High‑Vertical Pallet Rack Upgrade

Location: Doral, FL
Date: July 19, 2024
Project Type: Vertical Capacity Expansion with New System Installation

Client Background

A warehouse located in Doral, FL required expanded pallet storage capacity to support projected growth in inbound and outbound inventory. The facility needed a system capable of maximizing vertical utilization while maintaining operational safety and forklift access across all working aisles.

Project Overview

The objective of this installation was to substantially increase pallet position capacity without adding footprint or limiting maneuverability. The customer planned to accommodate higher volume on existing floor space, making vertical storage optimization essential. All structural specifications had to support long‑term scalability.

Project Challenges

1. The customer needed to significantly increase pallet capacity without altering the warehouse footprint.

2. Increasing vertical height required precise anchoring, alignment, and spacing to support safe handling.

3. Forklift clearance and travel patterns had to remain protected despite higher storage elevation.

4. The upgrade had to provide long‑term reliability for current and future throughput demands.

Solution and System Implementation

Bogardus delivered and installed a high‑vertical rack upgrade using:

• Brand‑new twenty‑six‑foot uprights

The increased upright height extended usable vertical storage while meeting required anchoring and alignment specifications. Installation included:

• Vertical calibration

• Horizontal spacing verification

• Safe aisle dimensional coordination

• Forklift travel lane preservation

All materials were staged and installed in a manner that minimized operational disruption.

Results and Outcomes

• The upgraded rack system provided significant vertical capacity expansion, increasing total pallet positions.

• Warehouse space efficiency improved without increasing physical footprint.

• Aisle spacing and forklift maneuverability were preserved, ensuring operational safety.

• The solution enabled immediate increases in inventory handling capacity.

Long‑Term Impact

The warehouse is now positioned to support long‑term scalability with higher vertical utilization and a structurally robust storage system. The upgrade will continue to support increasing product volume without requiring future layout changes or facility expansion. The installation delivered sustainable value by multiplying storage density while maintaining safe, efficient material handling conditions.