Catwalk Racking Systems for Multi-Level Storage Access

Catwalk racking systems use decked picking aisles and stairs to increase vertical storage while keeping inventory reachable across multiple levels. Southwest Solutions Group helps you plan the storage levels, access points, and layout details that fit your facility.

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Multi-level metal racking system with stairway walkways and shelves holding boxes.

What Are Catwalk Racking Systems?

Catwalk racking systems are multi-level shelving or racking layouts with integrated decked aisles and stairways for accessing stored inventory above the floor. Unlike an open mezzanine platform, the structure is planned around storage bays, picking paths, and upper and lower access to materials.

Planning Storage Levels, Dimensions, and Capacity Needs

Designing a catwalk rack storage system starts with mapping your facility height, floor space, storage mix, and picking routes. Exact dimensions and capacities are determined during project assessment, but the layout can be planned around bulky materials, small parts, rapid-turnover items, and existing building conditions.

Confirm available clear height, usable footprint, and the desired number of storage levels.
Place bulky or lower-turnover materials where upper-level storage makes sense for your picking process.
Plan lower-level shelving, dividers, or modular drawers for smaller items and faster-moving inventory.
Account for beams, columns, doors, air ducts, and other building obstructions before final layout.

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Warehouse catwalk racking system with metal shelving and yellow safety railings.

Multi-level blue and yellow racking system with integrated stairs and handrails.

Catwalk Racking Options and Access Features

Catwalk shelving systems can be configured with standard shelving, long-span shelving, modular drawers, mini-racking on upper levels, decked aisles, stairs, handrails, and railings. Lighting and fire-system coordination are reviewed during design so the proposed layout fits the building and the way staff move through the storage area.

Use long-span or standard shelves when upper levels must hold larger materials.
Add modular drawers or dividers where small parts need more organized lower-level access.
Locate stairs and railings around picking paths, replenishment routes, and available floor space.
Review lighting and fire-system needs as part of the project layout rather than after equipment selection.

Where Catwalk Rack Storage Systems Fit Facility Workflows

Catwalk rack storage systems are used in warehouses, distribution centers, e-fulfillment operations, manufacturing facilities, automotive storage areas, and retail backrooms. They help staff store and retrieve cartons, parts, tools, supplies, and other inventory across upper and lower levels without converting the project into a general open platform.

Two-level catwalk racking system filled with inventory above a warehouse sales floor.

A blue metal catwalk racking system with shelves, drawers, and an integrated staircase in an industrial room.

How to Plan a Catwalk Racking Project

Before requesting a layout, gather details about your facility, inventory, access needs, and workflow routes. Southwest Solutions Group specialists can review building obstacles, storage goals, stairs, decked aisles, lighting, and fire-system coordination before developing a catwalk system layout.

Facility layout, clear height, and available floor area.
Inventory list with item sizes, weights, and turnover patterns.
Preferred storage levels, aisle locations, and access points.
Picking, replenishment, and staging routes that must remain practical after installation.

A multi-level catwalk racking system with stair access and shelving holding small parts in an industrial setting. — Organize cartons and inventory with multi-level catwalk access.

Warehouse catwalk systems give pickers decked aisle access to inventory stored above the floor, which is useful when floor space is constrained but manual retrieval must remain practical. Lower levels can be planned for frequent picks, while upper levels can hold bulkier or slower-moving materials.

Helps teams separate pick faces by level instead of spreading inventory across more floor area.
Keeps stairs, aisle routes, and storage bays part of the same layout discussion.
Supports future layout review when inventory mix or picking routes change.

Multi-level metal catwalk racking system with stored bins and boxes in a large warehouse. — Support picking and packing with organized upper and lower levels.

Distribution and e-fulfillment teams can use catwalk shelving systems to organize products across multiple pick levels when order activity exceeds the capacity of a single floor layout. Pick modules may be reviewed separately when the operation needs a broader picking and packing workflow.

Places stored products along planned aisle routes for order picking.
Supports upper and lower storage zones without treating the system as only open floor space.
Keeps pick-module discussions tied to the facility workflow rather than the rack alone.

Multi-level catwalk racking with yellow railings and shelving in a warehouse. — Store parts and tools with organized access near production.

Manufacturing teams use industrial catwalk systems to store parts, tools, and supplies near production or maintenance areas while preserving floor space for work activity. The layout can separate small rapid-turnover items from larger materials that do not need the same level of access.

Supports parts organization close to production areas where retrieval time matters.
Allows different storage media, such as shelving or modular drawers, to be planned by item type.
Helps keep replenishment paths visible during the design review.

A warehouse interior with multi-level racking, stairs with yellow railing, and organized shelving accessed by a catwalk. — Organize service parts and components in a catwalk shelving layout.

Automotive operations can use catwalk shelving systems to organize replacement parts, components, and service inventory when a parts room needs more storage without simply expanding outward. Staff can categorize inventory by turnover, size, or retrieval frequency across upper and lower levels.

Supports categorized storage for mixed automotive parts inventories.
Uses vertical space in service or parts areas with limited floor area.
Allows layout changes to be reviewed as part categories and stock levels shift.

Two-level blue catwalk racking system with bins of stored items in an industrial stockroom. — Use vertical stockroom space for organized backstock access.

Retail stockrooms often have limited floor area for backstock, supplies, and bulk goods. Catwalk mezzanines and modular catwalk systems help staff use vertical space while keeping stored items arranged by level and reachable through planned stairs and aisles.

Supports backstock organization when floor space is constrained.
Helps separate frequently retrieved goods from bulk storage.
Keeps stockroom access planning tied to the shelving layout.

Planning Your Catwalk Racking System

Use these planning decisions to prepare for a project review. Final dimensions, capacity, and configuration depend on your facility conditions and inventory requirements.

Planning Decision	Why It Matters	What to Confirm
Storage Level Plan	Determining how many upper and lower storage areas the facility can support.	Confirm clear height, footprint, inventory volume, and where staff need access before selecting the layout.
Inventory Placement	Deciding which materials belong on lower levels, upper levels, shelves, drawers, or racks.	Match item size, weight, and turnover rate to the storage level and storage media.
Access Route Layout	Planning stairs, decked aisles, handrails, and picking paths around daily movement.	Review how workers pick, replenish, and stage materials before fixing stair and aisle locations.
Building Coordination	Facilities with beams, columns, doors, air ducts, lighting needs, or fire-system review requirements.	Identify building conditions early so the catwalk system can be planned around them.

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With 7 offices in Texas, Oklahoma, Kansas and Colorado, plus teams covering every major metro area nationwide, Southwest Solutions Group delivers expert case and tote conveyors sales, design, installation, and maintenance support wherever you need it.

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