Forklift Battery Maintenance Cost Calculator


If you are trying to estimate the costs to maintain a forklift battery. look no further. This forklift battery maintenance cost calculator will model for you the costs that go into the proper maintenance of a forklift battery and a forklift battery charger.

The Cost to Water Forklift Batteries

Battery companies will water your batteries for a charge. Using competitive battery watering service pricing, our calculator will estimate the cost to water your batteries on a regular basis.

Batteries need watering based the charging schedule. Batteries require water because during the charging cycle, the charger breaks apart the bonds of the water molecule into its component parts of hydrogen and oxygen. Those gases then escape from the battery into the atmosphere reducing the amount of water in the battery.

Your battery maintnenance technician then returns the water to each cell roughly every 2-weeks, but as often as every week in busy work applications.

The Cost to Repair Battery and Charger Connectors and Cables

Every time a forklift battery is charged, the charger and forklift connectors are inserted into each other to begin the charging process. Once the charge connection is complete, the cables are separated. Often, operators pull the connectors apart by the cables, damaging the cable insulation, the charger wire tips, and putting stress on the SB connectors. If the operator drops the connectors to the ground after the charging even, the connectors risk cracking, and the cables risk being damaged by forklifts rolling over the cables. We estimate that the cost to keep connectors and cables in good repair is $130/year. You can change this amount up or down.

Annual Battery Wash

Companies that perform regular battery washes save money in the long run. When acid escapes from the battery cells, it accumulates between the cells, at the bottom of the tray, and on the edges of the tray. Over time, it cause the tray to corrode and weaken. That is why many companies elect to wash their batteries.

Forklift Charger Maintenance

Many forklift and charger service companies offer an annual charger service. This usually involves an inspection and blowing out the cabinet. It is usually a good idea to have your chargers inspected regularly.

Pareto’s Law Pallet Racking Calculator


Designing a warehouse racking layout for your new warehouse? Before you decide on the storage media, use our Pareto’s Law Pallet Racking Calculator to help determine the best approach to pallet storage depth.

A Multi-Media Warehouse is an Efficient Warehouse

Using our Pareto’s Law pallet racking calculator, you can analyze the number of pallets and the number of SKUs to determine the best storage method to optimize warehouse space and racking design.

Reach Truck Aisle Dimension Estimator – Aisle Size

RAYMOND Reach Trucks neatly placed in a warehouse

Looking to know what to use for a Reach Truck aisle? Not sure how far apart to set racking when using a reach fork truck? Use this handy calculator to estimate the aisle needed for a reach truck to operate.

How much space do you need between racks to operate a reach truck safely?

Most people, if asked what aisle a reach truck needs to operate safely in would say, 9 feet. But there are a lot of parameters at play when spec’ing a warehouse aisle that needs to be considered. Such items include the following:

RAYMOND Reach Truck operating in a narrow aisle

Parameters that Impact the Warehouse Aisle Dimension

Length of Load

Consider the length of the pallet any product overhang on the pallet. The pallet might be a 48×40 pallet, but the product on top of the pallet might easily be 50″ x 42″. These dimensions will impact the narrow-aisle lift truck’s storage aisle dimension.

Width of Load

Notice if the product protrudes over the sides of the pallet.

Reach Truck Capacity

The mast on a higher capacity reach truck is an inch wider than the lower capacity reach truck. The wider mast makes the reach truck longer and therefore impacts the aisle dimension


If you want to move quickly, you will need more space in the aisle. We refer to this added space as maneuverability. Generally, we add an additional 12 inches to the aisle dimension to ensure the reach truck can move easily without hitting the product on the adjacent racking. It is possible to operate a reach truck in the engineered minimum, however, it is not easy and will add to the stress of the operator. Additionally, it will result in the possibility of increase rack damage, product damage, and will reduce productivity.

Baseleg opening (BLO)

Also known as outrigger inside dimension, the opening between the reach truck’s base legs impacts the aisle dimension. If the dimension is greater than 41″, add an inch to the width of the operating aisle.

Battery compartment size

Reach trucks come with various different battery compartment sizes to allow for longer shift life and increase capacity retention as the forklift lifts its load (pallet) higher in the air. The more lead in the battery compartment, the higher the weight capacity at full lift height. This is also called down-rating or d-rating. The wider the battery compartment, the longer the chassis length, and therefore, the wider the truck aisle needs to be.

Depth of the upright frame

Although the depth of the upright frame does not impact the width of the clear aisle, it is important to know when you are planning a warehouse and you are deciding where to put the racking. The aisle dimension is called the rack-to-rack dimension. It is different from the clear aisle dimension, also known as the product-to-product aisle.

Calculate the Aisle Needed for A Reach Truck

This calculator is provided for estimates only. Please contact us for a formal proposal with exact aisle dimensions. The other option is to contact the manufacturer of the reach truck to receive the aisle specification in writing from their engineers.

Crown mono-mast reach truck parked in an aisle
CROWN mono-mast reach truck parked in an intersecting aisle

Compare Warehouse Storage Density and Calculate Pallet Storage – Online Calculator

Now you know what aisle dimension you need for your Reach Truck to work in, use our online calculators to compare the number of pallets you can store in a warehouse using different aisle dimensions. Estimate pallet storage – click here!

Design Beam Elevations – Beam Heights in Pallet Racking

Calculate beam heights in pallet racking

You are thinking about moving into a new warehouse and you need to set the beam heights in your racking. You are wondering what the racking will look like and you need a tool to help you determine the heights of the beam levels and figure out how high your new forklift needs to lift.

There are two ways to do this. You can use this calculator to figure out how many pallets high you can store in the warehouse. Or you can use a more manual approach by setting different beam levels based on pallet heights using our calculator below.

The calculator helps design racking and set beam heights

Here are some of the other things you can learn from using this calculator:

  • Calculate 1st pallet rack beam level height
  • Determine the number of pallets stored vertically
  • Determine the number of beam levels per bay
  • Determine the number of beams needed per bay
  • Determine the height of the top load beam
  • Determine the fork elevation required on a forklift to work with your pallet rack
  • Know the optimal height of the pallet rack upright frame needed
  • Calculate the height to the top of the highest load stored in the pallet racking system
  • Determine the height of the sprinkler head in inches
  • Calculate the number of inches from the sprinkler head to the top of the highest pallet in the warehouse

Beam Height Calculator Instructions

We have set this calculator to work from bottom up. First fill in the height to the sprinkler head in feet to get started. You will need a laser to get an accurate distance. To buy a laser measuring device, you can find various laser measuring tool options here.

Now that you have the sprinkler height, you will need to determine the sprinkler type. Check your sprinkler riser for this information. It will say clearly if it is ESFR. If it does not say ESFR, select standard sprinklers. Your sprinkler height minus 18 inches (standard) or 36 inches (ESFR) will give you the maximum storage height. This dimension tells you the maximum height the tallest pallet on your top load beam can be.

Now start from the bottom of the calculator and work your way up. Each level will have a pallet height, a lift off, and a beam height (usually 4″-6″ tall)

We have assumed that the vast majority of racking systems will have at least two beam levels and therefore two beam heights.

Pallet Rack Repair Service

Damaged racking prior to pallet rack repair service

If you are looking for a pallet rack repair service, Lean Inc. can help. To repair pallet rack you will first need to identify what needs repairing. To do this, you will need to start with a rack repair survey performed by a qualified rack repair specialist.

Set an Appointment for a Pallet Rack Repair Service Site Survey

Start by setting an appointment with our Rack Repair Specialist at this link. It is important that fully trained rack repair specialist performs a detailed site survey to asses the damage and ensure the correct rack repair kits are manufactured for your racking system. The rack repair kits will vary based on the width of the racking column, the connector system, and the size and placement of the racking base plate. Additionally, it is important to know if additional horizontal and or diagonal struts are needed or not.

To Replace or Repair Pallet Rack

There are some good reasons to replace pallet racking after it has been damaged. Most businesses would attempt to replace the damaged racking rather that repair it. Some reasons to replace the racking versus repair the racking may include the following.

Replace Damaged Racking

  • You have surplus pallet rack beams and frames to replace the damage with
  • You need to reconfigure or move racking and therefore the racking must be disassembled any way
  • Your company is in a rush and a replacement upright frame is available in stock immediately
  • All anchor holes in the footplates of the upright frame have not been used, and there are unused holes open to received new anchors
  • You have already bought rack protection and do not need impact-resistant rack repair kits
  • Your current rack company does not specialize in rack repair, only rack replacement

But there are more reasons to repair racking. See below for reasons to repair racking rather than replace racking.

Reasons to Repair Damaged Pallet Racking Using an Engineered Repair Kit

  • Due to narrow aisles, or a congested warehouse, it is not practical to replace a tall upright frame
  • The frame has special backers that are nearly impossible to find used, and require a long lead time to manufacture new
  • Freight for the upright frame, plus its purchase price is far too expensive to justify its replacement
  • The operation is too busy to shut down to accommodate dismantling racking, its removal, and then the replacement of the frame with a new frame
  • In a warehouse prone to upright damage, it is important to replace the damaged racking with a more resilient-to-damage rack repair kit
  • The baseplate does not have any open holes to allow new drilling and anchoring

Rack Repair Audit Report

When you engage Lean Inc. for Rack Repair services, you can expect to receive a full rack audit report detailing the damage and the location of the damaged racking.

Rack Repair Audit Form
Rack Repair Audit Form from Lean Inc.

Repair Your Racking Before it is Too Late

If you have damaged pallet racking in your warehouse, contact Lean Inc. immediately to perform a rack audit and provide you with a full written report, and proposal.

Schedule an On-Site Pallet Rack Repair Service Audit Today

Use our online calendar booking service to schedule a walk-through of your warehouse and discuss whether rack repair is right for you.

Rack Relocation System by GondolaSkate – Photos

Rack Relocation System by GondolaSkate is a system to move rack in a warehouse safely and efficiently. GondolaSkate rack relocation systems are designed to move rack in a warehouse with minimum disruption. See below for photos of our warehouse rack mobilization systems.

men moving rack in a warehouse
Racking in Amazon being relocated using GondolaSkate racking mobilization system

System to Move Rack in a Warehouse – GondolaSkate

See below for images of our Rack Relocation System by GondolaSkate. See how it is used to move rack and how warehouse workers attach the system to the racking uprights. Notice the system uses heavy-duty poly wheels attach to a collar that fits around the racking upright using two strong pins. Once in place and secured correctly, the racking is ready to be moved.

To calculate the cost of moving rack using the GondolaSkate rack mobilization system and using the standard disassemble=reassemble method, follow this link: Move Rack Calculator

Rack mobilization system attached to pallet racking upright
GondolaSkate rack moving system designed to safely and efficiently move rack in a warehouse

Attach the GondolaSkate wheels to the Racking Upright

Using the holes on either side of the pallet rack upright, a yoke fits around the upright post and is secured with two pins. This is how the system is engineered to move rack. By attaching it securely, the rack relocation specialist is now ready to start lifting the racking column up off of the warehouse floor.

Attaching device to assist with moving racking in a warehouse
Attaching the Gondola Skate device to assist with moving racking in a warehouse.

Moving the racking is easy once the wheels have been securely attached and the racking has been lifted off the floor. At this point a metal hook is used to loop into the rack mobilization system at the bottom.

metal hook inserted into loop on the bottom of rack mobilization system designed to move racking in a warehouse
A metal hook is inserted into the loop on the bottom of rack mobilization system in order to move the racking in a warehouse

Warehouse Worker Pulls Racking with her team

Coordinated with the team, all warehouse workers, using the metal hooks attached to the rack moving system start to pull the racking in the same direction to the new position in the warehouse. You can use the rack mobilization system to move racking to a new location, change its orientation or narrow aisle for more efficient use of warehouse space.

Woman moving racking using a rack mobilization system from GondolaSkate
Warehouse worker moving racking using a rack mobilization system from GondolaSkate

Calculate the Cost to Move Pallet Rack

There are two ways to move warehouse racking:

1) Disassemble in the original location the racking and reassemble it in the new location

2) PIck up the rack and move it using the GondolaSkate Rack Relocation System

You can calculate the price to move racking in the warehouse using our free online rack relocation estimator. Estimate the cost to move rack here.