Hybrid Rack System Installation

Location: Nashville, TN
Date: April 17, 2024
Project Type: Cost‑Optimized Storage System Using New and Used Components

Client Background

A warehouse facility in Nashville, TN required new pallet storage capacity while operating under budget constraints. The customer needed a durable and reliable racking solution capable of supporting daily pallet handling and long‑term load stability, without the expense of a fully new system. The project emphasized performance-to-cost efficiency and quick installation.

Project Overview

The objective was to design and install a hybrid racking solution that combined used uprights with new beams and decking while maintaining structural integrity and load performance. The customer required rapid deployment to ensure operational continuity, and the system needed to support consistent forklift handling and pallet turnover.

Project Challenges

1. Material selection had to balance cost efficiency with performance and safety requirements.

2. Used uprights needed to integrate structurally with new beam materials.

3. Installation had to occur with minimal disruption to ongoing warehouse activity.

4. Decking alignment and anchoring precision were required to preserve long‑term structural reliability.

Solution and System Implementation

Bogardus installed a hybrid rack system using the following components:

• Fifteen‑foot used uprights

• Eight‑foot by four‑and‑a‑half inch new beams

• Forty‑two by forty‑six inch new wire decks

Installation procedures included upright positioning, beam elevation alignment, anchoring to floor specifications, and deck placement to meet required safety standards. The combination of used and new materials delivered structural stability and cost savings without compromising reliability.

Results and Outcomes

• The customer received a fully installed pallet rack system that delivered dependable performance at a lower total cost.

• The integration of new beams and decks with used uprights provided strength and consistency while minimizing material expense.

• Installation was executed efficiently, allowing immediate onboarding of palletized inventory.

• The system created reliable vertical storage capacity with proper forklift access and pallet handling clearance.

Long‑Term Impact

The hybrid system provided a durable and scalable storage solution that aligned with both operational goals and budget requirements. By combining used structural elements with new performance components, the solution delivered cost efficiency without sacrificing safety or load reliability. The installation positioned the warehouse for long‑term operational growth and efficient material handling.

Rapid Rack Deployment with Same‑Week Delivery

Location: Pennsylvania
Date: April 15, 2024
Project Type: Accelerated Rack Material Delivery to Maintain Operational Continuity

Client Background

A warehouse in Pennsylvania required pallet rack components to be delivered on an accelerated timeline to prevent disruption to inventory planning. With inbound product scheduled and staging activity already underway, the customer needed a rapid fulfillment solution that allowed warehouse operations to proceed without delay or rescheduling.

Project Overview

The objective of this engagement was to provide high‑capacity pallet racking materials with same‑week delivery, enabling the facility to continue scheduling and receiving shipments without operational downtime. Material specifications had to match existing system requirements while maintaining structural reliability and safety standards.

Project Challenges

1. The delivery timeline was critical, with minimal flexibility due to scheduled incoming product flow.

2. Material specifications needed to align with the warehouse’s existing racking configuration to avoid staging or installation delays.

3. Rapid sourcing, staging, and transport coordination were necessary to meet the deadline.

4. Delivery had to occur with full protection to prevent material damage and maintain immediate usability upon arrival.

Solution and System Implementation

Bogardus delivered the required racking components with same‑week turnaround, including:

• Twenty‑four‑foot uprights

• Ninety‑eight by three‑point‑sixty‑five inch beams

• Waterfall wire decks

Materials were prepared, staged, secured, and transported with protective wrapping and pallet stabilization to ensure damage‑free arrival. Delivery coordination was executed to align with ongoing warehouse scheduling and inbound inventory timing.

Results and Outcomes

• The customer received the racking materials within the same week of ordering, eliminating delays in warehouse operations.

• Inventory flow remained uninterrupted, preventing rescheduling and associated labor or handling inefficiencies.

• Materials were ready for immediate deployment, supporting seamless staging and installation planning.

• The rapid response demonstrated the capability to provide urgent fulfillment without compromising quality or reliability.

Long‑Term Impact

The expedited delivery allowed the warehouse to maintain operational timelines while preparing for ongoing throughput demands. By ensuring rapid access to compatible system components, Bogardus supported efficient capacity expansion and safeguarded scheduling commitments. This project illustrated scalable supply capabilities under time‑sensitive conditions, reinforcing reliability for future accelerated requests.

Optimized Rack Expansion Integration

Location: Sanford, FL
Date: April 5, 2024
Project Type: Integrated Rack Expansion within Existing Warehouse Layout

Client Background

A long‑term customer located in Sanford, FL required additional pallet rack capacity to support increasing product volume and warehouse growth. The system had to align seamlessly with their existing layout, maintaining uniform elevations, aisle spacing, and handling clearances to protect operational flow and minimize disruption.

Project Overview

The objective of this project was to supply and install additional pallet racking that expanded vertical storage while matching the structural characteristics of the customer’s existing system. The expansion was required to be scalable, reliable, and configured for long‑term use without requiring layout rework or future reconfiguration.

Project Challenges

1. The expansion needed to integrate precisely with the existing warehouse system to ensure continuity in storage elevations and travel lanes.

2. The customer required reliable load capacity that matched established pallet weight, rotation frequency, and handling intensity.

3. Material compatibility and anchoring alignment were essential to maintain structural uniformity and long‑term safety.

4. The system needed to be installed with minimal disruption to ongoing warehouse activity.

Solution and System Implementation

Bogardus provided all necessary materials and completed installation using the following components:

• Sixteen‑foot uprights

• Ninety‑six by four‑and‑a‑half inch beams

• Forty‑two by forty‑six inch wire decks

• Mixed uprights selected to ensure compatibility with the existing system

Installation work included precise layout alignment, anchoring operations, deck placement, and elevation matching to preserve continuity with the original system. All components were staged for efficient installation to minimize warehouse workflow impact.

Results and Outcomes

• The integrated rack expansion provided the customer with increased vertical storage capacity while maintaining functional alignment with existing infrastructure.

• System compatibility ensured long‑term performance without requiring changes to the warehouse floor layout.

• The installation supported higher inventory throughput and reduced congestion in staging areas.

• The expanded system created a scalable foundation for ongoing capacity growth.

Long‑Term Impact

The customer gained an optimized, structurally continuous rack expansion that strengthened long‑term storage capability and operational flexibility. By integrating new components that matched the original system, the expansion preserved workflow consistency, increased pallet density, and provided reliable service life for future growth requirements. The warehouse is now positioned to scale inventory volume efficiently without modifying layout or equipment strategy.