Cartons, tyres, spare parts, canisters, bulky assemblies: much of what a business stores is too wide or too heavy for a shelving unit, yet not palletised and therefore no case for pallet racking served by a forklift. This is exactly the gap that wide-span shelving fills. It is loaded by hand, offers bay widths of up to 2.5 m without an intermediate upright and carries several hundred kilograms per level.
This guide shows when wide-span shelving is the right choice, how to decide between the WS 2000, WS 3000 and W 100 systems, and which safety rules from DGUV Information 208-061 and DIN EN 15635 apply to hand-loaded shelving as well. If you are not yet confident about the difference between shelf load and bay load, read Shelf Load vs. Bay Load in Racking first.
What defines wide-span shelving
Structurally, wide-span shelving sits between two worlds: upright frames like pallet racking, hand loading like a shelving unit. Three characteristics set it apart from both neighbours:
- Bay width: standard grid from 1,500 to 2,500 mm. A shelving unit usually stops at around 1,300 mm because the shelf would otherwise sag.
- Shelf load: depending on the system, 400 to more than 1,000 kg per level, evenly distributed. Shelving units typically range between 80 and 330 kg.
- Loading: manual only. The levels consist of steel panels or chipboard on beams. No forklift drives in, so the rack protectors and push-through protection that are mandatory for pallet racking are not required.
Height is limited by hand loading. Anything above reach height can only be accessed with a step or a rolling shelf ladder. In practice, wide-span shelving therefore stays at 2,000 to 3,000 mm in height with three to six levels.
Wide-span, shelving unit or pallet racking: the decision table
The question "which rack" can almost always be answered with three criteria: how large is the load unit, how heavy is it, and how is it moved?
| Criterion | Shelving unit | Wide-span shelving | Pallet racking |
|---|---|---|---|
| Typical load unit | small parts, cartons, open-fronted storage bins | bulky cartons, tyres, canisters, assemblies, long items up to 2.5 m | Euro pallet, mesh box pallet |
| Bay width | up to approx. 1,300 mm | 1,500 to 2,500 mm | 1,800 to 3,600 mm |
| Shelf load per level | approx. 80 to 330 kg | 400 to 1,015 kg | 1,500 to 4,000 kg |
| Loading | by hand | by hand, with a step or ladder if needed | forklift or high-lift pallet truck |
| Rack protector / push-through protection | not required | not required | mandatory with forklift operation |
| Typical use | workshop, order picking, office | spare parts store, vehicle workshop, wholesale, tyre storage | goods receipt, dispatch warehouse, replacement for block storage |
Rule of thumb: if the load unit fits into a shelving unit, choose the shelving unit; it is cheaper and can be subdivided more flexibly. If the goods are palletised and a forklift is available, pallet racking is more efficient. Everything in between is wide-span territory. You will find the detailed comparison of the basic types under Racking Types Compared.
The three systems: WS 2000, WS 3000 and W 100
The Kreckler range includes three wide-span shelving series, which differ mainly in shelf load and dimensional grid. In each case, the shelf load applies to an evenly distributed load on the level.
| System | Shelf load per level | Bay widths | Depths | Suited for |
|---|---|---|---|---|
| WS 2000 | up to 400 kg | 1,500 to 2,500 mm | 400 to 800 mm | boxed goods, tyres, plastic containers, light assemblies |
| WS 3000 | up to 621 kg | 1,500 to 2,500 mm | 500 to 1,000 mm | spare parts, canisters, tool boxes, medium-weight goods |
| W 100 | up to 1,015 kg | 1,785 to 2,500 mm | 600 to 1,200 mm | heavy components, metal goods, drums and containers, wide stored goods |
All three systems are plugged together, not bolted, and can be extended into rows with add-on bays. The bay load, i.e. the sum of all levels between two upright frames, is a separate limit value and is stated on the load notice. For these systems it lies in the range of 2,000 to 3,000 kg. Anyone who fills six levels with 500 kg each has 3,000 kg in the bay and may therefore have exceeded the bay load, even though every single level is within the green zone. Always check both values.
Steel panel or chipboard?
The levels are available with either steel panels or chipboard. Steel is insensitive to moisture and oil, more stable under point loads and easier to clean, which makes it the first choice in vehicle workshops and for canisters. Chipboard is cheaper, smooth and cushions the placing of delicate parts, but it belongs in dry rooms. For both, DGUV Information 208-061, section 4.1.2.3 applies: the deflection of the load-bearing elements under working load may not exceed 1/200 of the span, or 1/150 for wood-based materials. At a bay width of 2,500 mm, that is 12.5 mm and around 17 mm respectively. If a shelf visibly sags more than that, the level is overloaded or the shelf is not approved for this system.
Checking the shelf load: the calculator
Whether WS 2000, WS 3000 or W 100 is sufficient is decided by the heaviest level. The calculator uses the number of levels, the load per level and the type of storage to determine the required shelf and bay load and shows which system fits. Select the rack type "Weitspannregal" (wide-span shelving) at the top.
Fachlast-Rechner
Erforderliche Fach- und Feldlast nach SCHULTE-Katalog und DGUV ermitteln
- Erforderliche Fachlast
- 150 kg
- Typ 150 (150 kg je Ebene) wählen
- Erforderliche Feldlast
- 600 kg
- Zulässig sind 1.740 kg - passt (Schulte 13011 Anhang A2).
- Höhe:Tiefe = 4.2:1 - Standsicherheit ohne zusätzliche Kippsicherung möglich (Herstellerangaben beachten). (DGUV 108-007 §4.1)
- Bodenabstand 807 mm - über 600 mm wird die Knicklänge der Stütze maßgebend. Mehr Ebenen einplanen oder niedriger bauen. (DGUV 108-007 §11)
- Ab 2.500 mm Bedienhöhe sind Hilfsmittel zum Be- und Entladen erforderlich (Tritt, Leiter oder Stapler). (DGUV 108-007 §4.1)
- Belastungsschild mit Fach- und Feldlast gut sichtbar anbringen und jährliche Prüfung durch eine befähigte Person durchführen lassen. (DIN EN 15635 / DGUV 208-061)
Richtwerte auf Basis der Schulte-Montageanleitungen (13011 Anhänge A2-A5, 13033, 13048) und DGUV Regel 108-007 (Nachfolger: DGUV Information 208-061). Der Rechner ersetzt keine statische Bemessung nach DIN EN 15512 - maßgeblich sind die Traglastangaben des Herstellers für Ihre konkrete Konfiguration.
The calculator does not replace structural design; it pre-sorts. Two things are frequently underestimated here:
- Point loads: the shelf load applies to an evenly distributed load. A single engine block standing in the middle of the bay acts on the shelf like a multiple of its weight. As a rule of thumb, a single load should not exceed a quarter of the nominal shelf load; when in doubt, distribute the load or switch to steel panels.
- Short rows: a single starter bay without add-on bays stands less stably than a long row. Observe the manufacturer's specifications on bracing and wall connection before using the full shelf load.
Special cases: tyres, long goods, order picking
Tyres and wheels are the classic case: wide-span shelving with a 2,500 mm bay width takes considerably more wheels per level than a shelving unit, and free access without an intermediate upright makes putting away and retrieving easier. For wide and heavy SUV wheels there are SUV wheel racks with extra-strong beams and a clear bay width of around 1,285 mm.
Long goods up to the bay width, such as profiles, pipes or strips up to 2.5 m, can be stored lying flat on wide-span levels. It does not get any longer than that: from there on, cantilever racking is the right system because it has no bay limits.
Manual order picking: wide-span shelving is suitable for items that are picked individually from cartons. In that case, pay attention to reach height: levels above roughly 1,800 mm are only of limited use without a step, and heavy load units belong in the zone between knee and shoulder height.
Safety: what also applies to hand-loaded shelving
A common misconception is that rules such as the load notice and the inspection obligation only concern pallet racking. DGUV Information 208-061 makes no such distinction; it is tied to the load.
The load notice is mandatory
Under section 4.2.7.1, fixed racking must display the manufacturer, type designation, year of manufacture or order number, permissible shelf and bay loads, and the maximum load of the load unit, permanently and clearly visible. The exception for hand-loaded shelving only applies at a shelf load below 200 kg or a bay load below 1,000 kg. Every wide-span shelving system is above that. If the notice is missing, for instance after a second-hand purchase or a conversion, nothing may be stored until the values have been confirmed by the manufacturer or a competent person.
Stability and installation
Section 4.2.1 requires stability in every operating condition, including during loading and unloading. For shelving that is loaded by hand, additional horizontal forces must be assumed (section 4.1.2.4). In practice this means: follow the manufacturer's specifications on anchoring or wall connection, connect rows to each other and install the shelving plumb. Under section 4.2.6, the deviation of the uprights from the vertical under full load may not exceed 1/200 of the upright height, i.e. 15 mm at a height of 3,000 mm. The floor must be able to carry the load (section 4.1.2.6), which quickly becomes relevant with a bay load of 3,000 kg on four base plates.
Inspection obligation
Storage equipment is work equipment within the meaning of the German Ordinance on Industrial Safety and Health (BetrSichV). Under section 3(6) BetrSichV, the employer must define the type, scope and intervals of inspection in the risk assessment (DGUV Information 208-061, section 6.1). For shelving that is only loaded by hand, the risk of damage is lower than with forklift operation, but not zero: overloading, displaced beams and missing safety pins are the typical findings. Regular visual checks by in-house staff plus an annual inspection in accordance with DIN EN 15635 are the state of the art here too. How both are organised is described in the guide to racking inspection.
Conversion only when unloaded
Moving beams, adding levels, attaching bays: under section 5.2.1.1, shelving may only be installed and converted by instructed persons in accordance with the assembly and operating instructions, and conversion may only take place in the unloaded state. If the conversion changes the level spacing or the bay width, the permissible shelf load changes as well, and the load notice must be updated.
Planning in five steps
- 1. Record the load units: greatest width, depth, height and the weight of the heaviest unit per level.
- 2. Determine shelf and bay load: with the calculator above; allow for point loads and reserves.
- 3. Choose the system: WS 2000 up to 400 kg, WS 3000 up to 621 kg, W 100 up to 1,015 kg per level.
- 4. Define the grid: bay width according to the load unit, depth according to reach, height according to loading height, number of levels according to bay load.
- 5. Clarify the installation: floor load capacity, wall connection, traffic routes in accordance with ASR A1.8, load notice, inspection interval.
In the wide-span shelving configurator you assemble starter and add-on bays with levels and shelves and immediately receive a parts list and price. For special cases such as multi-tier installations, unusual loads or connection to an existing row of shelving, our consulting service will support you.
Frequently asked questions
Is wide-span shelving heavy-duty shelving?
The term "heavy-duty shelving" is not standardised and is used in the trade for anything from 250 kg shelf load upwards. Wide-span shelving with 400 to 1,015 kg shelf load falls under it, as does pallet racking. What counts are the values on the load notice, not the name. Read more under Heavy-Duty Shelving: Calculating Load Capacity.
May I load wide-span shelving with a forklift?
No. Wide-span shelving is designed for hand loading; beams and shelves are not secured against lifting forces, and there are no rack protectors or push-through protection. If loading or unloading is carried out with handling equipment, the requirements for pallet racking apply (DGUV Information 208-061, sections 4.2.3.3, 4.2.4 and 4.2.5).
Does wide-span shelving need to be fixed to the wall?
That depends on the height-to-depth ratio, the row length and the manufacturer's specifications. A 3,000 mm high rack with a depth of 400 mm generally needs a wall connection or a connection to the adjacent row; a 2,000 mm high rack with a depth of 800 mm in a long row usually does not. The assembly and operating instructions are binding.
Sources
- DGUV Information 208-061 „Lagereinrichtungen und Ladungsträger", edition November 2023, updated version July 2024 (sections 4.1.2, 4.2.1, 4.2.6, 4.2.7, 5.2.1, 6.1)
- DGUV Information 208-043 „Sicherheit von Regalen", edition June 2020
- DIN EN 15635:2009-08 „Ortsfeste Regalsysteme aus Stahl – Anwendung und Wartung von Lagereinrichtungen"
- Betriebssicherheitsverordnung (BetrSichV), section 3(6) and section 14(2)
- ASR A1.8 „Verkehrswege"