In logistics warehouses and industrial storage facilities, forklift truck traffic places a continuous mechanical strain on load-bearing structures. Floor capacity—expressed as maximum allowable axle load—represents a critical technical threshold that every facility operator must strictly adhere to.
One of our clients in the Transport & Logistics sector operated a warehouse with limited floor load capacity. The various types and capacities of forklift trucks in operation were generating uncontrolled peak overloads that exceeded the building’s structural resistance limits.
Transport and logistics – industrial warehousing
Forklift truck overloads exceeding the storage facility floor capacity
Structural degradation of the floor, risk of localized collapse, endangerment of personnel
Standard BS EN 1991-1-1 / NF EN 1991-1-1 (Eurocode 1) regarding actions on structures, specifically for storage and industrial areas (Category E2)
Fleet of 12 forklift trucks (electric and IC engine counterbalanced forklifts)
5,500 kg on the front axle (when laden)
Permissible point load limited to 4,500 kg per axle on certain older slab areas
The vast majority of axle weigher use cases documented online focus on heavy goods vehicle (HGV) load control on public roads (road regulatory compliance). Load monitoring for structural building protection is a far less documented application. Yet, it addresses a very real and frequent challenge faced by modern logistics warehouses.
To address this challenge, Captels designed and installed two automatic weighing systems comprising fixed dynamic axle weighers. They enable real-time monitoring of the load exerted by each axle of the forklift trucks in operation.
| Specifications | Values |
|---|---|
| System type | R300 fixed axle weigher |
| Number of weighing units | 2 installed axle weighers |
| Weighing capacity per axle | 7,500 kg |
| Achieved measurement accuracy | ± 1% of laden weight |
| Metrological class | Class IV industrial metrology |
| Operating mode | Dynamic weighing |
| Display / Indicator | UCC 2 acquisition unit |
| Connectivity | Overload alert / prevents gate opening |
| Commissioning timescale | 1 week |
The solution was tailored to the specific conditions of the client site:
Ground constraint : Installation of pit frames flush with the concrete slab, with perfect levelling and integration of the axle weighers to avoid disrupting forklift traffic.
Traffic constraint : Strategic positioning at both entrances to the high-density storage area (narrow aisles) to filter access.
System integration : Automatic gate lock-out whenever an overload is detected—requiring no human intervention to stop the forklift.
Seamless operation for users : Weighing is automatic and silent when compliant; alerts trigger only in the event of an overload.
Following the installation and commissioning of the Captels system, the following results were measured and documented:
Achieved on-site measurement accuracy, exceeding nominal tolerance
Fault-free operation: 24 consecutive months of continuous operation in a dusty industrial environment without failure.
Prevented overloads: 14 critical overload events detected and blocked during the very first week alone.
| Indicator | Measured result |
|---|---|
| Structural compliance | 100% compliance achieved; no instances of exceeding the allowable floor load recorded since commissioning. |
| Incident reduction | Total elimination of slab cracking risks linked to forklift overloads. |
| Return on investment | Estimated at 18 months, calculated based on slab repair cost savings and extended forklift lifespan. |
| System durability | Zero major after-sales interventions; annual calibration check performed by Captels. |
| Operational satisfaction | Smooth inspection process with no noticeable slowdown in logistics throughput. |
This project demonstrates Captels' ability to resolve industrial weighing challenges that go beyond traditional regulatory frameworks. Here, load measurement is not used to comply with transport regulations, but rather to protect building infrastructure and ensure personnel safety.
Complete control over the entire value chain—from sensor to indicator, including the mechanical mounting system—allowed us to tailor the solution to the site's exact constraints, without compromising on measurement accuracy.
Citation client :
The Captels axle weighing solution enabled us to secure operations in a building where the floor had become a critical point of concern. Today, we have total confidence that no forklift truck is compromising our infrastructure. The interface with our automated gate makes the control process completely seamless for our drivers.
Logistics Manager, multi-site warehousing
Captels client since 2022
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