Core Tray Racking Solution for a Major Toowoomba Geotechnical Investigation
A large-scale geotechnical investigation in the Toowoomba region required a core tray racking solution that could handle a high volume of drill core for over 25 years of permanent storage, while keeping day-to-day handling safe, efficient, and organised. The project team chose CoreTech recycled plastic core trays paired with a custom racking system from Dynamics GTS.
The Requirement
The investigation generated a significant volume of core that needed to be permanently stored on site in a way that was safe to load and unload, space-efficient within the available footprint, organised for easy retrieval during logging and review, and able to grow if the program expanded.
Standard off-the-shelf shelving doesn’t address these requirements well. Shelf heights and aisle widths are designed for general warehouse storage, not for the specific demands of repeatedly loading and unloading core trays weighing up to 30 kg.
The Solution
Dynamics GTS designed and installed an RPEQ-certified, purpose-built core tray racking solution around the CoreTech core tray, with every dimension driven by safe handling and storage efficiency.
1.5m minimum loading aisle width. Each aisle between racking runs was set at a minimum of 1.5 metres – wide enough for a worker to stand with a pallet to load/unload, lift a loaded tray with balanced posture, and move freely without twisting or side-stepping. Narrower aisles force awkward body positions during loading, which is exactly the kind of manual handling risk the WHS Code of Practice flags.
1.6m maximum rack height – 16 trays per stack. The maximum loading height was capped at 1.6 metres, accommodating 16 core trays per vertical stack. This keeps the top tray within comfortable overhead reach for most workers, avoiding the need to lift heavy trays above shoulder height. Loading and unloading remain safe and convenient throughout the full shift, not just for the first few trays of the day.
Back-to-back rack configuration. Racks were connected back-to-back to maximise the storage footprint. This doubles the storage density per floor area compared to single-sided racking, while keeping every tray accessible from a loading aisle. The configuration makes efficient use of the available space without compromising access.
Expansion space at each run. Open space was left at the end of each racking run to allow for extensions if the drilling program expanded and additional storage was needed. This avoids the common problem of a racking system that’s full before the project is finished – and the cost and disruption of retrofitting additional capacity into a space that wasn’t designed for future expansion.
The Trays
The project utilised CoreTech recycled plastic core trays – manufactured in Australia from 100% recycled polypropylene. CoreTech trays were selected for this project for several reasons: the 1050mm internal length suits standard geotechnical core runs, the integrated end handles and finger grooves support safe manual handling when loading into racking, the flat-bottomed base sits stable on the racking without shifting or rocking, and the 25+ year UV resistance (certified by ExcelPlas) means the trays will outlast the storage obligation for the core.
The recycled Australian polypropylene construction also aligned with the project’s sustainability requirements.
Learn more about how CoreTech core trays are designed for WHS-compliant manual handling → WHS Compliant Core Trays
The Result
The racking system was designed, manufactured, and installed by Dynamics GTS. The project team received a core storage facility that handles the current program volume with room to extend, keeps every tray accessible without unstacking, and supports safe, efficient loading and unloading through considered aisle widths and rack heights.
Planning a core storage solution for your project? Request a quote for CoreTech core trays and custom racking → Core Tray Racking or call 1800 518 051.