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How to Get More Vertical Warehouse Storage for Your Facility
April 15, 2026
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Categories: Blogs, Ergonomics, Material Handling, Efficiency
If you need to increase operational capacity, you probably need to look up — literally. Vertical warehousing reduces costs and improves floor space utilization, and while it was once a niche tactic for specific industries, that’s no longer the case.
That’s largely due to the cost of space: The price for warehouse facilities in the United States jumped 8.3% from $7.96 per square foot in 2022 to $8.31 in 2024. Those costs aren’t likely to come down anytime soon, so growing businesses need to be somewhat creative.
But adding height to your facility introduces a new challenge: the transport of materials between levels. Without a strategic approach, new storage levels can quickly become bottlenecks.
At BHS, we’ve helped operations address those bottlenecks and find effective ways to scale. Below, we’ll outline how to effectively implement mezzanine systems and Vertical Reciprocating Conveyors (VRCs) to optimize your footprint. To discuss options with a member of our team, call 1.800.BHS.9500.
Expand Square Footage with Industrial Mezzanines
Before moving materials up, you must create the usable space for those materials. Mezzanine flooring systems provide a cost-effective way to add square footage within an existing footprint. Of course, you’ll need the right material equipment to utilize that space, but we’ll discuss that it a moment.
When incorporating mezzanines into your operation:
- Evaluate Ceiling Clearance: Ensure you have enough clear height to support both the mezzanine structure and the operations occurring above and below it without violating fire codes or obstructing HVAC systems.
- Assess Floor Load Capacity: Your existing concrete slab must be able to support the concentrated loads of the mezzanine’s columns; an engineering review is essential.
- Determine Intended Use: If you need to house heavy machinery or high-density racking, look for a structural steel mezzanine. For lighter-duty picking or office space, a roll-formed mezzanine will be less expensive.
- Prioritize Modularity: Choose a system that can be expanded or reconfigured. As supply chains shift, you’ll want to be able to grow or relocate your vertical storage.
Related: Using Warehouse Mezzanines to Improve Throughput
VRCs: Dedicated Material Handling for Mezzanines
Once you’ve built mezzanines, you need an effective way to move materials and products up to (and down from) those higher levels. We strongly believe that VRCs are the best solution for most facilities.
While you could use freight elevators (which can lift personnel — VRCs only lift materials), VRCs have lower maintenance costs, and they can be designed for automation-heavy workflows. Learn more about the differences between freight elevators and VRCs.
VRC Lifting Mechanisms
The core of vertical efficiency lies in the lifting mechanism of your VRC. Hydraulic VRCs are an excellent, affordable choice for two-story operations or mezzanines up to 15 feet, typically handling loads under 6,000 pounds.
Mechanical VRCs are a better choice for travel heights exceeding 15 feet, 24/7 operation, and other demanding environments. These units use a motor with a chain system to support higher capacities and faster travel speeds.
BHS engineers both types of systems to ensure your lift matches your specific weight and height requirements.
Related: Vertical Reciprocating Conveyors: 5 Sample Use Cases
Custom Traffic Patterns for Efficient Material Flow
The accessibility of a VRC is what prevents your new vertical storage from becoming a bottleneck. Choose a configuration that supports the specific traffic patterns of your facility. Carriage design dictates these options; for instance, cantilever models allow for same-side loading that straddle models can’t accommodate.
BHS designs VRCs with multiple access points to match your workflow:
- Z-Pattern: Loading from one side and unloading from the opposite.
- C-Pattern: Loading and unloading from the same side (requires cantilever carriages).
- 90-Degree or L-Pattern: Offering access from two sides.
Products from BHS, Inc.
The VRC-HC is a quiet, low-maintenance lift designed for two-level applications and mezzanines. Its compact two-post cantilever frame supports C, Z, and L-loading patterns while managing pallet loads with up to 15 feet of vertical travel.
Choose between 3,000 lb and 6,000 lb capacities with a consistent travel speed of 21 feet per minute. Standard carriage sizes up to 60” x 90” minimize the required footprint while supporting GMA pallets and AGV integration. Built-in velocity fuses and full ASME B20.1 compliance protect against carriage descent and ensure regulatory adherence.
Built for high-speed, high-capacity operations, the VRC-MS features a heavy-duty straddle design for multi-story buildings and conveyor lines. It’s capable of handling frequent duty cycles and faster travel speeds than hydraulic units, making it the premier choice for high-throughput distribution centers.
The electric motor and chain drive power a rapid 28 feet per minute travel speed for rises up to 25 feet. Large-scale carriage platforms up to 90” x 96” easily accommodate oversized loads or multiple pallets in a single cycle.
Ready to outfit your operation?
Maximize your facility's efficiency and reclaim your floor space today. Contact the BHS sales team at 1.800.BHS.9500 or use our online form to request a quote.
