Introduction

This 2025 edition provides updated cost guidelines for warehouse and distribution equipment planning. Since the 2010 edition, the industry has experienced significant changes including supply chain disruptions, technological advancement, and material cost volatility.

Key Changes Since 2010:

• Average equipment costs have increased 40-100%

• Automation and IoT integration now standard

• Steel price volatility affects rack pricing ±30%

• Lead times normalized to 6-12 weeks (vs. 30+ during 2021-2022)

Be sure to check online pricing tools for the most current estimates. Prices shown include delivery and installation based on typical 2024-2025 rates.

Using Rules of Thumb

Warehousing & Distribution Guidelines

This pocket guide provides practical estimation of capital equipment costs for alternative layouts, operating systems, equipment applications, security, warehouse technologies and general guidelines.

Cost estimates are high-level budget figures for rough calculation purposes. Actual costs vary significantly based on specific applications, quantities, and market conditions.

All cost estimates include delivery and installation (where applicable) based on typical transportation and labor rates.

Pricing Guidelines:

• Use high range for: small quantities, heavy-duty applications, complex installations

• Use low range for: large quantities, light-duty applications, simple installations

• Add 10-20% for expedited delivery or custom specifications

• Steel-intensive products may vary ±30% due to material costs

Note: Prices reflect 2024-2025 market conditions. For the most current pricing, obtain vendor quotes.

Table of Contents - Click to Navigate

Introduction

This 2025 edition provides updated cost guidelines for warehouse and distribution equipment planning. Since the 2010 edition, the industry has experienced significant changes including supply chain disruptions, technological advancement, and material cost volatility.

Key Changes Since 2010:

• Average equipment costs have increased 40-100%

• Automation and IoT integration now standard

• Steel price volatility affects rack pricing ±30%

• Lead times normalized to 6-12 weeks (vs. 30+ during 2021-2022)

Be sure to check online pricing tools for the most current estimates. Prices shown include delivery and installation based on typical 2024-2025 rates.

Using Rules of Thumb

Warehousing & Distribution Guidelines

This pocket guide provides practical estimation of capital equipment costs for alternative layouts, operating systems, equipment applications, security, warehouse technologies and general guidelines.

Cost estimates are high-level budget figures for rough calculation purposes. Actual costs vary significantly based on specific applications, quantities, and market conditions.

All cost estimates include delivery and installation (where applicable) based on typical transportation and labor rates.

Pricing Guidelines:

• Use high range for: small quantities, heavy-duty applications, complex installations

• Use low range for: large quantities, light-duty applications, simple installations

• Add 10-20% for expedited delivery or custom specifications

• Steel-intensive products may vary ±30% due to material costs

Note: Prices reflect 2024-2025 market conditions. For the most current pricing, obtain vendor quotes.

PICKING TECHNOLOGIES

Pick-To-Light

Base System (includes software) ................ $150,000 - $200,000
Full Function Slot Display (each) .............. $125 - $200

Put-To-Light

Base System (includes software) ................ $185,000 - $250,000
Full Function Slot Display (each) .............. $125 - $200

Voice Directed Software

Small Site (10-20 concurrent users) ............ $60,000 - $100,000
Medium Site (21-50 concurrent users) ........... $100,000 - $180,000
Large Site (51-100 concurrent users) ........... $180,000 - $300,000
Enterprise (100+ users) ......................... $300,000 - $500,000

Multimodal Voice Terminal

With Scanner/Imager ............................. $2,500 - $4,000
Industrial Voice Recognition Headset ............ $300 - $450

RF Picking

Base System ..................................... $150,000 - $200,000
Hand Held RF/Scanning Device .................... $750 - $2,200
Wrist Mounted RF/Scanning Device ................ $1,200 - $2,200
Vehicle Mount Terminal .......................... $2,500 - $4,000

RFID Systems

Basic RFID Reader ............................... $1,500 - $3,000
RFID Tags (per tag) ............................. $0.10 - $2.00
RFID Portal System .............................. $10,000 - $25,000

SECURITY EQUIPMENT

Video System Equipment

Interior Fixed Camera (2MP) ..................... $1,500 - $2,000
Interior Fixed Camera (4K) ...................... $2,000 - $3,000
Exterior Fixed Camera (2MP) ..................... $2,500 - $3,500
Exterior Fixed Camera (4K) ...................... $3,500 - $5,000
Interior PTZ Camera (5MP) ....................... $3,500 - $4,000
Exterior PTZ Camera (5MP) ....................... $4,500 - $6,000
22" LCD Desktop Monitor ......................... $200 - $450
42" LCD Wall Mounted Monitor .................... $2,000 - $3,500
Network Video Recorder w/Software & 2TB ......... $15,000 - $20,000

Access Control Equipment

Small System (1-16 readers) ..................... $8,000 - $12,000
Mid-size System (16-64 readers) ................ $15,000 - $25,000
Large System (64-128 readers) ................... $45,000 - $120,000
Enterprise System ............................... $200,000 - $350,000
Electric Lock ................................... $600 - $1,200
Card Reader ..................................... $450 - $750
Access Control Cards (per card) ................ $3 - $5
Biometric Reader ................................ $1,500 - $3,000

Physical Barriers

Chain Link Fence (per foot) .................... $15 - $22
Decorative Fence (per foot) .................... $45 - $70
High Security Mesh (per foot) .................. $60 - $90
Jersey Barrier (12' x 32") ..................... $900 - $1,200
Fixed Bollard ................................... $300 - $500
Movable Bollard ................................. $1,800 - $2,200
Large Vehicle Barrier ........................... $120,000 - $180,000

Intrusion Detection Systems

Burglar Alarm System ............................ $3,500 - $5,000
Motion Detectors ................................ $150 - $225
Door Position Sensor ............................ $12 - $18
Sounders ........................................ $35 - $60
Duress Buttons .................................. $25 - $40
Glass Breakage Device ........................... $90 - $120

Screening Equipment

Walk Through Magnetometer ....................... $4,500 - $6,000
X-ray Small (personal items) .................... $30,000 - $45,000
X-ray Medium (conveyor belt) .................... $250,000 - $400,000
X-ray Large (cargo containers) .................. $700,000 - $1,200,000

HANDLING EQUIPMENT

Electric Lift Trucks (with battery & charger)

Walkie Pallet Jack - 48" Forks

4,000 lb. ....................................... $5,000 - $8,000
6,000 lb. ....................................... $9,000 - $12,000

Rider Pallet Jacks - 48" Forks

6,000 lb. ....................................... $13,000 - $16,000
8,000 lb. ....................................... $14,000 - $19,000

Rider Pallet Jacks - 96" Forks

6,000 lb. ....................................... $13,000 - $17,000
8,000 lb. ....................................... $14,000 - $19,000

Low Level Order Picker

3,000 lb. ....................................... $17,000 - $28,000

Tugger

Standard ........................................ $12,000 - $18,000

Walkie Straddle Stacker

3,000 lb. ....................................... $17,000 - $23,000

Walkie Reach Truck

3,000 lb. ....................................... $23,000 - $28,000

Counterbalanced Electric Forklift

3,000 lb. ....................................... $25,000 - $35,000
4,000 lb. ....................................... $28,000 - $40,000
5,000 lb. ....................................... $32,000 - $45,000
6,000 lb. ....................................... $38,000 - $50,000
8,000 lb. ....................................... $45,000 - $55,000

Note: Add $2,500-$5,000 for battery and charger
Lithium-ion batteries add $10,000-$20,000

Narrow-Aisle Reach Truck

3,000 lb. ....................................... $35,000 - $45,000
4,000 lb. ....................................... $38,000 - $50,000
4,500 lb. ....................................... $40,000 - $55,000

Narrow-Aisle Deep Reach Truck

2,500 lb. ....................................... $37,000 - $50,000
3,200 lb. ....................................... $38,000 - $52,000

Side Loader Truck

6,000 lb. ....................................... $130,000 - $145,000
10,000 lb. ...................................... $140,000 - $175,000

Four Directional Truck

4,500 lb. ....................................... $65,000 - $85,000

Order Picker Truck

3,000 lb. ....................................... $32,000 - $55,000

Wire Guidance Package

Add-on .......................................... $9,000 - $12,000

Turret Truck - Operator Up

w/Wire Guidance 3,000 lb. ....................... $115,000 - $160,000

Swing Mast Truck

w/Wire Guidance 4,000 lb. ....................... $70,000 - $120,000

Narrow Aisle Articulating Truck

4,000 lb. ....................................... $75,000 - $105,000

Manual Pallet Trucks

Standard Steel (48" L x 27" W) .................. $400 - $1,400
Stainless Steel (FDA/USDA) ...................... $1,400 - $4,200
Heavy-Duty ...................................... $1,800 - $3,000

Truck Guidance Systems

Wire Guidance (per foot installed) .............. $4 - $7
Rail Guidance (per foot installed) .............. $17 - $24
Laser Guidance System ........................... $15,000 - $25,000
Vision Guidance System .......................... $25,000 - $40,000

Battery Changing/Charging Systems

Charging System Base Price ...................... $35,000 - $55,000
Additional Battery Position ..................... $600 - $1,200
Fast Charging Station ........................... $15,000 - $25,000
Battery Management System ....................... $10,000 - $20,000

Propane Counterbalanced Lift Trucks

3,000 lb. ....................................... $20,000 - $28,000
4,000 lb. ....................................... $23,000 - $32,000
5,000 lb. ....................................... $26,000 - $35,000
6,000 lb. ....................................... $30,000 - $40,000
8,000 lb. ....................................... $35,000 - $45,000

Diesel Counterbalanced Lift Trucks

5,000 lb. ....................................... $28,000 - $38,000
8,000 lb. ....................................... $35,000 - $48,000
10,000 lb. ...................................... $45,000 - $60,000
15,000 lb. ...................................... $60,000 - $85,000
20,000 lb.+ ..................................... $85,000 - $150,000

Lift Truck Options & Attachments

Carton Clamp .................................... $11,000 - $18,000
Paper Roll Clamp ................................ $13,000 - $25,000
Layer Picker Clamp .............................. $25,000 - $45,000
Push/Pull Attachment ............................ $10,000 - $17,000
Side-Shifter .................................... $2,100 - $3,500
Fork Positioner ................................. $3,500 - $5,500
Drum Handler (single non-hydraulic) ............. $2,100 - $2,800
Drum Handler (double non-hydraulic) ............. $3,500 - $5,500
Drum Handler (single hydraulic) ................. $8,500 - $12,500
Drum Handler (double hydraulic) ................. $10,000 - $14,000
Lift Height Sensors ............................. $700 - $2,800
Mast Camera Monitors ............................ $4,200 - $5,500
Truck Mounted Scales ............................ $700 - $8,500
Load Backrest Extension ......................... $1,500 - $2,500

Automated Guided Vehicles (AGVs)

AGV Unit-Load Carrier w/Roller Deck ............. $280,000 - $420,000
AGV Tow Vehicle ................................. $210,000 - $280,000
AGV Tow Trailer (no roller) ..................... $4,200 - $7,000
AGV Tow Trailer w/Non-Powered Rollers ........... $17,000 - $22,000
AGV Tow Trailer w/Powered Rollers ............... $28,000 - $35,000
AGV w/Mast and Forks (Outrigger) ................ $350,000 - $490,000
AGV Pick-Up & Delivery Stations ................. $12,500 - $21,000

AGV Pallet Jack Style

First Vehicle ................................... $130,000 - $175,000
Additional Vehicles ............................. $70,000 - $140,000

Autonomous Mobile Robots (AMRs)

Basic AMR Unit .................................. $25,000 - $50,000
AMR with Lifting Capability ..................... $40,000 - $80,000
AMR Fleet Management Software ................... $50,000 - $150,000

Trailer Switching Tractors

Yard Use Only ................................... $95,000 - $115,000
DOT Approved (Road & Yard) ...................... $115,000 - $135,000
Electric Yard Truck ............................. $150,000 - $250,000

Conveyor Systems

Powered Conveyor (per linear foot)

Belt Conveyor ................................... $215 - $390
Powered Roller .................................. $290 - $430
Zero Pressure Accumulation ...................... $350 - $500
Modular Plastic Belt ............................ $400 - $550

Gravity Conveyor (per linear foot)

Gravity Roller .................................. $50 - $140
Skate Wheel ..................................... $45 - $120
Flexible/Expandable ............................. $105 - $245

Specialty Conveyor

Trash Conveyor (per foot) ....................... $175 - $460
Spiral Conveyor (per vertical foot) ............. $2,500 - $4,000
Vertical Reciprocating Conveyor ................. $75,000 - $150,000

Sortation Systems (Cartons)

Pop-Up Wheel Sorter

Base system (per foot) .......................... $580
Per divert ...................................... $2,900 - $7,100

Pusher Sorter

Base system (per foot) .......................... $510
Per divert ...................................... $4,300 - $7,300

Shoe Sorter

Base system (per foot) .......................... $5,000 - $6,500
Per divert ...................................... $3,600 - $7,300

Sortation Systems (Unit)

Cross-Belt Sorter

Base system (per foot) .......................... $5,500 - $8,500
Per divert ...................................... $4,700 - $9,000

Tilt-Tray Sorter

Base system (per foot) .......................... $4,600 - $8,400
Per divert ...................................... $2,800 - $9,000

Bomb-Bay Sorter

Base system (per foot) .......................... $4,000 - $6,000
Per divert ...................................... $3,500 - $6,000

Sortation Support Systems

Induction Systems

Low Speed (40-60 CPM) ........................... $28,000 - $100,000
Medium Speed (70-90 CPM) ........................ $58,000 - $140,000
High Speed (100-150 CPM) ........................ $105,000 - $190,000
Very High Speed (150+ CPM) ...................... $200,000 - $350,000

Sortation Control System & PLCs

Low Complexity .................................. $35,000 - $85,000
Medium Complexity ............................... $50,000 - $90,000
High Complexity ................................. $110,000 - $420,000
Enterprise WCS/WES .............................. $500,000 - $2,000,000

Conveyor Systems Project Cost Breakdown

For complex integration projects:

Controls Engineering ............................ 7%
Mechanical Engineering .......................... 8%
Project Management .............................. 5%
Electrical Installation ......................... 12%
Control Hardware ................................ 15%
Mechanical Systems .............................. 10%
Mechanical Installation ......................... 15%
Mechanical Hardware ............................. 28%
Total ....................................... 100%

Hanging Garment Systems

Storage Rail (per foot) ......................... $22 - $30
Traffic Rail (non-powered, per foot) ............ $33 - $50
Traffic Rail (powered, per foot) ................ $180 - $230
Trolleys (36" long, each) ....................... $45 - $70
Garment Sorter System ........................... $250,000 - $500,000

Miscellaneous Handling Equipment

Hoists & Cranes

Chain Hoist (500-4,000 lbs) .................... $2,000 - $7,000
Electric Hoist .................................. $3,500 - $10,000
Gantry Crane (10-15' span) ...................... $2,100 - $6,300
Jib Crane - Floor Mount (500-2,000 lbs) ......... $2,200 - $5,600
Jib Crane - Floor Mount (2,000-6,000 lbs) ....... $3,500 - $7,500
Bridge Crane (5 ton, 30' span) .................. $35,000 - $60,000

Drum Equipment

Drum Dolly - Plastic ............................ $40 - $280
Drum Dolly - Steel .............................. $85 - $240
Drum Dumper (forklift attachment) ............... $2,100 - $2,800
Drum Dumper (stationary) ........................ $4,200 - $5,600
Drum Hand Truck - Steel ......................... $210 - $980
Drum Hand Truck - Aluminum ...................... $700 - $1,400

Material Transport

Hand Truck - Steel .............................. $140 - $800
Hand Truck - Aluminum ........................... $250 - $900
Platform Truck (24"x36" to 36"x72") ............. $150 - $1,300
Platform Truck - Narrow Aisle ................... $225 - $500
Picking Cart - Two Shelf ........................ $110 - $700
Stock Picking Cart w/Ladder ..................... $850 - $1,250
Utility Cart - Plastic .......................... $200 - $500
Utility Cart - Steel ............................ $300 - $800

Ladders & Platforms

Rolling Ladder (2-4 steps) ...................... $230 - $665
Rolling Ladder (5-10 steps) ..................... $420 - $3,500
Rolling Ladder (11-16 steps) .................... $850 - $3,650
Order Picker Platform ........................... $1,500 - $3,000
Maintenance Platform ............................ $2,500 - $5,000

Lifting & Positioning

Scissor Lift/Pallet Positioner .................. $2,800 - $6,300
Lift Table ...................................... $3,000 - $8,000
Self-Dumping Hopper (1-5 cu yd) ................. $850 - $4,550
Tilt Truck (0.5-2.5 cu yd) ...................... $700 - $4,500
Pallet Inverter ................................. $8,000 - $15,000
Pallet Dispenser ................................ $3,500 - $7,000

STORAGE EQUIPMENT

Pallet Rack Systems

Pricing per pallet position including floor positions
Based on 48"x40" pallets, 2,500# max load, 4-5 levels high

Selective Pallet Rack

Roll-formed ..................................... $50 - $75
Structural steel ................................ $75 - $100

Double Deep Pallet Rack

Standard ........................................ $80 - $120
With specialized reach truck .................... $100 - $200

Drive-In Pallet Rack

2 Deep .......................................... $100 - $150
3 Deep .......................................... $105 - $145
4+ Deep ......................................... $105 - $140

Drive-Through Pallet Rack

2 Deep .......................................... $110 - $165
3 Deep .......................................... $110 - $160
4+ Deep ......................................... $110 - $155

Push Back Pallet Rack

2 Deep .......................................... $110 - $140
3 Deep .......................................... $130 - $170
4 Deep .......................................... $155 - $200
5 Deep .......................................... $175 - $220
6 Deep .......................................... $200 - $250

Gravity Flow Pallet Rack

2 Deep .......................................... $190 - $365
3 Deep .......................................... $250 - $400
4+ Deep ......................................... $300 - $500

Mobile Pallet Rack

Per position (add to selective rack cost) ....... $150 - $250
Mobilization system (per bay) ................... $8,000 - $15,000

Pallet Rack Accessories

Wire Deck (per pallet position) ................. $21 - $63
Pallet Supports (per pair) ...................... $14 - $35
Column Protector (each) ......................... $50 - $300
End-of-Aisle Protector (each) ................... $140 - $420
Row Spacers (per set) ........................... $25 - $45
Safety Netting (per bay) ........................ $150 - $300
Rack Labels (per position) ...................... $2 - $5

Stacking Frames

Frame for Wood Pallet ........................... $120 - $140
With Steel Base ................................. $175 - $225
Portable Rack System ............................ $200 - $350

Plastic Pallets

48" x 40" Standard Size

Nestable/Export

Light duty (2,200 lbs) .......................... $25 - $45

Rackable

Medium duty (2,500 lbs) ......................... $90 - $140
Heavy duty (4,000 lbs) .......................... $125 - $270
FDA/USDA approved ............................... $150 - $350

Fire Retardant

Add to base price ............................... +25-40%

Cantilever Rack

Per 8' wide bay with arms

8' Height

Single-sided (4 arms) ........................... $650 - $1,050
Double-sided (8 arms) ........................... $850 - $1,330

12' Height

Single-sided (6 arms) ........................... $770 - $1,260
Double-sided (12 arms) .......................... $1,330 - $1,960

16' Height

Single-sided (8 arms) ........................... $1,400 - $2,100
Double-sided (16 arms) .......................... $2,240 - $3,100

20' Height

Single-sided (10 arms) .......................... $1,800 - $2,700
Double-sided (20 arms) .......................... $2,900 - $4,000

Drum Storage

2 Drum Stacking Rack ............................ $63 - $140
3 Drum Stacking Rack ............................ $110 - $155
4 Drum Horizontal Rack .......................... $150 - $250
Drum Storage Cabinet (12 drums) ................. $2,500 - $4,000

Wide Span Storage Rack

96"W x 96"H x 24-36"D with 4 shelves, per bay

Particle Board Deck ............................. $420 - $700
Wire Deck ....................................... $700 - $910
Corrugated Steel Deck ........................... $630 - $980

Carton Flow Rack

Full Bay Systems

8'D x 8'W x 8'H (4 shelves, 6 lanes each) ....... $1,470 - $3,500
8'D x 5'W x 8'H (5 shelves, 4 lanes each) ....... $1,260 - $2,100

Flow Track Only

32-54" Track (span one section) ................. $56 - $70
84-120" Track (span back-to-back) ............... $84 - $112

Roller Deck

Select Deck Multiple Rollers (8'x8') ............ $420 - $700

Shelving Systems

Open Steel Shelving

36-48"W x 12-24"D x 72-96"H with 6 shelves

Light/Medium Duty (20-22 ga) .................... $245 - $490
Heavy Duty (18 ga) .............................. $350 - $550
Extra Heavy Duty (16 ga) ........................ $450 - $700
High-Bay (16' high) ............................. $1,015 - $1,225

Closed Steel Shelving

Same dimensions as open shelving

Light/Medium Duty ............................... $250 - $560
Heavy Duty ...................................... $400 - $650

Wire Shelving

60-84"H x 14-24"D x 36-48"W with 4-5 shelves

Chrome Plated ................................... $525 - $910
Epoxy Coated .................................... $500 - $850
Stainless Steel ................................. $1,485 - $2,200

Mobile Shelving

Add to base shelving cost ....................... +40-60%
Mechanical Assist Mobile System ................. $2,000 - $4,000/unit
Powered Mobile System ........................... $5,000 - $10,000/unit

Storage Cabinets

36-48"W x 18-24"D x 72-84"H

Standard Storage

Plastic ......................................... $245 - $560
Light/Medium Steel .............................. $475 - $785
Heavy Duty Steel ................................ $1,120 - $1,820

Flammable Storage Cabinets

Standard Doors (30 gal) ......................... $1,100 - $1,400
Self-Closing Doors (30 gal) .................... $1,300 - $1,700
Standard Doors (60 gal) ......................... $1,400 - $2,100
Self-Closing Doors (60 gal) .................... $1,700 - $2,500
Standard Doors (90 gal) ......................... $1,800 - $2,800
Self-Closing Doors (90 gal) .................... $2,200 - $3,200

High-Density Storage Drawers

30"W x 28"D modular units

Bench Height (33"H, 4-8 drawers) ................ $1,260 - $2,800
Counter Height (45"H, 6-12 drawers) ............. $1,540 - $3,650
Full Height (60"H, 8-16 drawers) ................ $2,240 - $5,600
Extra Height (84"H, 12-20 drawers) .............. $3,500 - $7,500

Drawer Accessories

Divider Kit (4-9 compartments) .................. $28 - $91
Divider Kit (12-48 compartments) ................ $35 - $147
ESD Protection (per drawer) ..................... $50 - $100
Lock Kit (per cabinet) .......................... $150 - $300

Vertical Storage Systems

Vertical Lift Modules (VLM)

Basic Unit (20' high) ........................... $75,000 - $150,000
With Controls & Software ........................ $100,000 - $200,000
Additional Tray ................................. $500 - $1,000

Vertical Carousel

Basic Unit (15' high) ........................... $40,000 - $80,000
With Controls ................................... $50,000 - $100,000
Carrier/Shelf ................................... $200 - $400

Horizontal Carousel

Single Unit (40' long) .......................... $30,000 - $60,000
Pod of 3-4 Units ................................ $100,000 - $200,000
With Pick-to-Light .............................. Add $15,000 - $25,000

Lockers

Personnel Lockers

Single Tier (60-72"H x 12-15"W x 12-18"D) ....... $210 - $420
Double Tier (per opening) ....................... $140 - $250
Six Tier Box Lockers (per opening) .............. $70 - $140

Smart Lockers

Basic Electronic Lock ........................... $500 - $800
With Package Management System .................. $800 - $1,500
Refrigerated Locker ............................. $2,000 - $4,000
Outdoor Package Locker .......................... $1,000 - $2,000

DOCK EQUIPMENT

Dock Levelers

Mechanical

Pit-Style ....................................... $4,900 - $9,800
Edge-of-Dock .................................... $850 - $2,950

Air-Powered

Pit-Style ....................................... $6,300 - $11,200

Hydraulic

Pit-Style ....................................... $8,400 - $28,000
Vertical Storing ................................ $12,000 - $20,000

Surface Mount

Manual .......................................... $6,300 - $7,700
Powered ......................................... $10,000 - $15,000

Dock Boards & Plates

Aluminum

5,000 lbs capacity (with curbs) ................. $560 - $1,680
10,000 lbs capacity (with curbs) ................ $1,120 - $2,100
5,000 lbs capacity (no curbs) ................... $840 - $2,520

Steel

10,000 lbs capacity (with curbs) ................ $980 - $2,800
15,000 lbs capacity (with curbs) ................ $1,400 - $3,500

Dock Seals & Shelters

Dock Seals

Foam Pad ........................................ $980 - $2,100
Inflatable ...................................... $3,500 - $5,500

Dock Shelters

Rigid Frame ..................................... $1,680 - $6,300
Inflatable ...................................... $5,000 - $8,000
Retractable ..................................... $7,000 - $12,000

Vehicle Restraints

Manual Wheel Chock .............................. $280 - $700
Automatic Restraint System ...................... $5,000 - $14,000
Hydraulic Hook System ........................... $8,000 - $12,000

Dock Accessories

Bug Screen Door ................................. $1,680 - $2,800
Dock Bumpers (each) ............................. $70 - $210
Wheel Guides (pair) ............................. $150 - $300
Dock Light (LED arm-mounted) .................... $420 - $630
Dock Fan (24" diameter) ......................... $380 - $980
Light & Fan Combo ............................... $800 - $1,200
Safety Barrier Gate ............................. $1,500 - $3,000
Loading Dock Warning Light System ............... $500 - $1,500

WORKSTATIONS

Work Benches & Tables

30-36"D x 48-72"W

Basic Work Bench ................................ $280 - $1,120
ESD-Safe Work Bench ............................. $700 - $2,950
Height-Adjustable Bench ......................... $1,000 - $2,500

Packing Tables

30-36"D x 48-72"W

Standard ........................................ $1,260 - $2,950
With Scale Integration .......................... $2,500 - $4,500
With Conveyor Feed .............................. $3,000 - $5,000

Production Tables

30-36"D x 72-120"W

Standard ........................................ $420 - $1,120
Mobile .......................................... $600 - $1,500
With Power/Data ................................. $800 - $2,000

Industrial Seating

Bench Chair (adjustable height) ................. $280 - $700
Bench Stool ..................................... $210 - $700
ESD-Safe Seating ................................ $350 - $800
Sit/Stand Support ............................... $400 - $900

Workstation Accessories

Overhead Tool Balancer .......................... $150 - $400
Articulating Arm Mount .......................... $200 - $500
Parts Bins (set of 10) .......................... $50 - $150
Tool Shadow Board ............................... $100 - $300
Anti-Fatigue Mat ................................ $50 - $200

GENERAL FACILITY RELATED

Painting & Sealing

Installation costs vary based on surface condition and access requirements

Walls (per sq ft)

Masonry Block

• Filler: $1.55 - $1.95

• Latex Finish (2 coats): $1.70 - $2.30

• Oil Finish: $1.70 - $2.10

• Epoxy Finish: $1.75 - $2.95

Drywall

• Latex (prime + 2 coats): $0.70 - $1.20

• Oil: $1.55 - $1.95

• Epoxy: $1.55 - $2.10

Ceilings (per sq ft)

Open Joists Sprayed (1 coat) ................... $0.77 - $1.33

Floors (per sq ft)

Shot Blasting Prep .............................. $1.35 - $1.70
Enamel (1 coat) ................................. $1.55 - $2.30
Epoxy (2 coats) ................................. $9.30 - $10.85
Non-Skid Epoxy .................................. $12.20 - $16.65
Polished Concrete ............................... $3.00 - $8.00
Sealer/Dust Control ............................. $0.65 - $1.55
Line Striping (4" wide, per foot) ............... $0.90 - $1.25

Pre-Engineered Structures

Mezzanines

8' clearance, 9' deck height, 125-150 PSF
Includes stairs, handrail, IBC compliant

Plywood over Steel Deck (per sq ft) ............. $24 - $56
Resin Wood Deck ................................. Add $7 - $11
Bar Grating Deck (per sq ft) .................... $25 - $57
Concrete Deck ................................... Add $12 - $18

Add-Ons

Additional Stair & Landing ...................... $4,200 - $7,700
Pivot Gate (single pallet) ...................... $3,500 - $4,500
Pivot Gate (double pallet) ...................... $4,000 - $5,500
Vertical Reciprocating Conveyor ................. $75,000 - $150,000

In-Plant Offices

Per sq ft of floor space

Basic Modular Office ............................ $35 - $50
Class A Office Space ............................ $50 - $75
Clean Room Rated ................................ $75 - $125
Sound Proof ..................................... Add $15 - $25

Components

3" Wall Panel System (per sq ft) ................ $105 - $120
Roof Deck w/Acoustical Ceiling (per sq ft) ...... $10 - $13
Solid Core Door ................................. $665 - $1,120
Window (per sq ft) .............................. $25 - $35
HVAC (per sq ft) ................................ $8 - $15

Wire Security Partitions

Per linear foot, 10 ga wire, without doors

8' High ......................................... $39 - $120
10' High ........................................ $45 - $170
12' High ........................................ $56 - $210
16' High ........................................ $75 - $280
20' High ........................................ $95 - $350

Wire Partition Options

Roof (per sq ft) ................................ $5.50 - $11
Service Window (2'x2') .......................... $200 - $350
Single Swing Door ............................... $420 - $700
Double Swing Door ............................... $700 - $1,400
Sliding Door .................................... $700 - $1,050

Barrier Rail Systems

Per linear foot installed

Standard Guard Rail

Single Rail (42"H) .............................. $50 - $75
Double Rail (42"H) .............................. $75 - $110

Heavy-Duty Barrier

Single Rail w/Kick Plate ........................ $98 - $180
Double Rail w/Kick Plate ........................ $98 - $190
Triple Rail System .............................. $120 - $210

Bollards & Posts

Standard Bollard (4"x42") ....................... $300 - $500
Removable Bollard ............................... $400 - $700
Flexible Bollard ................................ $200 - $350

Construction Costs

Per square foot, excluding site work

Warehouse Buildings

Standard (22-26' clear) ......................... $75 - $95
High-Bay (30-40' clear) ......................... $85 - $110
Extra High-Bay (40-50' clear) ................... $95 - $125
Temperature Controlled ........................... Add $35 - $50
Freezer ......................................... Add $140 - $170
Clean Room ...................................... Add $100 - $200

Office Space

Basic Build-Out ................................. $140 - $180
Class A Finish .................................. $180 - $250

Specialty Equipment

Stretch Wrap Systems

Manual Wrapper .................................. $500 - $1,000
Semi-Auto Turntable ............................. $8,400 - $18,200
Fully Automatic ................................. $25,000 - $45,000
Robotic Mobile Wrapper .......................... $16,800 - $19,600
Orbital Wrapper ................................. $15,000 - $30,000

Strapping Machines

Manual Tool ..................................... $300 - $800
Semi-Auto Table ................................. $3,000 - $8,000
Fully Automatic ................................. $15,000 - $35,000
Pallet Strapper ................................. $8,000 - $20,000

Packaging Equipment

Case Sealer ..................................... $3,000 - $15,000
Case Erector .................................... $15,000 - $40,000
Void Fill System ................................ $2,000 - $8,000
Shrink Wrapper .................................. $5,000 - $25,000

Scales

Floor Scale (5,000 lbs) ......................... $2,500 - $4,500
Pallet Scale (10,000 lbs) ....................... $3,500 - $6,000
Counting Scale .................................. $500 - $2,000
Bench Scale ..................................... $300 - $1,500
Truck Scale (70,000 lbs) ........................ $35,000 - $65,000

Air Systems

Ceiling Fan (24' diameter, HVLS) ................ $6,300 - $7,150
Dock Door Fan ................................... $500 - $1,200
Portable Blower ................................. $200 - $800
Air Curtain (per foot) .......................... $150 - $300

Maintenance Platforms

Portable Work Platform .......................... $700 - $1,540
Fixed Access Platform (custom) .................. $100 - $200/sq ft

Automated Storage & Retrieval

Mini-Load AS/RS

Per Storage Location ............................ $150 - $300
Complete System (1,000 locations) ............... $500,000 - $1,500,000

Unit-Load AS/RS

Per Pallet Location ............................. $500 - $1,000
Complete System (1,000 pallets) ................. $2,000,000 - $5,000,000

Shuttle Systems

Shuttle Vehicle ................................. $25,000 - $50,000
Rack System (per location) ...................... $75 - $150
Mother-Daughter System .......................... $75,000 - $150,000

DECIBEL SOUND LEVELS

OSHA requires hearing protection at 90 dB for 8-hour exposure. Action level begins at 85 dB TWA.

Sound Level Examples:

50 dB - Light traffic, normal conversation, quiet office
60 dB - Air conditioner at 20 feet, normal speech
70 dB - Vacuum cleaner, busy restaurant
80 dB - City traffic, garbage disposal, alarm clock

Potentially Hazardous (Requiring Protection):

90 dB - Forklift, conveyor system, power tools
100 dB - Pneumatic equipment, chain saw
110 dB - Rock concert, car horn
120 dB - Ambulance siren, thunderclap
130 dB - Jackhammer, jet takeoff (100m)
140 dB - Gunshot, jet engine

Warehouse Equipment Typical Levels:

• Electric forklift: 75-85 dB

• Propane forklift: 85-95 dB

• Conveyor system: 80-90 dB

• Packaging equipment: 75-85 dB

• Stretch wrapper: 70-80 dB

• Air compressor: 85-95 dB

TYPICAL OFFICE SPACE REQUIREMENTS

Square Feet Per Person

Executive Offices

• President/CEO: 300-500

• Vice President: 200-300

• Director: 150-200

• Manager: 120-150

Administrative

• Supervisor: 80-120

• Analyst/Specialist: 80-100

• Administrative Assistant: 60-80

• Clerk: 50-70

Common Areas

 (per person using)

• Conference Room: 25-35

• Break Room: 15-25

• Reception: 150-300 total

• Training Room: 20-30

Support Spaces

• File Room: 50-150 per 10 people

• Copy/Print Center: 100-200

• IT Server Room: 150-400

• Storage: 10-20 per person

PALLET STORAGE SPACE ESTIMATES

Square feet per pallet position including aisles

LIGHTING LEVEL RECOMMENDATIONS

Foot-candles at task height

Warehousing

• Inactive Storage: 5-10 fc

• Active Storage: 10-20 fc

• Loading Docks: 20-30 fc

• Packing/Shipping: 30-50 fc

• Inspection Areas: 50-100 fc

Manufacturing

• Rough Assembly: 30-50 fc

• Medium Assembly: 50-100 fc

• Fine Assembly: 100-200 fc

• Quality Control: 100-300 fc

Office Areas

• Corridors: 10-20 fc

• General Office: 30-50 fc

• Computer Work: 30-50 fc

• Detailed Work: 50-100 fc

LED Conversion Factors

• LED typically provides 30-50% energy savings

• Higher CRI (85+) recommended for inspection

• 5000K color temperature for warehouses

• 4000K for offices

OPERATING RATES

These are general guidelines - actual rates vary significantly

Forklift Operations

Pallet Movements per Hour:

• Counterbalance: 12-18

• Reach Truck: 10-22

• Order Picker: 8-15

• VNA Turret: 15-25

• AGV/AMR: 20-30

Order Picking

Cases per Hour:

• Floor Pick to Pallet: 60-120

• Pick to Cart: 30-80

• Conveyor Pick: 100-250

• Pick Module: 150-350

• Voice-Directed: 120-200

• Pick-to-Light: 200-400

• Robotic Picking: 300-600

Each/Piece Picking per Hour:

• Static Shelving: 60-150

• Flow Rack: 100-200

• Carousel: 200-400

• VLM/Shuttle: 250-500

• A-Frame: 1,500-2,500

Loading/Unloading

Cases per Hour:

• Floor Load Trailer: 200-350

• Palletized (per pallet): 15-25

• Conveyor Unload: 400-600

• Robotic Unload: 500-800

Receiving/Shipping

Transactions per Hour:

• Manual Check-In: 5-10

• RF Check-In: 15-25

• ASN Receiving: 25-40

• Cross-Dock: 30-50

PROJECT ELAPSED TIME ESTIMATES

Weeks from order to operational

Racking Systems

• Design & Permits: 3-5

• Manufacturing: 4-8

• Delivery: 1-2

• Installation: 2-4

• Total: 10-19 weeks

Conveyor Systems

• Design & Engineering: 4-6

• Manufacturing: 8-12

• Delivery: 1-2

• Installation: 4-8

• Testing & Commissioning: 2-4

• Total: 19-32 weeks

AS/RS Systems

• Design & Engineering: 8-12

• Manufacturing: 16-24

• Site Preparation: 4-8

• Installation: 12-20

• Commissioning: 4-8

• Total: 44-72 weeks

Material Handling Equipment

• Standard Forklift: 8-16

• Custom Forklift: 16-24

• AGV System: 20-32

• Packaging Equipment: 12-20

Building Construction

• Design & Permits: 8-16

• Site Work: 4-8

• Foundation: 4-6

• Structure: 12-20

• MEP & Finishes: 8-12

• Total: 36-62 weeks

Software Implementation

• WMS Basic: 12-20

• WMS Enterprise: 26-52

• WCS/WES: 16-26

• Integration: 8-16

Notes

This guide represents typical 2024-2025 market pricing based on available data. Actual costs vary based on:

• Geographic location (±20-30%)

• Order quantity and negotiation

• Customization requirements

• Installation complexity

• Current material costs

• Vendor relationships

• Project timeline

For accurate budgeting, always obtain multiple current quotes from qualified vendors.

2025 Edition compiled from market research, vendor data, and industry reports. While every effort has been made to ensure accuracy, prices are estimates only and subject to change.