Mixed Rack Configuration Installation

Location: Miami, FL
Date: February 5, 2024
Project Type: Combined Storage System Supporting Multiple Inventory Types

Client Background

A Miami‑based warehouse required a pallet rack layout capable of supporting varying load types, including lighter SKUs as well as standard palletized inventory. The system had to maximize available cubic storage while maintaining flexibility for changing product dimensions and throughput demands. The warehouse aimed to expand vertical utilization without dedicating excess square footage or compromising accessibility.

Project Overview

The objective of this installation was to build a mixed configuration rack system that accommodated multiple product classes within a single cohesive layout. Strategic equipment selection and spacing alignment were key to ensuring that both light‑duty and standard pallet loads could coexist while preserving efficient forklift travel lanes, staging areas, and inventory access.

Project Challenges

1. The system required blended strength characteristics to suit multiple product load capacities.

2. Component sizing had to be coordinated to maintain stability while delivering operational versatility.

3. Multiple deck configurations were needed to support different pallet and SKU dimensions.

4. Storage density requirements had to be balanced with forklift accessibility and safe maneuvering patterns.

Solution and System Implementation

Bogardus installed a mixed‑configuration rack system using the following components:

• Ten‑foot by forty‑two‑inch uprights

• Eight‑foot light‑duty beams

• Ten‑foot by twenty‑four‑inch uprights

• Twenty‑four by forty‑six inch decks

• Forty‑two by forty‑six inch decks

The system layout provided multiple beam elevations to handle diverse SKU sizes while maintaining structural safety and consistent vertical spacing. Installation work included alignment calibration, anchoring operations, and deck staging to support immediate utilization after completion.

Results and Outcomes

• The installation provided optimized cubic storage, increasing usable vertical height without increasing floor footprint requirements.

• The mixed‑configuration layout supported both light‑duty and standard palletized inventory with reliable stability.

• SKU diversification improved warehouse flexibility, enabling product expansion without reconfiguration.

• The system supported efficient forklift handling and simplified inventory accessibility for ongoing operations.

Long‑Term Impact

The warehouse gained a customized solution capable of sustaining long‑term SKU diversification without requiring future structural modification. The mixed‑capacity system provided the adaptability necessary to support ongoing changes in product mix while delivering reliable vertical storage performance. This installation enhanced the facility’s organizational strategy, equipment utilization, and throughput consistency.