Summary
Planning an AS/RS system requires more preparation than most companies expect.
Your building needs structural evaluation before installation. The floor must support heavy loads, and ceiling height determines storage capacity. Most facilities need electrical upgrades to handle 200-400 amps of power, and fire suppression systems can cost $50,000 to $200,000.
Software compatibility is critical. Your warehouse management system must connect to the AS/RS, which sometimes requires upgrades taking 3-6 months. Many projects also need warehouse control system (WES) software to bridge the gap between your WMS and the automation.
Installation takes 12+ weeks for small systems and 6+ months for large ones. You can't shut down operations during installation, so expect phased implementation with night and weekend work. Staff need at least 40 hours of training before the system goes live.
Budget for hidden costs that add 20-30% to initial quotes. These include site preparation, building modifications, fire systems, IT and software upgrades, training, and spare parts inventory.
Success comes from thorough planning, not just good technology. Start planning 6-12 months before installation, involve IT and operations teams early, and choose integration partners with proven experience. Companies that rush the planning phase end up paying for problems later.
Getting an AS/RS system wrong costs money. A lot of it. The good news? Most problems come from missing basic planning steps, not from the technology itself.
Here’s what you need to know before you start an ASRS systems integration project.
Your Building Matters More Than You Think
AS/RS systems are tall. Some reach 100 feet high. That means your building needs to handle the weight and the height.
Start with a structural engineer. They need to check your floor’s load capacity. Concrete floors often need reinforcement. Steel buildings might need extra support columns. Older warehouses sometimes can’t support modern AS/RS at all.
Don’t skip this step. We’ve seen projects delayed six months because the floor wasn’t ready. One client had to pour a new foundation. Another needed to add 12 support columns. Both could have been avoided with early planning.
Your ceiling height sets your storage capacity. Every foot of height means more inventory you can store. But you also need room for fire suppression systems, lighting, and HVAC. Plan for at least 18 inches of clearance at the top.
Your Current WMS Needs a Health Check
An AS/RS talks to your warehouse management system constantly. Every pick, every putaway, every inventory move goes through that connection.
If your WMS is old or custom-built, integration gets harder. Some older systems can’t handle the speed of automated storage. Others lack the API connections modern AS/RS systems need.
Ask these questions about your WMS:
- When was it last updated?
- Does it have API capability?
- Can it handle real-time inventory tracking?
- How fast can it process pick orders?
- What’s the vendor’s support policy?
Sometimes the WMS needs an upgrade before you add AS/RS. Sometimes you need WES (warehouse execution system) software to sit between your WMS and the automation. Sometimes you need both.
Figure this out early. WMS upgrades can take 3-6 months. That affects your whole project timeline.
Power Requirements Are Bigger Than Expected
Some AS/RS systems can use a lot of power. The cranes run constantly. The conveyors never stop. The control systems need clean power without interruptions.
Your electrical system needs three things:
Enough capacity. A typical AS/RS uses 200-400 amps. Small warehouses sometimes need a complete electrical upgrade. Budget for it.
Clean power. Control systems hate power fluctuations. You might need dedicated circuits, surge protection, or even a UPS backup system.
The right locations. Power needs to reach the crane rails, the conveyor motors, and the control panels. Running new lines through an operating warehouse costs more than installing them in an empty building.
Get an electrical contractor involved in month one, not month six.
Fire Suppression Gets Complicated
Fire codes for AS/RS are strict. Storage racks that reach the ceiling create fire hazards. Automated systems can’t evacuate themselves.
Most AS/RS installations need in-rack sprinkler systems. That means sprinkler heads inside the storage structure, not just on the ceiling. The cost varies, but plan for $50,000 to $200,000 depending on system size.
Your local fire marshal needs to approve the design. In some cities, this approval process takes months. Start it early.
Some AS/RS designs use ESFR (early suppression fast response) sprinklers. Others use standard sprinklers with draft curtains. Your building height, product (including packaging), storage density, and local codes determine which you need.
Layout Planning Takes Real Work
Where the AS/RS sits in your warehouse matters. It affects everything else.
Receiving proximity. Putting the AS/RS too far from receiving docks means long conveyor runs. Each foot of conveyor costs money and needs maintenance.
Shipping access. Pick faces need to be close to shipping areas. Workers shouldn’t walk 200 feet to retrieve picked orders.
Column spacing. Existing building columns might block the ideal layout. Sometimes you can work around them. Sometimes they force you to choose a different AS/RS.
Traffic flow. Forklifts, people, and automation need to coexist. Poor planning creates bottlenecks and safety hazards.
Draw it out. Use tape on the floor. Build a mock-up if you need to. Walking through the layout catches problems that look fine on paper.
Product Matters
Product size and shape play a critical role in AS/RS design, but it’s not just about the individual SKU. How the product is stored matters just as much — including vendor case sizes, inner packs, and the quantities you plan to hold and move through the system. Variability in dimensions, weights, and packaging can quickly limit storage density or complicate picking if it’s not understood upfront.
This is why accurate product and order data is essential early in the process. Providing 12 months of outbound order history will help to establish realistic design rates for both storage and picking. That data helps determine slotting strategies, throughput requirements, and whether the system can scale with seasonal or promotional spikes.
Replenishment also needs careful consideration. Replenishment should be simple, intuitive, and predictable. If the process becomes overly complex, labor-intensive, or error-prone, it’s usually a sign that the storage strategy or system configuration needs to be rethought before moving forward.
Integration Time Is Real Time
You can’t install AS/RS in a weekend. Even small systems take weeks. Large ones take months.
Most warehouses can’t shut down for installation. That means working around ongoing operations. Night shifts. Weekend work. Phased installations.
Plan for these phases:
Week 1-2: Site prep. Floor reinforcement, electrical work, fire suppression rough-in, safety system testing.
Week 3-6: Structural install. Rack assembly, crane installation, conveyor placement.
Week 7-10: Systems integration. Control software setup, WMS connection, ongoing safety system testing.
Week 11-12: Testing and training. System testing, staff training, process documentation.
Week 13+: Go-live and optimization. Gradual ramp-up, issue resolution, performance tuning.
These timelines assume everything goes right. Add buffer time for problems. They always happen.
Staff Training Can’t Be an Afterthought
AS/RS systems change how your warehouse works. Your team needs to learn new skills.
Operators need to understand the control system. They monitor dashboards, handle exceptions, and troubleshoot basic problems.
Maintenance staff need to know the mechanical systems. Crane maintenance is different from forklift maintenance.
Supervisors need to understand the workflow changes. Pick processes are different. Put-away processes are different. Inventory management is different.
Start training before installation finishes. Good vendors provide training during installation, not just after. Plan for at least 40 hours of training per person who will operate the system.
Maintenance Planning Starts on Day One
AS/RS systems need regular maintenance. Cranes have bearings that wear out. Rails need alignment. Sensors need cleaning. Control systems need updates.
Set up a maintenance program before you go live. You need:
Spare parts inventory. Critical components should be on site. Waiting three days for a motor to ship means three days of downtime.
Maintenance schedule. Daily checks, weekly inspections, monthly service, annual overhauls. Put it in writing.
Trained staff or service contract. Someone needs to do the work. Internal staff saves money but needs training. Service contracts cost more but provide expertise.
Documentation. Keep electrical schematics, mechanical drawings, and software documentation organized. You’ll need them.
The best time to plan maintenance is before you need it.
Budget for Hidden Costs
AS/RS quotes often miss items. Watch for these:
- Site prep (floor work, electrical upgrades)
- Building modifications (doors, walls, roof penetrations)
- Fire suppression systems
- WMS upgrades or WCS software
- Training beyond basics
- Project management
- Installation during off-hours
- Spare parts inventory
- First-year maintenance
These “extras” can add 20-30% to your project cost. Budget for them upfront.
Success Depends on Good Partners
ASRS systems integration isn’t a solo project. You need partners who understand the big picture.
Look for integrators with:
Real project experience. Ask for references. Visit completed installations. Talk to their customers.
Engineering capability. They should handle structural, electrical, and software engineering in-house or through trusted partners.
Post-installation support. The relationship doesn’t end at commissioning. You need ongoing support.
Industry knowledge. Warehouse automation changes fast. Your integrator should know current best practices.
Clear communication. Projects have problems. Good partners communicate early and often.
Since 1996, we’ve learned that successful AS/RS projects share one thing: good planning. The companies that plan thoroughly get systems that work. The ones that rush hit problems.
Questions to Ask Before You Sign
Before you commit to an ASRS systems integration project, get answers to these questions:
- What’s the total project cost, including all site work and modifications?
- What’s the realistic timeline from contract to go-live?
- What building modifications do we need?
- Does our WMS work with this system?
- What training do you provide?
- What’s the maintenance plan and cost?
- What’s included in the warranty?
- Who handles service calls and how fast do they respond?
- Can we visit a similar installation?
- What’s your commissioning process?
If the answers aren’t clear, keep asking. Good vendors welcome questions. They know informed customers make better partners.
Start With Assessment, Not Shopping
Don’t start by picking an AS/RS system. Start by understanding your needs.
What are you storing? How much volume do you handle? What are your peak demands? How does product flow through your building? What’s your growth plan?
Answer these questions first. Then look at systems that match your needs.
AS/RS systems work great in the right application. They’re expensive mistakes in the wrong one. The difference is in the planning.
Getting Help
AS/RS systems integration takes expertise. Most companies do it once or twice in their lifetime. That’s not enough to learn all the details.
Working with experienced integrators makes the difference between a smooth project and a difficult one. Look for partners who ask tough questions, provide honest answers, and have a track record of successful installations.
At Systems in Motion, we’ve been integrating AS/RS systems since 1996. We’ve seen what works and what doesn’t. We know the questions to ask and the problems to avoid.
If you’re considering AS/RS for your warehouse, we can help you figure out if it’s the right move and what it takes to make it work. Call us at (800) 678-9091 or visit our website to talk about your project.
Good AS/RS systems integration starts with good planning. Take the time to do it right.
