Calculator Inputs
Example Data Table
| Timestamp | Mode | Pallets stored | Positions | Net (m²) | Gross (m²) | Suggested L×W (m) | Gross (ft²) |
|---|---|---|---|---|---|---|---|
| No calculations yet. Try the sample inputs above. | |||||||
| 2026-02-04 09:00:00 | Throughput | 54 | 27 | 32.40 | 50.03 | 10.00 × 5.00 | 538.53 |
Formula Used
- Pallets to store = Daily pallets × Dwell days (throughput mode) or Total pallets (direct mode).
- Ground positions = ceil(Pallets to store ÷ Stack levels).
- Net storage area = Positions × Pallet length × Pallet width.
- Gross staging area = Net × (1 + Aisle%) × (1 + Buffer%) + Loading add-on.
- Suggested footprint uses the selected ratio: Width = sqrt(Gross ÷ Ratio), Length = Width × Ratio.
How to Use This Calculator
- Pick Units matching your site drawings and takeoffs.
- Select Throughput × dwell when deliveries are steady; use Direct count for a known inventory peak.
- Enter realistic pallet dimensions for crates, bundles, or skid packs.
- Set stack levels based on weight limits and lift plans.
- Adjust aisle allowance for turning radii, pedestrian routes, and exclusion zones.
- Add a loading/setdown area for banding, kitting, or quality checks.
- Press Calculate to view results above the form, then export CSV or PDF.
Delivery Throughput and Dwell Planning
Staging demand rises when inbound volume increases or when materials sit longer. This calculator estimates pallets to store using daily throughput multiplied by average dwell days. For example, 18 pallets per day with a 3‑day dwell suggests 54 pallets on site. If stacking is 2 levels, ground positions become 27, which drives the base storage footprint.
Pallet Footprint and Net Storage Area
Net storage area is calculated from pallet length and width, multiplied by ground positions. A 1.2 m by 1.0 m pallet occupies 1.20 m². With 27 positions, net storage equals 32.40 m² before aisles. Using accurate dimensions for skids, crates, or bundles reduces surprises during mobilization and material control.
Aisle Allowances and Safety Buffers
Access lanes, turning radii, exclusion zones, and pedestrian routes require space beyond net storage. The aisle allowance adds handling room, while the safety buffer adds contingency for mixed loads, weather delays, and sequencing changes. With 35% aisles and a 10% buffer, a 32.40 m² net area expands to 48.33 m² before any dedicated loading pad is added.
Loading Pads and Suggested Footprint
Many sites need a setdown zone for banding, kitting, quality checks, and truck access. The loading add‑on is added directly to gross area, then the calculator proposes a practical rectangle using a chosen length‑to‑width ratio. A 2:1 layout provides a longer face for deliveries, while 1:1 suits compact yards and tight constraints.
Operational Checks and Reporting
Results include both metric and imperial outputs to match drawings and procurement documents. Use the history table to capture multiple scenarios such as peak deliveries, weekend closures, or reduced stacking limits. Export CSV for estimators and planners, and export PDF for toolbox talks and coordination meetings. Always validate against lift plans, traffic flow, and local safety rules.
FAQs
1) When should I use throughput mode instead of direct count?
Use throughput mode when deliveries are steady and you can estimate average dwell days. Use direct count when you know the maximum pallet inventory expected at any time.
2) What aisle percentage is typical for forklift handling?
Many sites start between 30% and 50%, then adjust for turning radius, one‑way traffic, pedestrian separation, and exclusion zones. Tight yards often require higher allowances.
3) How does stacking change staging requirements?
Stacking reduces ground positions because pallets are stored vertically. Ground positions equal pallets to store divided by stack levels, rounded up, so higher stacking generally lowers net storage area.
4) Why add a separate loading or setdown area?
Drops, banding, kitting, inspection, and short‑term holding often happen outside pallet rows. A dedicated loading pad prevents congestion and helps maintain safe access routes.
5) Does the suggested footprint replace a site logistics plan?
No. The footprint is a quick, ratio‑based rectangle for planning. Final layouts should consider vehicle paths, crane swing, drainage, fire lanes, and any temporary fencing or barriers.
6) What should I export and share with the team?
Share the PDF during coordination meetings to align on space needs and constraints. Use the CSV to compare scenarios, document assumptions, and support takeoffs and procurement planning.