AGV Aisle Sizing and Layout

Aisle Width by Vehicle Class

Vehicle Class	Manned Aisle Width	AGV Aisle Width
Counterbalanced forklift	12-14 ft (3.7-4.3m)	12-13 ft (3.7-4.0m)
Reach truck	8.5-10 ft (2.6-3.0m)	~8-9 ft (2.4-2.7m) single-direction
Pallet jack AGV	N/A	1.8-2.5m single; 2.5-3.0m bi-directional
VNA / Turret	5-7 ft (1.5-2.1m)	<6.5 ft (<2.0m)
High-density narrow AGV	N/A	1.2m minimum with specialized nav

Note: AGV aisle widths must account for sensor field clearance, not just vehicle body width. An aisle that is “just wide enough” for a manual forklift is often too tight for an AGV’s obstacle detection zones.

Turning Radius by AGV Type

AGV Type	Turning Radius
Automated pallet truck (light)	1.5-2.5m
AGV pallet truck (standard)	2.0-3.0m
Heavy-duty AGV forklift	3.0-5.0m+

Outer turning radius = distance from center of turning circle to outermost point of the AGV during a turn. Manufacturers publish inner and outer radii in product specs. Use outer radius for aisle calculation.

RASA Formula (Right Angle Stacking Aisle)

The RASA calculation determines minimum aisle width for a 90-degree turn into a rack face:

RASA = r + max(R, R₁) + 2 × safety clearance

Variable	Definition
r	Minimum turning radius of the vehicle body
R	Cargo rotation radius: outermost corner of load during 90-degree turn
R₁	Fork tine rotation radius: distance from turning center to fork tip
Safety	100mm per side minimum (200mm total)

Use max(R, R₁) — whichever is larger governs. On heavy-duty or long-fork AGVs, R₁ often exceeds R.

Cargo rotation radius derivation:

R = √((load_width/2)² + load_depth²) + front_overhang (L2)

For a standard 48”×40” pallet: inner diagonal ≈ 1,195mm; add L2 (~400mm) → R ≈ 1,595mm.

Examples:

Config	r (mm)	max(R, R₁) (mm)	Safety (mm)	RASA	Approx
Light CB AGV	2,192	1,597	200	3,989mm	~13 ft
Heavy CB AGV	3,560	3,010	200	6,770mm	~22 ft

Source: agvmotor-aisle-width-calculation

Cross-Aisle and Transfer Aisle Widths

• Cross aisles connecting rack aisles: minimum 11-12 ft for counterbalanced AGV, wider for head-on passing
• Transfer aisles for bi-directional AGV traffic: add 50% to single-direction aisle width minimum
• End-of-aisle staging areas: size to accommodate full vehicle + load turn without encroaching on adjacent aisles

Guidepath Clearance (Safety Requirement)

ANSI/ITSDF B56.5 requires:

• Minimum 0.5m (19.7 inches) clearance on both sides of the AGV guidepath
• Exception: VNA restricted areas where clearance on both sides is <0.5m — these require additional safety measures (barriers, light curtains, restricted access)

VNA Transfer Corridor

VNA rack aisles require a dedicated transfer corridor perpendicular to the rack aisles for transit between aisles:

• Working aisle (between rack faces): 1,600mm minimum
• Transfer corridor (connecting aisle ends): 7,000mm minimum

The 7m transfer corridor accommodates the VNA AGV making a full turn from the rack aisle into the corridor. Under-sizing the transfer corridor is a common layout error that forces single-direction flow or restricts fleet throughput. Source: agvnetwork-agv-specifications

Layout Design Rules for AGV

1. Sensor field first: Size aisles to the vehicle’s obstacle detection field, not just the vehicle body. A safety scanner warning field at 2 m/s may extend 1.5-2m ahead.
2. No mixed traffic in rack aisles: AGV and manned forklift cannot share a rack aisle without traffic control interlocks.
3. Straight-in aisle entry: AGVs cannot correct approach angle in tight aisles. Entry geometry must allow straight alignment before aisle entry.
4. Charging and staging zones: Outside of rack aisles; size for full vehicle + load with clearance on all sides.
5. End-of-aisle detection: Install sensors or stops at aisle ends; do not rely solely on software.
6. Design for growth: Size aisles to the current AGV class plus one size class up. Widening aisles after racking is installed requires re-slotting; the retrofit cost far exceeds the design-time increment.