Cantilever Rack and Custom Fabricated Storage for Colorado Springs Manufacturer

A Colorado Springs manufacturer was relocating to a new facility and needed a storage system that could handle long, heavy, and irregular inventory including springs, rails, and oversized crates. The move created a tight window to design, fabricate, and install a complete storage solution before operations transferred to the new building.

The Challenge: Irregular Inventory in a New, Unfamiliar Space

The client’s inventory presented an immediate storage challenge. Garage door components including springs and rails are long, heavy, and awkward to store in standard pallet rack or shelving configurations. Standard rack systems could not efficiently accommodate the dimensions and weight of these materials without wasting significant floor space or creating unsafe storage conditions.

Moving into a new facility added complexity. The client had not yet worked within the new floor plan and needed help optimizing the layout before committing to a storage configuration. A particular piece of inventory required a completely custom storage solution that did not exist as an off-the-shelf product.

Key requirements included:

• Maximizing storage positions for long and irregular materials within a new, unfamiliar footprint
• Designing a layout that improved warehouse flow from day one
• Fabricating a custom solution for a unique, high-value inventory item
• Meeting a tight relocation timeline and defined budget

The Solution: Cantilever Rack With Custom Fabricated Spring and Rail Storage

Double-sided cantilever rack installation, showing open-arm configuration allowing long materials to be loaded and retrieved from both sides of the row.

Cantilever rack storing long panels and sheet goods — an application where standard pallet rack bays cannot accommodate the length or irregular inventory dimensions.

Western Storage and Handling surveyed the new facility and worked directly with the client’s operations team to design a layout that maximized storage density and improved overall warehouse flow. Cantilever rack was specified as the primary storage system for the long, irregular materials — the open-arm design of cantilever rack is purpose-built for items that cannot be palletized or stored in standard bays.

For the unique spring and rail inventory, WSH’s in-house fabrication team designed and built a custom 8-foot slotted pull storage unit from scratch. The fabricated solution was designed specifically around the dimensions and weight of the client’s springs and rails, creating organized, accessible storage for components that had previously been difficult to manage. At the client’s request, the fabricated unit was finished in custom Bronco colors.

Key Features of the Installation

• Cantilever rack system for long and irregular garage door components
• Custom fabricated 8-foot slotted pull unit for spring and rail storage
• AutoCAD layout design developed in collaboration with the operations team
• Custom color finish per client specification
• Project management coordinating installation with the facility relocation timeline

Results: On-Time Move With a Purpose-Built Storage Solution

The project was completed on schedule, with the facility relocation and rack installation coordinating successfully. The custom fabricated storage unit gave the client an organized, purpose-built home for their most challenging inventory items for the first time, eliminating the handling difficulties that had previously complicated their spring and rail operations.

Custom fabricated vertical divider storage for garage door springs and rails, built and installed by WSH’s in-house fabrication team in Colorado Springs.

Project outcomes included:

• On-time delivery and installation aligned with the facility relocation schedule
• Optimized warehouse layout designed for the new space from day one
• Custom fabricated storage solution for unique spring and rail inventory
• Budget met

Need a Custom Storage Solution for Irregular or Oversized Inventory?

Western Storage and Handling designs and installs cantilever rack systems and custom fabricated storage solutions for manufacturers, distributors, and industrial facilities throughout Colorado, Eastern Wyoming, and Western Nebraska. If your inventory does not fit a standard storage system, our in-house fabrication team can build something that does.

Request a Proposal to discuss your storage requirements.