How One Warehouse Racking Walkthrough Adds 359 Pallet Positions

We had only completed one small project with this customer before, so when they reached out about racking for a new 56,000-square-foot facility in Connecticut, I was glad they trusted us enough to start the conversation.

On paper, the project seemed straightforward. In reality, many details could affect the final layout, capacity, permitting, installation timeline, and the system’s long-term safety.

The Warehouse Walkthrough

The customer mentioned he was working with a consultant and would share the drawings once he had them. I asked if I could walk through the new site first, because drawings are helpful, but they don’t always tell the full story.

We would focus on four key areas:

1. Making the most of the space

• Clear heights to maximize vertical space and increase pallet positions
• Aisle widths based on the forklift or reach truck being used
• Pallet dimensions, weight capacity, and beam elevations

2. Confirming site conditions

• Lighting in the aisles
• Slab thickness and PSI strength to ensure we can anchor uprights
• Sprinkler locations and required flue space
• Columns, caging, overhead doors and tracks, HVAC ducts, electrical outlets, piping, and other obstructions

3. Planning for code, safety, and protection

• Town permitting and building code requirements
• Fire protection considerations
• Post protectors and end-of-row guards to prevent structural damage
• Emergency exits, pedestrian doors, and fire extinguishers

4. Understanding the project logistics

• Desired timeline
• Installer working hours: can we work 12-hour shifts?
• Rental equipment such as forklifts and scissor lifts
• Budget expectations
• Other vendors involved in the process

After the walkthrough, it became clear that the customer and consultant needed to review a few important details before finalizing the design. Rather than work in separate silos, we set up a call with the customer and consultant so everyone could align on the layout, site conditions, permitting requirements, and equipment plan.

Why the extra time up front paid off

In the end, the customer selected Abel Womack for the project because we helped identify and address details that could have affected the project later. These included things like permitting, aisle layout, equipment selection, slab conditions, and potential obstructions.

By slowing down at the beginning and validating the space in person, we recommended a narrow-aisle layout using reach trucks, which increased pallet positions by 359. Abel Womack also worked directly with the town on permitting, taking the responsibility off the customer’s plate. The final solution included both teardrop racking and cantilever racking to support the customer’s storage needs.

After we completed the project, the customer trusted us with two additional racking projects without going back out to bid. To me, that reinforced something we see often, taking the time to ask the right questions up front can save time, reduce unexpected issues, and create a better outcome in the long run.

Have a racking or storage project on the horizon?

Let’s take a look before you finalize the layout. A warehouse racking walkthrough now can uncover opportunities, avoid surprises, and help you make the most of your warehouse space before you lock in decisions.