Major Heavy‑Duty Storage System – Phase 2

Location: Gainesville, FL
Date: March 12, 2025
Project Type: Large‑Scale High‑Capacity Rack Deployment

Client Background

Following the successful rapid deployment of Phase 1, the Gainesville warehouse continued its multi‑stage installation plan. Phase 2 represented the primary expansion effort, adding substantial high‑capacity storage to accommodate escalating throughput demands and increasing pallet density requirements.

Project Overview

The objective of Phase 2 was to complete the primary structural buildout of the warehouse by installing a large‑volume heavy‑duty racking system. The system needed to maximize vertical cube utilization while maintaining safe forklift travel patterns and precise alignment throughout the facility.

Project Challenges

1. Material volume was significantly higher than Phase 1, requiring coordinated staging, sequencing, and labor allocation.

2. Upright heights of 192 and 240 inches required precise anchoring for long‑term structural sustainability.

3. Beam and wire deck placement had to remain consistent across large sections to support predictable pallet positioning.

4. Work needed to occur rapidly while maintaining safety and operational readiness for incoming inventory.

Solution and System Implementation

Bogardus installed the following system components:

• Seventy‑five uprights, measuring 240 by 42 inches

• Thirty uprights, measuring 192 by 42 inches

• Six hundred eighty‑eight beams, measuring 4.5 by 96 inches

• Six hundred eighty‑eight wire decks, measuring 42 by 46 inches

• Eight post protectors positioned in high‑exposure forklift zones

Installation procedures included anchor placement, elevation calibration, deck staging, and safety component integration. Layout, spacing, and alignment were engineered to maximize cube utilization and support high‑rotation warehouse activity.

Results and Outcomes

• The phase produced a significant increase in pallet storage capacity across the warehouse.

• Vertical cube utilization was optimized, allowing maximum pallet density without expanding the warehouse footprint.

• Structural consistency and beam spacing supported efficient forklift handling and reliable stocking procedures.

• The customer gained extensive usable storage immediately upon completion of Phase 2.

Long‑Term Impact

Phase 2 established the core storage infrastructure for high‑volume warehouse operations, building on the foundation established during Phase 1. The system delivered long‑term structural reliability, enhanced pallet density, and improved storage efficiency, making the facility capable of sustained growth and increased daily throughput.

Heavy‑Duty Pallet Rack Deployment – Phase 1

Location: Gainesville, FL
Date: March 4, 2025
Project Type: Phase‑Based Installation for Rapid Operational Activation

Client Background

A Gainesville warehouse began a multi‑stage expansion plan requiring immediate pallet rack installation to support inbound shipments. The customer needed the first phase completed with accelerated timing to meet scheduled receiving activity and maintain production flow.

Project Overview

The objective of Phase 1 was to establish a structurally reliable heavy‑duty pallet rack system capable of immediate use. Installation had to be coordinated under strict time constraints while ensuring full safety compliance, load integrity, and clean aisle access.

Project Challenges

1. Phase 1 had to be completed rapidly to meet inbound shipment deadlines beginning the same business day.

2. Heavy‑duty uprights and beams required precise placement to maintain load stability and elevation consistency.

3. Post protector placement had to be integrated during installation, not after, to prevent forklift impact during inbound traffic.

4. Deployment timing and staging required sequencing to avoid handling delays and congested work conditions.

Solution and System Implementation

Bogardus installed a heavy‑duty rack system consisting of:

• Sixteen‑foot uprights

• Twenty‑foot uprights

• Eight‑foot beams with four‑and‑a‑half inch profiles

• Forty‑two by forty‑six inch wire decks

• Post protectors at high‑exposure locations for structural safeguarding

Installation sequencing ensured uninterrupted progress, with alignment verification, anchoring, and deck placement executed methodically to maintain rack stability and operational readiness.

Results and Outcomes

• The entire phase was completed in eight hours, meeting the customer’s immediate activation requirements.

• Inbound shipments began the same day without delays to staging or stocking activity.

• Structural reliability and load protection were achieved through coordinated installation and safety accessory integration.

• The warehouse gained high‑capacity vertical storage supported by a durable heavy‑duty configuration.

Long‑Term Impact

Phase 1 delivered a fully functional framework that supported immediate operational throughput and prepared the facility for subsequent phases. The structural integrity, load stability, and aisle safety enhancements provided measurable long‑term storage value. The rapid completion validated the ability to execute phase‑based deployments under accelerated timelines.

Industrial Safety Net Installation for Aisle Protection

Location: Undisclosed
Date: March 1, 2025
Project Type: Fall‑Prevention Safety System for Active Warehouse Aisles

Client Background

The customer operated a high‑activity warehouse with multiple live pick aisles. The risk of product or pallet fall‑through jeopardized employee safety, equipment reliability, and stored inventory. A safety‑focused solution was needed to prevent accidental drops between rack levels and reduce exposure to workplace hazards.

Project Overview

The objective of this installation was to implement industrial safety netting across critical aisles to protect personnel, prevent debris fall‑through, and maintain uninterrupted warehouse activity. The system had to be durable, securely anchored, and able to withstand ongoing operational conditions without obstructing material handling processes.

Project Challenges

1. Safety netting needed to span long aisle sections without sag, obstruction, or clearance issues.

2. The installation had to be completed without interfering with active picking and forklift travel.

3. Anchoring and tensioning needed to ensure reliable containment integrity under operational stress.

4. Coverage had to be targeted at the highest‑risk zones to maximize safety effect.

Solution and System Implementation

Bogardus installed industrial safety netting across active warehouse aisles using:

• Seventy‑five feet by twelve foot industrial safety nets

• Secure mounting and tensioning to maintain containment performance and clearance spacing

Installation sequencing ensured minimal disruption to day‑to‑day handling while providing complete fall‑prevention coverage. Anchoring methods were selected to ensure long‑term durability under daily material movement.

Results and Outcomes

• The installation significantly improved personnel protection in active pick aisles.

• Risk of pallet and product fall‑through was substantially reduced, lowering exposure to equipment damage.

• Warehouse operations continued without interruption during installation activity.

• The solution provided a dependable safety layer compliant with routine handling, rotation, and stocking conditions.

Long‑Term Impact

The safety net system delivered a durable and reliable protection measure designed to prevent injuries, protect equipment, and improve warehouse safety compliance. The addition of fall‑prevention infrastructure supports long‑term operational safeguards and reduces the likelihood of workplace disruptions caused by accidental drops.