High‑Capacity Pallet Rack Installation

Location: Medley, FL
Date: January 27, 2023
Project Type: High‑Density Vertical Storage System

Client Background

A distribution facility based in Medley, FL had reached a critical point in warehouse utilization efficiency. Despite operating with adequate floor space, the lack of vertical storage infrastructure significantly limited throughput and obstructed forklift maneuverability. Increasing inbound product volume made continued floor‑level staging unsustainable for operational efficiency and safety.

Project Overview

The objective of this project was to install a reinforced pallet rack system to maximize vertical cubic capacity, create clearer forklift travel lanes, and improve inventory accessibility. The installation required durable structural components capable of supporting long‑term heavy throughput and providing scalability to meet future operational demands.

Project Challenges

1. The facility lacked efficient vertical storage utilization, resulting in congested staging areas.

2. Forklift maneuverability was impacted due to dispersed pallet locations and narrow routing paths.

3. Safety concerns included insufficient pallet containment and lack of collision protection at critical rack points.

4. The customer required a high‑density solution delivered without disrupting ongoing warehouse activity.

Solution and System Implementation

Bogardus provided and installed a reinforced pallet rack system engineered for maximum load distribution and long‑term structural reliability.

System specifications included:

• Uprights measuring 42 x 216 inches

• Heavy‑duty 6 x 144 inch beams

• Reinforced 6 x 6 inch structural footplates

Safety and accessibility features included:

• Industrial plastic wrap containment

• Forklift‑support integration

• Rack safety guards positioned at high‑impact locations

• Rolling ladder systems to support safe elevated access

• Dock ramp integration enabling uninterrupted staging and movement flow

The installation was completed in phases to maintain ongoing warehouse operations, verify clearances, and validate forklift routing patterns.

Results and Outcomes

• The customer achieved a significant increase in usable pallet positions due to maximized vertical utilization.

• Floor congestion was reduced, enabling more efficient forklift travel and staging workflow.

• Operational safety improved with the addition of containment systems and impact‑resistant rack guards.

• Loading and unloading efficiency increased due to clearer traffic flow and improved inventory accessibility.

• The warehouse transitioned into a fully optimized high‑density storage environment capable of supporting higher daily throughput without the need for additional building expansion.

Long‑Term Impact

The system installed provides long‑term value by supporting anticipated increases in inbound product volume while maintaining safe, efficient travel lanes and pallet access. The reinforced design and layout optimization strategically position the facility to absorb operational growth without the requirement for structural changes or external storage leasing.