Full Warehouse Setup With Forklift Operations & Permits

Date: October 31, 2025

Project Scope

This project involved the complete launch of a fully operational distribution facility. The customer needed an end‑to‑end implementation including rack installation, permitting, engineering approval, equipment sourcing, and operational readiness. The scope included both storage infrastructure and the deployment of forklift operations to enable immediate receiving, stocking, and outbound flow. The goal was to convert a vacant building into a productive logistics environment within an accelerated timeframe.

Challenges & Requirements

• All permitting and municipal compliance had to be coordinated in advance to prevent delays.

• The building had no pre-existing infrastructure, requiring full warehouse layout planning from scratch.

• Forklift operations had to be integrated safely alongside newly installed pallet rack systems.

• The system needed to support multi-shift throughput and scalable inventory volume.

• Installation sequencing required precise coordination to avoid setbacks in operational readiness.

Solution Implementation

Bogardus installed 24' Interlake Mecalux uprights paired with 98" x 3.65" beams and 42" x 46" wire decks, configured to maximize vertical cube utilization without reducing forklift maneuverability. Engineering drawings and load data were submitted to support the permitting process. Placement, anchoring, row spacing, and beam elevation decisions were made to ensure consistency with safety and compliance standards.

Beyond the racking installation, Bogardus managed permitting and municipal approval, ensuring the warehouse met required code specifications. Forklift selection, placement, and testing were coordinated so that material handling operations could begin immediately following installation.

Outcome

The warehouse transitioned from an empty structure to a fully functional distribution center in record time. The facility achieved complete operational readiness, enabling receiving, stocking, and fulfillment workflows on day one. Forklift operations integrated seamlessly with the new racking, supporting efficient pallet handling and travel paths.

Long-Term Benefits

• Rapid go‑live allowed the business to begin generating value from the facility immediately.

• The scalable rack layout supports significant future growth without redesign.

• Code‑approved installation ensures safe long-term operation and reduced compliance risk.

• The optimized vertical configuration maximizes pallet density while protecting forklift circulation lanes.

Lessons & Observations

This project demonstrates the advantage of integrating permitting, engineering, racking installation, and forklift deployment under a single coordinated provider. Proactive planning, structural alignment, and precise layout sequencing were essential in achieving immediate operational flow without delays or rework.

Fully Permitted Racking Installation – Miami, FL | High-Density Storage Environment

Date: October 25, 2025

Project Scope

This project required the design, engineering, permitting, and installation of a high‑density pallet rack storage system for a Miami‑based distribution facility. The customer needed maximum cubic utilization while meeting municipal codes, seismic requirements, and internal material‑handling safety standards. Precision layout planning and staged sequencing were necessary to avoid disruption to the client’s ongoing operational activity.

Challenges & Requirements

• The installation had to comply fully with local permitting and seismic conditions.

• AutoCAD‑based engineered drawings were required for approval and anchoring specifications.

• The warehouse layout needed to achieve maximum storage density without restricting forklift travel or staging areas.

• Signage, load identification, and compliance documentation had to be coordinated and posted before activation.

Solution Implementation

Bogardus installed 24' uprights, 12' beams, and 42" x 46" wire decks configured into a vertical high‑density environment. Precise anchoring methods were used to meet engineering specifications. Load signage was installed throughout the system to maintain consistent safety compliance. Seismic considerations were accounted for in spacing, anchoring, and lateral support. Layout refinements were validated using full AutoCAD drawings and coordinated approvals.

Outcome

The final system delivered a structurally reinforced, code‑approved racking environment with exceptional pallet density and optimized aisle flow. The client received a full documentation package and immediate operational readiness, empowering the facility to support sustained high‑volume throughput.

Long‑Term Benefits

• Increased cubic storage capacity without requiring facility expansion

• Reduced risk of compliance‑related operational delays

• Clear load signage contributing to safer forklift handling and pallet placement

• Stronger positioning for future growth due to scalable, engineered infrastructure

Key Project Lessons

The installation demonstrated the value of integrating engineering, permitting, and layout planning before physical deployment. Proactive compliance and precision staging enabled an efficient installation while maintaining the highest possible safety standards.

Warehouse Expansion – PROMOTEX | 50% Pallet Capacity Increase

Date: October 10, 2025

Project Scope

PROMOTEX required a major warehouse expansion to support rapidly increasing inbound and outbound inventory flow. The objective was to increase pallet storage capacity without relocating or disrupting ongoing fulfillment. The expansion needed to integrate seamlessly with existing lanes, picking paths, and forklift circulation to support high‑volume operations.

Challenges & Constraints

• The project required careful reconfiguration of existing aisles to avoid reducing forklift maneuverability.

• Material sizes varied (16' and 24' uprights), requiring precise spacing and anchored alignment to maintain structural consistency.

• The warehouse continued daily operations during the expansion, meaning installation activity needed to be staged and sequenced without impeding active workflow.

Solution Implementation

Bogardus supplied and installed 96" beams, 16' uprights, 24' uprights, and 42" x 46" wire decks in a layout engineered for vertical optimization and balanced load distribution. Aisles were reworked to support efficient travel paths and ensure consistent, repeatable picking patterns. The installation was executed with full load‑bearing safeguards and engineered compliance considerations.

Outcome & Operational Impact

The expansion increased total pallet positions by 50% while keeping the facility fully operational. PROMOTEX achieved significantly greater vertical utilization, eliminated the immediate need for costly relocation, and gained the ability to scale throughput as inventory demand grows. Long‑term operational benefit includes improved storage density, smoother forklift routing, and sustainable growth capacity within the existing footprint.

Full Installation With Permits – Beauty & Logistics | High‑Volume Pallet Storage

Date: October 3, 2025

Project Scope

Beauty & Logistics required a turnkey pallet storage system to accommodate high‑volume daily throughput operations. The objective was to install a high‑density racking system engineered for vertical optimization, safety compliance, and efficient order fulfillment. The installation included complete permitting and engineering coordination to ensure certification and long‑term performance.

Challenges & Constraints

• High SKU velocity required the warehouse to remain partially operational during installation, limiting aisle blockage and staging space.

• 24' uprights required precise anchoring and engineered layout spacing for safe forklift clearance and pallet loading.

• Permitting and engineering documentation had to be completed without delaying the build timeline.

Solution Implementation

Bogardus supplied and installed 24' uprights, 144" beams, and 42" x 46" wire decks as part of a vertically optimized, structurally compliant racking configuration. The installation followed engineered drawings and municipal permitting requirements. Beam elevations were strategically set to support pallet stacking, maintain visibility, and preserve safe forklift maneuvering paths.

Outcome & Operational Impact

The warehouse received a fully engineered, fully permitted storage system structured for immediate large‑scale operations. Order fulfillment efficiency improved due to better aisle alignment and pallet accessibility. Long‑term impacts include increased vertical utilization, safer staging areas, higher storage density, and compliance documentation that supports future audits, expansions, and facility reconfiguration.