Stack-iT’s Next Generation Cantilever Storage System
17/02/2026
Cantilever Storage System
Case Study: Engineering Validation Supports Scalable Cantilever Development
As warehouse and trade storage systems evolve, manufacturers face growing pressure to deliver higher capacities, faster installations, and safer performance under real operational loads. However, developing new structural storage components without proper engineering validation risks costly redesigns, reduced capacity, or compliance challenges when systems are deployed across multiple sites.
Stack-iT Storage Solutions engaged Brevity to undertake engineering analysis for a new cantilever storage system, ensuring that updated configurations could be safely deployed and scaled across future projects.
The Challenge: Moving Beyond Trial-and-Error
Cantilever storage systems carry significant bending forces and connection loads, particularly in industrial storage where arm capacities and rack heights continue to increase. Traditionally, product development relied on iterative physical testing, which is slow and often fails to account for the full range of operational load scenarios.
The Solution: Digital Validation through FEA
Rather than relying on manual prototyping, Brevity conducted Finite Element Analysis (FEA) across multiple configurations. This allowed the behaviour of both current and proposed cantilever systems to be tested digitally before manufacturing changes were rolled out.
The analysis covered:
- Existing and proposed cantilever arm and profile configurations.
- Column insert add-ons and baseplate reinforcement options.
- Structural behaviour under specific operational load scenarios.
By modelling stress distribution and connection behaviour, potential performance limitations were identified early, allowing design refinement before market deployment.
Key Industry Takeaways
- Risk Mitigation: Engineering validation removes the "guesswork" that leads to unexpected capacity limits or costly retrofits after installation.
- Predictable Scaling: Validated systems allow suppliers to confidently scale products across different regions while maintaining strict compliance with AS 4084 and AS/NZS 1170.
- Speed to Market: Digital testing (FEA) identifies structural response faster than physical prototyping, enabling quicker innovation cycles.
- Compliance Readiness: A proactive engineering framework ensures that product rollouts meet MBIE and Engineering New Zealand standards from day one.
Outcome
Stack-iT gained total clarity on how their updated cantilever configurations would perform. This collaboration provided a clear pathway toward a safer, scalable storage system ready for real-world warehouse use. When engineering is straightforward, innovation moves faster.
Relevant resources
Engineering New Zealand — Producer Statements & Engineering Guidance
Industry guidance supporting engineering assurance and compliance pathways.
https://www.engineeringnz.org/engineer-tools/engineering-documents/producer-statements/
AS 4084 Steel Storage Racking Standard
Governs design and performance of steel storage systems.
https://store.standards.org.au/product/as-4084-1-2023
AS/NZS 1170 Structural Design Actions
Defines structural loading requirements used for engineering analysis.
https://store.standards.org.au/product/as-nzs-1170-0-2002
MBIE Building Performance Guidance — Structural Compliance
Framework supporting structural compliance in New Zealand.
https://www.building.govt.nz/building-code-compliance/b-stability/b1-structure/
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