PROJECT CASE · THAILAND

Thailand — 32 m Four-Way Shuttle High-Bay, 24,000+ Pallet Positions

A 32-meter four-way shuttle high-bay with 24,000+ pallet positions — one of the tallest shuttle systems in Southeast Asia. At this height, lane-rail alignment and frame plumb decide whether shuttles hold speed at the top levels; the structure was engineered to FEM 10.2.19 shuttle-racking design rules with project-specific calculations.

The project

For an automotive manufacturing group's Thai operation, JISE designed and built a 32-meter high-bay four-way shuttle racking system with 24,000+ pallet positions, running Bullseye four-way shuttle cars. High-bay warehouse racking at this height is a structural engineering project first and a storage project second.

Automotive logistics runs on sequence and takt: components must reach the line on schedule, which means the storage system cannot be the bottleneck — shuttle speed and availability are production KPIs.

Engineering at 32 meters

At 32 m, frame plumb and lane-rail straightness decide system performance. A rail deviation that is invisible at 8 m becomes a shuttle fault at 32 m — multiplied by dynamic load amplification at height. The structure was engineered to FEM 10.2.19, the shuttle-racking design code, with project-specific FEA covering the moving-load cases the shuttles impose.

Rail profiles, guide clearances and lift-shaft interfaces were engineered jointly with the shuttle supplier's interface data, so steel and robots were designed as one system — not patched together on site.

Build and commissioning

Before shipment, the system's critical assemblies were trial-erected at JISE's factory test facility — full-height bays with shuttles running — so interface issues were solved in Dongtai, not on the Thai site. JISE crews then installed the system in Thailand, with rail alignment verified level by level as the bays rose.

The project anchors JISE's four-way shuttle references in Southeast Asia and demonstrates the pattern we recommend for tall systems: engineer to FEM 10.2.19, test at the factory, install with factory crews.