Bricking (Block Stacking in Warehouses)

In warehouse operations, bricking is sometimes used informally to describe block stacking: the practice of storing palletized goods directly on the floor in dense, compact blocks or "bricks." Block stacking is a simple, cost-effective storage method that foregoes racking in favor of high-density floor stacking. While it’s not suitable for all inventory types, bricking/block stacking is often used for homogeneous, non-velocity-sensitive items and is a practical strategy for maximizing cubic utilization when racking is unavailable or too costly.

How block stacking (bricking) works

Block stacking involves arranging pallets in rows and tiers on the warehouse floor. Pallets are placed tightly together to form a continuous mass of inventory. Typically, stacks are organized by SKU or product family to avoid mixing goods and to simplify retrieval. The number of tiers (height of stacks) depends on pallet and product strength, local regulations, and available lift equipment capability.

Advantages of bricking/block stacking

• Low capital expense: No racking is required—saves on initial investment and maintenance costs.
• High space utilization: By placing pallets close together and stacking vertically, warehouses can maximize available storage volume.
• Flexible layout: Areas used for bricking can be reconfigured easily as demand or product mix changes.
• Fast to implement: Setting up block stacking zones is operationally quick compared to installing racks.

Limitations and trade-offs

Block stacking has trade-offs that must be managed carefully:

• Reduced selective access: Pallets stored in the middle of a block are harder to access, which complicates FIFO/LIFO strategies and may increase handling time.
• Inventory control challenges: Manual tracking may become error-prone without solid labeling and inventory systems.
• Suitability: Not appropriate for fragile, mixed-size, or very high-value goods that require selective access or protection.
• Potential for damage: Improper stacking or unstable pallets increase the likelihood of pallet collapse and product loss.

Operational strategies to make bricking work

When using bricking/block stacking, follow these beginner-friendly operational strategies:

• Zone by SKU and velocity: Group fast-moving items where access is required and slower-moving products deeper in the block. Reserve aisles or lanes for picking to avoid disrupting other stacks.
• Label clearly: Use visible pallet IDs and barcode labels and ensure the Warehouse Management System (WMS) tracks the precise location of each pallet in the block.
• Plan stacking patterns: Use stable stacking patterns—such as brick stacking of cases on pallets—to reduce collapse risk and distribute weight evenly.
• Limit stack height: Set safe stacking height limits based on pallet and product strength and OSHA or local regulations. Regularly inspect stacks for leaning or instability.
• Maintain forklift access lanes: Provide adequate space for safe forklift maneuvering and retrieval from the block without causing damage.

When to choose bricking over racking

Consider block stacking when:

• Inventory is large, homogeneous, and has predictable replenishment cycles.
• Capital for racking installation is limited or temporary storage is needed.
• Products are not highly fragile and can withstand floor stacking and forklift handling.
• Storage is temporary—during seasonal peaks or before full system upgrades.

Examples in practice

1) A beverage distributor uses bricking in a holding area for large runs of a single SKU. Since pallets are identical and shipments are large, dense floor stacking reduces cost and speeds loading. 2) A manufacturing plant stages raw materials in block stacks near production lines; their WMS records exact pallet coordinates so operators can pick the next pallet efficiently without scanning every unit in the block.

Inventory accuracy and technology

One of the biggest concerns with bricking is maintaining accurate inventory. Modern WMS and inventory-management tools help by assigning precise GPS-like locations on the floor (aisle/row/slot systems adapted for blocks) and by integrating mobile scanning and cycle-count routines. For high accuracy, pair bricking with routine cycle counts and clear labeling protocols. RFID readers can accelerate inventory counts across block stacks, reducing manual scanning time.

Safety and compliance

Safety is paramount. A few practical safety measures include:

• Training: Lift-operator training specific to block retrieval reduces accidents.
• Stack inspection: Regular checks for damaged pallets, leaning stacks, or compromised packaging.
• Weight distribution rules: Avoid overloading lower pallets—distribute heavy items at the base.
• Fire regulations: Ensure compliance with local fire codes regarding aisle widths and sprinkler accessibility.

Conclusion

Bricking as block stacking is a practical, cost-effective storage strategy when applied to the right inventory mix. It offers high density and flexibility at low capital cost, but requires disciplined labeling, strict stacking rules, safety controls, and WMS integration to avoid the most common pitfalls. For beginners, bricking can be a smart choice for seasonal surges, homogeneous product runs, or temporary storage solutions—provided clear procedures and checks are in place to maintain access, accuracy, and safety.