Double-Deep Pallet Rack Installation for Denver Warehouse Expansion

Case Study: Reece HVAC Warehouse Optimization in Denver, CO

Reece HVAC needed to expand pallet storage capacity inside its Denver warehouse without increasing the facility footprint. Western Storage & Handling (WSH) designed and installed a high-density double-deep pallet rack system that significantly increased storage positions, improved warehouse organization, and supported future growth.

The project included rack teardown, reconfiguration, new rack installation, and safety enhancements — all completed within a four-week lead time.

The Challenge: Increase Storage Density Within an Existing Facility

Reece HVAC was experiencing inventory growth that exceeded the capacity of its current pallet rack layout. The warehouse required more pallet positions but did not have additional square footage available. Expanding the building was not an option.

The client needed a solution that would:

• Increase pallet storage capacity

• Maintain safe and efficient forklift access

• Minimize downtime during installation

• Meet an aggressive timeline

Traditional rack layouts would not provide the density required without sacrificing operational flow.

The Solution: High-Density Double-Deep Pallet Rack System

WSH engineered a double-deep pallet rack configuration that allows pallets to be stored two positions deep per bay. This approach reduces the number of required aisles while dramatically increasing storage density.

Project scope included:

• Teardown and reconfiguration of 41 existing pallet rack bays

• Installation of 88 additional pallet rack bays

• Installation of 67 post protectors for rack protection

• Layout optimization and system redesign

• Complete delivery and professional installation

Because WSH maintains extensive pallet rack inventory in stock at its Denver facility — including multiple upright sizes, beam lengths, and wire deck options — the project was executed quickly and efficiently.

Why Double-Deep Pallet Racking Was the Right Fit

Double-deep pallet rack systems are ideal for warehouses storing large quantities of similar SKUs. By reducing aisle requirements and increasing pallet positions per bay, the system maximizes available space without expanding the building footprint.

For Reece HVAC, the solution provided:

• Higher storage density

• Better use of existing square footage

• Improved organization and accessibility

• Enhanced rack safety with post protection

• Infrastructure built for long-term scalability

Results: Expanded Capacity and Improved Operational Efficiency

The completed installation significantly increased pallet storage capacity within the existing Denver warehouse. The upgraded layout improved workflow, enhanced rack protection, and positioned the facility to support continued inventory growth.

By combining in-stock materials, expert layout design, and professional installation, WSH delivered a fast, cost-effective storage expansion solution tailored to the client’s operational needs.

Need to Increase Storage Capacity Without Expanding Your Warehouse?

Western Storage & Handling designs and installs engineered pallet rack systems that help warehouses maximize space, improve efficiency, and support growth throughout Colorado and the Rocky Mountain region. Request a consultation to optimize your warehouse storage system.