AGV Aisle Sizing and Layout

Aisle Width by Vehicle Class

Vehicle Class	Manned Aisle Width	AGV Aisle Width
Counterbalanced forklift	12-14 ft (3.7-4.3m)	12-13 ft (3.7-4.0m)
Reach truck	8.5-10 ft (2.6-3.0m)	~8-9 ft (2.4-2.7m) single-direction
Pallet jack AGV	N/A	1.8-2.5m single; 2.5-3.0m bi-directional
VNA / Turret	5-7 ft (1.5-2.1m)	<6.5 ft (<2.0m)
High-density narrow AGV	N/A	1.2m minimum with specialized nav

Note: AGV aisle widths must account for sensor field clearance, not just vehicle body width. An aisle that is “just wide enough” for a manual forklift is often too tight for an AGV’s obstacle detection zones.

Turning Radius by AGV Type

AGV Type	Turning Radius
Automated pallet truck (light)	1.5-2.5m
AGV pallet truck (standard)	2.0-3.0m
Heavy-duty AGV forklift	3.0-5.0m+

Outer turning radius = distance from center of turning circle to outermost point of the AGV during a turn. Manufacturers publish inner and outer radii in product specs. Use outer radius for aisle calculation.

RASA Formula (Right Angle Stacking Aisle)

The RASA calculation determines minimum aisle width for a 90-degree turn into a rack face:

RASA = r + max(R, R₁) + 2 × safety clearance

Variable	Definition
r	Minimum turning radius of the vehicle body
R	Cargo rotation radius: outermost corner of load during 90-degree turn
R₁	Fork tine rotation radius: distance from turning center to fork tip
Safety	100mm per side minimum (200mm total)

Use max(R, R₁) — whichever is larger governs. On heavy-duty or long-fork AGVs, R₁ often exceeds R.

Cargo rotation radius derivation:

R = √((load_width/2)² + load_depth²) + front_overhang (L2)

For a standard 48”×40” pallet: inner diagonal ≈ 1,195mm; add L2 (~400mm) → R ≈ 1,595mm.

Examples:

Config	r (mm)	max(R, R₁) (mm)	Safety (mm)	RASA	Approx
Light CB AGV	2,192	1,597	200	3,989mm	~13 ft
Heavy CB AGV	3,560	3,010	200	6,770mm	~22 ft

Source: agvmotor-aisle-width-calculation

Cross-Aisle and Transfer Aisle Widths

• Cross aisles connecting rack aisles: minimum 11-12 ft for counterbalanced AGV, wider for head-on passing
• Transfer aisles for bi-directional AGV traffic: add 50% to single-direction aisle width minimum
• End-of-aisle staging areas: size to accommodate full vehicle + load turn without encroaching on adjacent aisles

Guidepath Clearance (Safety Requirement)

ANSI/ITSDF B56.5 requires:

• Minimum 0.5m (19.7 inches) clearance on both sides of the AGV guidepath
• Exception: VNA restricted areas where clearance on both sides is <0.5m — these require additional safety measures (barriers, light curtains, restricted access)

Vertical Clearance (Overhead Height)

Minimum path height is governed by the mast height in travel configuration, not the vehicle body height or maximum lift height. Even with forks fully lowered, the mast structure extends well above the cab and is the fixed obstacle that must clear every overhead element along the guidepath.

AGV Type	Mast Height at Travel	Governing Clearance
Pallet mover (mastless)	Vehicle height only (~1.5–2.0m)	Low concern
Counterbalanced AGV forklift	3–5m (spec-dependent)	Path routing constraint
Reach truck AGV	4–6m+	Path routing constraint
VNA / turret truck AGV	8–14m+	Full building height must clear

Minimum overhead clearance = mast height (travel config) + 100–200mm safety margin

Practical survey checklist — measure against mast height, not fork height:

• Sprinkler drops and branch lines
• Conduit runs and cable trays
• Structural beams and bridging
• Dock leveler overhead clearance at grade transitions
• Mezzanine edges and floor penetrations

Mast height is fixed at equipment selection. Survey the full guidepath against the specified mast height before finalizing routing. Rerouting after installation is costly; overhead obstructions are often discovered too late.

VNA Transfer Corridor

VNA rack aisles require a dedicated transfer corridor perpendicular to the rack aisles for transit between aisles:

• Working aisle (between rack faces): 1,600mm minimum
• Transfer corridor (connecting aisle ends): 7,000mm minimum

The 7m transfer corridor accommodates the VNA AGV making a full turn from the rack aisle into the corridor. Under-sizing the transfer corridor is a common layout error that forces single-direction flow or restricts fleet throughput. Source: agvnetwork-agv-specifications

Layout Design Rules for AGV

1. Sensor field first: Size aisles to the vehicle’s obstacle detection field, not just the vehicle body. A safety scanner warning field at 2 m/s may extend 1.5-2m ahead.
2. No mixed traffic in rack aisles: AGV and manned forklift cannot share a rack aisle without traffic control interlocks.
3. Straight-in aisle entry: AGVs cannot correct approach angle in tight aisles. Entry geometry must allow straight alignment before aisle entry.
4. Charging and staging zones: Outside of rack aisles; size for full vehicle + load with clearance on all sides.
5. End-of-aisle detection: Install sensors or stops at aisle ends; do not rely solely on software.
6. Design for growth: Size aisles to the current AGV class plus one size class up. Widening aisles after racking is installed requires re-slotting; the retrofit cost far exceeds the design-time increment.

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Door and Opening Sizing for Roll Handling AGVs

Roll handling AGVs (reel fork, roll clamp) transport oversized cylindrical loads — rolls up to 2,050 mm long × 1,500 mm diameter — in horizontal orientation. Standard door sizing for pallet AGVs is insufficient. Every door, wall penetration, and fire door on a roll handling AGV route must be sized against the cargo rotation radius.

Clear Width — Turn Approach to Opening

Apply the RASA cargo rotation methodology to the approach geometry:

R = √((roll_length/2)² + roll_diameter²) + front_overhang

Example: roll 2,050 mm long × 1,500 mm diameter, 400 mm front overhang
R = √(1,025² + 1,500²) + 400
  = √(1,050,625 + 2,250,000) + 400
  = 1,816 + 400 = 2,216 mm

Minimum clear width (turn approach) = R + vehicle half-width + 200 mm safety each side
                                     ≈ 2,216 + 900 + 400 = ~3,516 mm → specify 3,500 mm clear

Practical specifications:

Approach Type	Minimum Clear Width	Notes
90° turn into opening	3,000–3,500 mm	Governed by cargo rotation radius
Straight-through travel	Roll length + 600 mm	2,050 mm roll → 2,650 mm min; specify 3,000 mm
Bi-directional AGV traffic	Add 50% to single-direction width	Stagger openings if bi-directional width is impractical

Clear Height

Parameter	Dimension	Basis
Reel fork AWT mast height (travel)	3,000–4,000 mm	Vehicle-specific; confirm from manufacturer
Minimum overhead clearance	+200 mm above mast	Mast deflection under load
Practical door height spec	4,000–4,500 mm clear	Includes overhead door mechanism hardware

This significantly exceeds standard personnel door height (2,100 mm) and standard dock door height (3,000 mm). All doors on roll handling AGV routes must be specified as purpose-built industrial openings, not adapted from standard warehouse door catalogs.

Door Type and AGV Interlock

• High-speed roll-up doors (fabric or sectional) minimize open dwell time and reduce dust/moisture infiltration on paper mill paths
• AGV interlock required: Fleet Controller signals door open → door confirms open → AGV proceeds → door closes after clearance confirmed
• Failure mode must be fail-safe: door interlock failure → AGV stops and holds, does not proceed
• Fire-rated doors on roll warehouse boundaries: held open by magnetic releases tied to the fire alarm system; on alarm signal, they release and close; AGV Fleet Controller must recognize loss of door open confirmation and stop all vehicles approaching that opening