Designing for Growth: 8,578 Pallet Positions in a 60,000 Sq Ft Warehouse Transformation

Project Overview

In this warehouse racking case study, SOURCE Racks partnered with Logomark to design and install a comprehensive storage solution within a 60,000-square-foot distribution facility. The objective was to significantly increase general storage capacity while also creating a compliant customs bonded section within the same warehouse footprint.

The final solution delivered 8,578 pallet positions and a fully integrated layout that balanced operational efficiency, compliance requirements, and long-term scalability.

The Challenge

Logomark needed to solve two competing operational priorities:

• Expand general pallet storage capacity
  
  
• Create a secure customs bonded warehouse section
  
  

Designing for both functions within a single 60,000 sq ft building required multiple layout iterations and detailed collaboration. The bonded area had to meet regulatory requirements while remaining operationally efficient and logically integrated into overall warehouse flow.

This complexity demanded careful planning, engineering precision, and consistent communication throughout the design phase.

The Solution

SOURCE Racks worked closely with the client to develop a tailored warehouse racking system that addressed both storage expansion and bonded security requirements.

The project included:

• Selective pallet racking to maximize flexibility and accessibility
  
  
• Chain-link fencing to establish a secure bonded section
  
  
• Electrical and lighting coordination to support safe and efficient operations
  
  
• Permit management and documentation support
  
  
• Ongoing design collaboration to refine layout and optimize pallet count
  
  

Selective racking was chosen for its versatility, allowing the client to store a wide range of SKUs while maintaining direct pallet access.

Timeline & Execution

• Project sign-off: 11/17/25
  
  
• Material lead time: 8 weeks
  
  
• Material delivery: 1/14/26
  
  
• Installation start: 1/14/26
  
  
• Installation completion: 2/17/26
  
  
• Permits: Submitted and pending final city approval (anticipated within weeks)
  
  

Installation began immediately upon material delivery. The team completed the full racking and fencing buildout in just over one month, keeping the project on schedule and minimizing operational delays.