
automated, 8, 53 colored, 5
automatic, 10-11 column, 6, 8, 63 31 32
back mesh, 2, 6, 30 compartment, 2, 6, 10, 16-17, 19, 22, 32, 35- 33 34
back-to-back, 6, 14, 38-40 37, 67
35 36
backflow, 17 compliance, 52-54
backstop, 2, 6, 30 compliancy, 10 37 38
baffles, 35 compliant, 5, 44-45, 52-53, 62, 64-65 39 40
bar in/out, 6, 59, 61 configuration, 2, 10, 12, 18, 22-26
41 42
bay, 6, 8, 17-19, 32, 53, 56, 60-61 connector, 6, 57-58
beam, 2-3, 6-8, 10-12, 14, 17-18, 21-25, 27- construction, 8, 13, 54 43 44
30, 33-34, 50-51, 54, 57-60 contractors, 12 45 46
beam connector, 6, 57-58 conventional, 52
47 48
beam level, 6, 17 corner, 55, 64
bearing, 5, 16, 19, 40, 56, 59 corroded, 57 49 50
bending, 6, 56 corrosion, 57 51 52
bolt, 3, 6-7, 12, 28, 58 crack, 59, 61
brace, 3, 6-8, 11-12, 55-56, 67 cracked, 57, 59-60
53 54
bracing, 54 cross brace, 3, 6-8, 11-12, 55-56, 67 55 56
buckling length, 2, 6, 10, 17 customer, 1, 5, 7, 12, 31 57 58
cable tie, 6, 11-12, 28, 59 daily, 52-54
cap, 7, 32 day, 8, 64 59 60
decking, 7 61 62
deflection, 6, 57-58, 61 63 64
65 66
67 68

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 68
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Page
Navigator
deformation, 6, 52-57, 59-60, 64 fall through protection, 2, 7, 30-31
deformed, 55-57, 59 falling, 7, 29
1 2
dent, 6, 57 fastener, 6 3 4
digital, 52-53 feet, 43, 50, 62-63 5 6
dislodged, 7, 28, 59 fibreboard, 7
display shelve, 6, 21 fire, 7-8, 10, 13, 34-35, 64-65 7 8
divider, 36-37, 67 firmly, 12, 21, 27 9 10
documented, 64 fixated, 8 11 12
drawing, 28 fixation, 12, 52-53
drill, 13 fixed, 13, 21, 27-28 13 14
drive-through, 6, 16, 17, 18, 27, 29 flange, 7, 56 15 16
dynamic forces, 6, 63 floor, 4, 6-7, 10, 12, 17, 21, 27, 33-34, 36-40, 17 18
earthquake, 8 42-44, 50-52, 61
edge, 7, 57 floorplate, 8 19 20
electrical, 51 flue space, 6-7, 34-39, 62, 64-65 21 22
element, 2, 7-8, 13, 20, 28, 32, 43-44, 50, 59 flush, 7, 44-45, 50
23 24
elevated location, 7, 39-40, 50 forbidden, 30
end cap, 7, 32 force, 6, 8, 12, 63 25 26
end frame, 2, 7, 11-12, 27, 29, 60 fork arm, 28 27 28
end frame protector, 7, 11, 27, 60 forklift, 3, 5-8, 28-29, 36-37, 40-41, 44-45, 60
29 30
end podia, 7, 21 -61, 66
equipment, 5-7, 12-13, 31-32, 51, 53, 65-66 frame, 2, 6-7, 10-12, 14, 16, 27, 29, 39-40, 50, 31 32
equipped, 34 55-57, 60 33 34
erect, 12 frequency, 3, 52-53
35 36
erected, 12 gap, 30, 55, 60
excellence, 5 gross-row-spacer-share, 7 37 38
experienced, 53-54 handling equipment, 6-7, 65 39 40
exposed area, 7, 22-25, 30 handover, 10, 12, 27
41 42
extend, 29, 56, 59 head and torso, 30
extended, 2, 29 heat, 7, 34 43 44
extending, 29, 56 heavy duty mesh, 7, 19, 47 45 46
extension, 12 high-level picking area, 7, 11
47 48
external, 6, 53, 64 hole, 8, 13
extinguish, 7 honeycomb, 7, 63 49 50
extinguisher, 13 horizontal, 3, 33 51 52
eye, 54 hybrid storage profile, 7, 19, 59
face, 55, 57, 59 independent, 53, 65
53 54
facilitate, 33 information, 8, 10, 12, 27, 32 55 56
facility, 6, 13, 52-53 initiate, 52, 54 57 58
factor, 54, 63 inside protector, 7, 27, 60
inspection, 3, 5, 7, 52-53 59 60
inspector, 3, 52-54 61 62
insurance, 6-7 63 64
65 66
67 68

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 69
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Page
Navigator
integrity, 10, 54 particle board, 7, 63
intertwined, 6-7 pedestrian, 8, 63, 66
1 2
irregular, 35-37 pen, 54-55 3 4
jack, 7, 51 perimeter, 60-61 5 6
language, 12 period, 55, 57
layout, 12, 67 perpendicular, 35, 37, 63 7 8
leg, 3, 7, 14-15, 49 picking, 3, 7-8, 11, 14, 18, 20, 28, 30-33, 36- 9 10
legged, 14, 49 38, 50-51, 63, 66-67 11 12
level, 6-7, 10-12, 17, 19, 21, 30-32, 34, 36-42, picking location, 3, 7-8, 18, 20, 28, 32-33, 36
51, 54-56 -38, 50-51, 67 13 14
liability, 54 pin, 3, 7, 11-12, 28, 58 15 16
licensed, 52 plastic, 6-7 17 18
lighting, 12-13 plate, 27
loading unit, 7, 66 platform, 12, 52, 66 19 20
locking, 3, 7, 11-12, 28, 58 podia, 7, 12, 21 21 22
locking pin/bolt, 7 pothole, 63
23 24
magnetic, 28 powered, 51
management, 6, 10, 12, 19, 22, 33-34, 41, pp, 43, 50, 62-63 25 26
52-53 presentation, 18, 21 27 28
manager, 1, 5 procurement, 31, 54
29 30
mandatory, 54 profile, 2-3, 7-8, 10-12, 19-20, 22-25, 28, 32,
manoeuvring, 41 43-45, 50, 59, 67 31 32
manufactured, 6 profile element, 7-8, 20, 28, 32, 43-44, 50, 33 34
mapping, 7, 19, 22 59
35 36
mattresses, 36-37 protected, 7, 27
mdf, 7, 63 protection, 2-4, 7-8, 10, 12, 27, 30-32, 34, 60 37 38
mesh, 2-4, 6-7, 11, 19, 28, 30-31, 36-37, 47, protective, 7-8 39 40
61 protector, 7-8, 11, 27, 60
41 42
metal, 6-8, 20, 32, 54, 59, 66 puncture, 13
model, 12, 21 punctured, 57 43 44
module, 7, 17, 50 pushed, 30 45 46
month, 53 pyramid, 63
47 48
monthly, 53 qualified, 10, 12-13, 67
motorised, 52 radius, 41 49 50
non-commercial, 62 ready-to-sell, 20, 28, 32 51 52
nut, 6 repair, 61
object, 2, 6, 8, 13, 39 replace, 12, 55-57, 60-61
53 54
operator, 8, 12, 44-45, 52, 54, 60-61 replaced, 12, 56-57 55 56
opul, 7 replacement, 2, 12, 59-61 57 58
order picker, 12, 30 replacing, 59, 67
osb, 7, 63 representative, 52-53 59 60
pallet, 3-4, 7-8, 14, 19-20, 32, 42-47, 49, 51, responsibility, 2, 5, 53 61 62
63, 65-66 responsible, 5, 52-54, 64 63 64
paper pallet, 3-4, 8, 19-20, 32, 42-45, 63, 65 row, 7-8, 11, 14-15, 39
65 66
67 68

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 70
 SOP4GH CARING WAREHOUSE RACKING AND BLOCK STACKING

Page
Navigator
row spacer, 8, 11, 14-15, 39 theoretical, 3, 10, 39-40
ruler, 54 tie, 6, 11-12, 28, 59
1 2
run, 6-8, 18, 27, 29 tier, 35, 38, 63 3 4
screw, 56, 59 timber, 7 5 6
section, 12, 56, 60 tolerance, 3, 6, 8, 52, 54, 56
seismic, 6, 8, 10-11, 16 tools, 3, 12, 54 7 8
senior, 54 top, 6, 8, 10, 17, 33-34, 38, 59, 63, 66 9 10
sgf, 8, 12, 33-34, 41, 55-61 trailer, 7 11 12
shank, 59 trained, 10, 12, 53, 67
sharp, 54 training, 32 13 14
shelve, 6, 21 truck, 51 15 16
show, 12, 18, 21-22, 28, 31, 53 tunnel, 8, 44-45 17 18
showcase, 8, 21 twist, 56
showing, 7, 57 twisted, 3, 56 19 20
sign, 3, 6, 10-12, 19, 32 ul, 3, 8, 43-44, 46-47, 49-50 21 22
silo, 8, 53 ull, 8, 63-65
23 24
smoke, 7 unit load, 3-5, 7-8, 14-15, 19-21, 28-30, 32-35,
sofas, 36-37 39-46, 49-53, 62-66 25 26
software, 6, 8, 67 unit load label, 8, 63 27 28
spacer, 7-8, 11, 14-15, 39 upright, 2-4, 6-8, 10-12, 17, 27-29, 33, 36-37,
29 30
specialist, 10, 53-54, 61 39-40, 51, 54-57, 60-61
spliced, 12 upright protector, 8, 11, 27, 60 31 32
splicing, 12 vertical, 3, 12, 33-40 33 34
sprinkler head, 3, 8, 34-38 visibility, 42-44, 52
35 36
sprinkler system, 7-8, 10 visible, 32, 52, 59
sprinkler zone, 8, 35-37 visitor, 31 37 38
stack, 5, 8, 36-37, 63-67 walk-through, 2, 7-8, 29, 31 39 40
stacking capacity, 8, 63-64 webshop, 54
41 42
static forces, 8, 63 week, 55, 57, 64
storage location, 3, 6-8, 12, 16, 19-20, 22, weekly, 52-53, 55, 57, 64 43 44
29, 32-33, 35, 38-42, 51, 59, 62 weight, 8, 13, 16-17, 19-20, 32, 56, 63-64 45 46
storage profile, 2-3, 7-8, 10-12, 19-20, 22- weld, 57, 60
47 48
25, 28, 32, 43-45, 59, 67 width, 2-3, 10, 14-16, 22-25, 30, 39, 41, 43,
storage profile element, 7-8, 28, 32, 43-44, 50, 64, 67 49 50
59 wood, 7, 59 51 52
strap, 62 wooden, 3, 7-8, 14, 19-20, 27, 42, 46-47, 49,
strapped, 42, 66 60, 66
53 54
strapping, 62, 67 wrapping, 62 55 56
structural, 6, 10 year, 52-53, 64 57 58
structure, 2, 6-7, 10, 12-13, 21, 30, 33 yearly, 53
supplied, 54 zone, 8, 35-37 59 60
supplier, 6, 10, 12-13, 16, 31-32, 53-54, 63- 61 62
65 63 64
supply, 8, 16
65 66
67 68

(1)
See important notes on page 8. SOP4GH – WR – V5.2.3
(2)
Not required, but recommended, for 1) non-IKEA branded or 2) non-INGKA owned, leased, or operated units. Page 71