Planning a barrel room starts with density: how much floor each barrel needs once you account for aisles, and how high you can safely stack.
Barrel Density
Square feet per barrel includes the barrels and any aisles between them, but not forklift avenues (the space where the forklift turns 90°). Forklift avenues should be at least 13 feet wide for two-barrel racks and 17 feet wide for four-barrel racks. Add that area when working out the total space you need, or subtract it from the room before calculating gallons per square foot.
| Square feet per barrel | 3 high | 4 high | 5 high | 6 high |
|---|---|---|---|---|
| Close pack (racks on 5' centers) | 2.92 | 2.19 | 1.75 | 1.46 |
| 12"+ aisles along bilges (6' centers) | 3.50 | 2.63 | 2.10 | 1.75 |
| 12"+ aisles along heads | 3.33 | 2.50 | 2.00 | 1.67 |
| 18"+ aisles along bilges (6.5' centers) | 3.79 | 2.84 | 2.28 | 1.90 |
| 18"+ aisles along heads | 3.54 | 2.66 | 2.13 | 1.77 |
| Gallons per square foot (60-gal barrels) | 3 high | 4 high | 5 high | 6 high |
|---|---|---|---|---|
| Close pack (racks on 5' centers) | 20.57 | 27.43 | 34.29 | 41.14 |
| 12"+ aisles along bilges (6' centers) | 17.14 | 22.86 | 28.57 | 34.29 |
| 12"+ aisles along heads | 18.00 | 24.00 | 30.00 | 36.00 |
| 18"+ aisles along bilges (6.5' centers) | 15.82 | 21.10 | 26.37 | 31.65 |
| 18"+ aisles along heads | 16.94 | 22.59 | 28.24 | 33.88 |
Density is slightly better with aisles along the heads, but if you have the space, aisles along the bilges are recommended because bung access is so much better.
Choosing Aisle Widths
- Close pack (5' centers): some space between barrels is allowed for, so these figures are conservative.
- 12" aisles (6' centers): if you'll work the wine in place, aisles should ideally fit a ladder. Climbing between stacks isn't recommended, but it's done, especially with stacks only 3 or 4 high.
- 18" aisles (6.5' centers): room for a narrow ladder (18" wide with a 28" base whose wheels roll under the barrels). The ladder clears even 70-gallon barrels by at least 2" on each side.
Stack Heights
Overall height by the number of barrels high and the size of the rack's forklift opening. * = using a half rack at the bottom.
| Bordeaux barrels high | 7" | 7"* | 4" | 4"* |
|---|---|---|---|---|
| 1 | 3'2" | 2'7" | 2'11" | 2'7" |
| 2 | 6'1" | 5'6" | 5'7" | 5'3" |
| 3 | 9'0" | 8'5" | 8'3" | 7'11" |
| 4 | 11'11" | 11'4" | 10'11" | 10'7" |
| 5 | 14'10" | 14'3" | 13'7" | 13'3" |
| 6 | 17'9" | 17'2" | 16'3" | 15'11" |
| Burgundy barrels high | 7" | 7"* | 4" | 4"* |
|---|---|---|---|---|
| 1 | 3'3" | 2'8" | 3'0" | 2'8" |
| 2 | 6'3" | 5'8" | 5'9" | 5'5" |
| 3 | 9'3" | 8'8" | 8'6" | 8'2" |
| 4 | 12'3" | 11'8" | 11'3" | 10'11" |
| 5 | 15'3" | 14'8" | 14'0" | 13'8" |
| 6 | 18'3" | 17'8" | 16'9" | 16'5" |
Stacking an Odd Number of Barrels
Two handy devices stack a single barrel above tiers of two. The pyramid stacking cradle keeps overall stack height lower and doesn't tie up an extra rack. The center (removable) cradle lets the single barrel be moved without disturbing the two barrels beneath it.
Rack Specifications
| Rack | Length | Width | Cradle center to center | End forklift opening | Side forklift opening |
|---|---|---|---|---|---|
| 52–70 gal, double bar | 30.5" | 44.5" | 29.5" | 7" | 3" |
| 52–70 gal, low profile | 30.5" | 44.5" | 29.5" | 4" | – |
| 52–70 gal, half rack | 30.5" | 44.5" | 29.5" | 4" | 4" |
| 52–70 gal, four-barrel | 70.0" | 44.5" | 29.5" | 7" | 3" |
| 30 gal | 24.0" | 44.5" | 29.5" | 7" | 3" |
| 15 gal | 20.0" | 44.5" | 29.5" | 7" | 3" |
| 300 L hogsheads & 350 L cognac | 33.5" | 50.0" | 29.5" | 7" | 3" |
| 500 L puncheons | 37.0" | 57.0" | 39.0" | 9" | 3" |
Puncheon racks are made with 2" square tubing; all others with 1.5" square tubing. Racks are powder coated (beige standard; gray, green and bronze at no extra charge), with the 7" double bar two-barrel and 7" four-barrel racks also offered in stainless steel.
The Original Sheets, Courtesy of Western Square Industries
For current rack models, options and ordering, visit Western Square Industries.
Thinking about used racks? Read our blog post A technical reason to avoid used barrel racks.