High Density Pallet Rack Installation For National 3PL

The Project

High-density selective pallet rack installation for a national 3PL's 500,000 sq ft retail distribution facility in Bath, PA. Hammerhead designed, permitted, and installed 8,260 pallet positions at six levels high in a 36-foot clear building, on an expedited schedule driven by a major customer ramping up inbound volume.

The Challenge

Smart Warehousing's facility was running out of floor space fast: a large electrical customer was sending in thousands of pallets weekly, and the building needed racking as soon as possible. The project required expedited permitting, and the racking scope had to be coordinated with new electrical and lighting work for the service aisles and egress paths.

The Outcome

Hammerhead expedited the permit package and scaled up installation crews to run the racking and coordinated electrical work in parallel. The system delivered 8,260 pallet positions at six beam levels with wire decking, post and row-end protection, egress tunnels through the long rack rows, and reduced 10- and 11-foot service aisles for lift access. The permit inspection found zero deficiencies, and the racking was approved for use ahead of schedule.