Logistics centres & high-bay warehouses: which work platform for maintenance?

A defective sprinkler pipe on the top racking level, the annual stocktake at 12 metres height, a light fitting hanging exactly above the narrowest aisle. Maintenance work in the high-bay warehouse shares a common problem: the racks are high, the aisles are narrow, and warehouse operations are supposed to continue as normally as possible in the meantime. Not every work platform fits through these aisles – and not every one reaches high enough.

This article classifies which platform suits which situation in the high-bay warehouse and what to consider during planning.

For rack maintenance, stocktaking or replacing lighting at heights up to about 12.65 m, the mast lift is the most compact solution. Models such as the JLG Toucan or the Haulotte Star work purely vertically, without a lateral boom arm, and bring exactly the properties a high-bay warehouse demands: a very narrow overall width that fits through tight aisles and normal doors, non-marking tyres that leave epoxy-resin floors and industrial parquet undamaged, and an electric drive that works quietly and emission-free alongside ongoing order-picking operations. The point load capacity of around 200 kg is sufficient for tools and smaller spare parts (mast lifts at Luibl Rental).

If this height is not enough, the high-bay scissor lift comes into play. This special class is purpose-built for modern logistics centres in which standard machines are either too wide or too low, and covers working heights from 18.50 m to 33.00 m. It is narrow-aisle capable and matched to common aisle widths in high-bay warehouses, while load capacities of 500 to 1,000 kg also allow larger maintenance and conversion work. The top model in the Luibl rental fleet is the Holland Lift HL330_E14_4WDS with 33 m working height (high-bay scissor lifts at Luibl Rental).

The working height is the first and most important filter: up to around 12 m, a mast lift is usually sufficient; for the top levels of modern high-bay systems above 18 m, the high-bay scissor lift is the right choice. Both machine types are designed for narrow aisles, but the exact aisle width ultimately determines the specific model – a look at the actual width in the warehouse is therefore worth more than an estimate based on rack height alone. It is also important whether the machine has to be driven while at extended height: certain high-bay scissor lifts can do this, which saves considerable time during stocktaking across several rack compartments, and should be stated accordingly with the enquiry. The floor covering – industrial parquet, epoxy resin or sensitive coatings – requires non-marking tyres, which are standard for both machine types in the Luibl rental fleet. And because warehouse operations usually continue as normal during maintenance, the electric drive is almost always a given: quiet, odourless, without exhaust fumes in the enclosed hall.

In everyday use, both platform types are used above all for the annual stocktake on the upper rack levels, for sprinkler installation and sprinkler maintenance beneath the hall ceiling, for changing lighting above aisles and rack rows, for repairing damaged rack sections after collision damage caused by forklifts, for laying cables and lines along the hall ceiling, and for converting and expanding rack systems during ongoing operations.

For the selected machine to actually fit on the day of use, more than just the rack height should be established in advance. The exact aisle width determines whether the model fits through at all, while ceiling height and obstacles such as sprinkler pipes, ventilation ducts or cable trays often reduce the usable working height more than one initially assumes. The floor covering should be stated with the enquiry so that the appropriate tyres are supplied straight away, and because maintenance work during regular order-picking operations usually requires an aisle closure, a clear agreement on the time window is worthwhile. If the machine runs across several shifts, battery charging times must also be factored in.

Because forklift and foot traffic are almost always underway in parallel in the high-bay warehouse, the affected aisle must be cordoned off during the operation so that no one crosses paths. On the platform itself, personal protective equipment against falls is mandatory, and every operator must be instructed in accordance with DGUV Grundsatz 308-008 before the first use. The UVV inspection certificate is in any case provided with every machine from the Luibl rental fleet at handover.

It starts with the enquiry stating rack height, aisle width, floor covering and the planned deployment window. This is followed by the matching offer including transport, supplemented if necessary by a consultation on the aisle width based on photos or plans. Delivery takes place with our own low-loader fleet, and the operating team is instructed directly in the warehouse. During the maintenance or stocktaking work, technical support is available for any queries, and at the end the machine is collected on the agreed date – with a credit for earlier return.

Whether a compact mast lift for rack maintenance up to 12 m or a high-bay scissor lift for the top levels up to 33 m – the decisive factor is the exact combination of height, aisle width and floor covering. Luibl Rental advises on the right machine before the wrong platform blocks the aisle.

➜ Enquire now without obligation – we will find the right platform for your warehouse.

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