Large‑Scale Full Warehouse Buildout

Location: Fort Pierce, FL
Date: April 5, 2023
Project Type: Complete Storage System Engineering and Installation

Client Background

A distribution operation in Fort Pierce, FL was preparing a warehouse to support high‑volume logistics activity and anticipated sustained growth in palletized inventory. Due to space utilization requirements and increased throughput expectations, the facility required a fully engineered storage system capable of maximizing density, supporting efficient forklift traffic, and providing safety compliance from day one.

Project Overview

The facility required a complete warehouse buildout, including system design, material sourcing, delivery, and installation. The project involved establishing multiple rack elevations, optimizing pallet storage positions, maintaining accessibility, and integrating safety systems. The scope of work encompassed both structural installation and operational workflow considerations.

Project Challenges

1. The storage system needed to substantially increase pallet density while preserving forklift travel lanes.

2. The configuration required structural reliability to support consistent load demands across large inventory volumes.

3. Safety systems needed to be integrated to reduce collision exposure and pallet handling risk.

4. Installation required sequencing to position uprights, beams, decks, and safety components while maintaining clear staging zones.

Solution and System Implementation

Bogardus provided a full‑scale warehouse buildout including material planning, delivery, and installation. System components were installed as follows:

• Thirty‑three 12‑foot uprights

• Sixty 14‑foot uprights

• Four hundred thirty‑two 6 x 144 inch heavy‑duty beams

• Six hundred forty‑eight 42 x 46 inch wire decks

• Thirty end‑of‑row guards for impact protection

The Bogardus team designed the rack layout to support high‑density pallet storage while preserving optimal forklift access patterns. Installation work included alignment verification, anchoring, stability adjustments, and staged sequencing to ensure structural consistency and safe compartmentalization.

Results and Outcomes

• The customer received a fully engineered warehouse storage system with substantial pallet density.

• Safety conditions were strengthened through the use of end‑of‑row guards and strategic layout spacing.

• Forklift routing efficiency improved due to structured aisle planning and vertical utilization.

• The facility achieved modern logistics standards through a durable, scalable storage infrastructure.

Long‑Term Impact

The storage system design and installation positioned the warehouse to handle increased volume demands with reliable load performance and sustained safety compliance. The high‑density configuration reduced storage limitations and enabled more efficient inbound and outbound product flows, supporting operational scaling and long‑term throughput growth.