Large‑Scale Pallet Rack Relocation

Location: Louisville, KY
Date: February 15, 2023
Project Type: High‑Volume Rack System Relocation During Active Operations

Client Background

A high‑throughput facility located in Louisville, KY required a large‑scale pallet rack relocation while maintaining full operational capacity. The warehouse supported time‑sensitive distribution workflows that could not tolerate shutdowns or staging interruptions. The facility leadership prioritized continuity of operations and required a relocation solution that ensured product movement, picking, and shipping would remain uninterrupted.

Project Overview

The project involved relocating and reinstalling 440 pallet rack sections with strategic sequencing designed to maintain live operations. The system needed to be dismantled, transported, and reinstated while protecting materials, equipment, and travel lanes. Bogardus was selected due to extensive experience with high‑volume warehouse projects requiring precise coordination, workplace safety controls, and multi‑phase execution.

Project Challenges

1. The warehouse could not shut down operations or suspend fulfillment activity during relocation.

2. Material flow pathways needed to remain open to prevent bottlenecking or shipment delays.

3. The volume of pallet rack components required strategic staging to prevent congestion and maintain productivity.

4. Rack movement, reassembly, and anchoring needed to occur without impairing forklift navigation or staging areas.

Solution and System Implementation

Bogardus executed the relocation using a multi‑phase structured methodology. The system components consisted of 28‑foot uprights paired with 8‑foot beams, reinstalled according to pre‑validated layout specifications.

Execution included:

• Controlled dismantling sequences prioritizing rack sections adjacent to active staging areas.

• Staging of dismantled structural components in designated zones to preserve forklift access.

• Logistical planning to coordinate transport timing and minimize internal traffic disruption.

• Reinforcement of anchoring points and alignment verification to support load integrity.

Every phase was performed while live operations continued, requiring coordinated communication between facility personnel and the Bogardus installation team.

Results and Outcomes

• The relocation was completed without operational shutdown, enabling the facility to maintain continuous production and order fulfillment.

• Forklift pathways and travel lanes remained accessible throughout all relocation stages.

• No shipment delays, workflow interruptions, or staging conflicts occurred during the project.

• The reinstalled system provided stable load distribution, organized material access, and continued adaptability for ongoing operations.

Long‑Term Impact

The successful relocation demonstrated the facility’s ability to upgrade and realign its racking infrastructure without losing productivity. The project also established repeatable relocation procedures for future expansions or reconfigurations. The structural integrity and configuration precision of the reinstalled racking system positioned the warehouse for continued growth without unnecessary downtime or capacity reduction.