Installation – Boltless Rivet Shelving System | Small-Parts Storage Optimization

Date: December 5, 2025

Project Overview

The client required a structured storage solution for small parts, consumables, and hand-pick SKUs that could not be efficiently staged on pallet racking. Their existing system relied heavily on floor-level sorting, limiting visibility and increasing time spent locating materials. Bogardus provided a boltless rivet shelving configuration specifically designed for fast, efficient, ergonomic access, while freeing pallet rack space for larger, palletized inventory.

This strategic deployment helped the customer not only solve an immediate organization problem but restructure workflows for long-term efficiency.

Operational Challenges

During pre-installation planning, several constraints and needs were identified:

• Limited Picking Efficiency: Existing storage methods forced employees to search through bins and floor staging.

• SKU Overlap: Small parts mixed with low-volume items created labeling and accessibility issues.

• Aisle Navigation: Material overflow was beginning to restrict walk-path access and slow picking operations.

• Space Utilization: Large pallet rack bays held small parts, wasting premium vertical storage capacity.

Bogardus ensured these challenges were addressed directly through equipment selection, layout optimization, and shelf configuration.

Solution Deployment

Bogardus delivered and installed:

• 18" x 36" Boltless Rivet Shelving

• Configured at 6 feet tall

• Light-duty grade for rapid hand-pick access

Key implementation components included:

• Strategic spacing between shelf levels for maximum SKU separation

• Horizontal sequencing for visual grouping and labeling efficiency

• Placement away from forklift lanes to ensure employee picking safety

• Layout design that promoted a fast, intuitive picking order

The shelving was installed in a clean, organized footprint that allowed immediate stocking without workflow interruption.

Results

Following the installation, the customer experienced multiple measurable improvements:

• Enhanced SKU visibility dramatically reducing pick times

• Significantly improved workstation flow and hand-pick staging

• Floor-space recovery eliminating clutter and improving safety pathways

• Freeing pallet rack positions for higher-value palletized storage

• Cleaner organization supporting better labeling, accuracy, and replenishment

This optimization directly improved fulfillment speed, employee efficiency, and operational clarity.

Long-Term Impact

This shelving system generated benefits beyond immediate organization:

• Expandable layout allows additional shelves to be added as SKU counts grow

• Improved inventory tracking with easy barcode scanning and shelf labeling

• Better ergonomic working conditions reducing strain during repeated picking

• Improved warehouse zoning supporting clearer workflow separation

• Long-term maintenance savings due to durable rivet steel design

The storage approach positions the customer for efficient scaling without requiring additional floor space.

Project Insights & Lessons Learned

• Small-parts storage should never occupy pallet rack space intended for palletized goods.

• Boltless rivet shelving provides a highly economical foundation for organized inventory management.

• Workflow zoning is critical; small-parts picking areas require different priorities than palletized lanes.

• Even minimal layout adjustments can produce major efficiency gains when applied to the correct storage challenge.

Bogardus continues to provide cost-effective, scalable storage solutions tailored to customer workflow requirements, ensuring both immediate and future operational value.

Delivery & Installation – Complete Racking Setup | Medium-Scale Warehouse

Date: December 1, 2025

Project Overview

As the customer prepared for a significant inbound inventory wave, they required a rapid deployment of a medium-scale pallet rack system. Speed was essential, as the warehouse was transitioning from staging conditions into core fulfillment operations. The system needed to provide immediate pallet positions, safe forklift navigation, and optimized vertical clearance to ensure efficient operational flow.

This installation marked a pivot point in the customer's expansion, enabling them to transition from manual floor stacking to structured, barcode-ready inventory storage.

Operational Challenges

Several project challenges were identified during initial planning:

• Time Sensitivity: Inbound freight was scheduled, necessitating installation completion prior to arrival.

• Space Constraints: The facility operated with pre-defined forklift lanes that needed to remain unobstructed during installation.

• Anchoring Control: The customer’s concrete slab thickness varied by section, requiring precision anchoring setup.

• Rack Layout Planning: Final beam elevations needed careful planning to avoid creating unsafe forklift lift angles.

Bogardus addressed all challenges through staged layout planning, material sequencing, and coordinated communication with warehouse personnel.

Solution Deployment

Bogardus delivered and installed the entire pallet rack system using:

• 12-foot uprights

• 12-foot x 6.25-inch beams

• 42" x 46" wire decks

Key installation elements included:

• Optimized aisle spacing to support efficient forklift maneuvering and high pallet turnover

• Anchoring placement based on slab examination to ensure structural integrity

• Customized beam elevation spacing to maximize vertical cube while preserving ergonomic picking height

• Staged assembly allowing active forklift routes to remain open throughout the installation

The system was installed cleanly and efficiently, with all rows aligned for straight-flow pick paths and structured storage zoning.

Project Results

The installation delivered measurable improvements including:

• Immediate stocking readiness enabling incoming pallets to be stored with zero delays

• Improved vertical utilization increasing pallet positions beyond ground-level staging

• Enhanced safety through secure anchoring, spacing compliance, and full wire decking coverage

• Reduced congestion by establishing predictable, one-way forklift lanes

The warehouse transitioned seamlessly into organized racked storage, eliminating prior workflow bottlenecks.

Long-Term Impact

This installation created several lasting operational benefits:

• Scalability: The system design allows for future vertical beam adjustments as SKU volume increases.

• Inventory Traceability: Structured racking improves barcode scanning, cycle counting, and replenishment accuracy.

• Forklift Efficiency: Optimized aisle alignment lowers forklift travel time and reduces accidental pallet impacts.

• Maintenance Benefits: Full wire decking makes cleaning, sweeping, and debris management more efficient.

This infrastructure will support continued business growth while maintaining safe and predictable warehouse operations.

Key Takeaways & Lessons Learned

• Upfront layout planning prevents long-term congestion and operational inefficiency.

• Consistent vertical spacing and anchoring accuracy are critical to safe equipment use.

• Even medium-scale facilities can achieve immediate ROI when racking replaces floor stacking.

• Future expansion capacity should be built into the design from day one.

Bogardus’s ability to deliver rapid, precise, safety-compliant installations continues to support customer growth, operational stability, and warehouse modernization.