QMH Warehouse Solutions & Services
Posted by Julia on October 8, 2015
Quality Material Handling has over 32 years of experience modifying and improving warehousing storage systems and facilities. This project took place in San Diego County. This Southern California warehouse facility was inefficient, with major issues such as limited storage, improper spacing for forklift usage, and inefficient inventory management. The QMH team was excited to take on this project and turn it into an efficient, effective and safe work environment.
Last updated: July 2026. Reviewed by the Quality Material Handling Inc. project design team.
Quick answer
This Escondido, San Diego warehouse struggled with inefficient vertical pallet racking layout, aisles too narrow for safe forklift use, and undersized shelving that wasted floor space. QMH redesigned the layout, installed new higher-capacity pallet racking and a boltless shelving catwalk mezzanine, and added custom workbenches, resulting in safer forklift access, better inventory management, and significantly more usable storage space.
Problems Identified:
- Their existing heavy duty pallet racking ran along the facility vertically, resulting in inefficient use of their forklifts. The lack of efficiency stemmed from the long path of travel from the dock to the pallet positions due to the configuration.
- Improper spacing of the pallet racks resulted in smaller aisles, impeding the use of forklifts and creating potential hazards in the facility. This also caused damage to the upright frames over time.
- The facility was also using smaller shelving units that did not fulfill their storage needs and used an unnecessarily large portion of their warehouse square footage.
Solutions provided by QMH:
Our warehouse specialists decided to completely redesign the warehouse to maximize space, storage, and efficiency.
- Performed a complete teardown of existing pallet racks and boltless shelving.
- Pallet Rack Installation of brand new racks with higher levels, more capacity and increased pallet positions.
- Designed and installed a boltless shelving catwalk mezzanine. This replaced the preexisting smaller shelving units and provided more storage in less space. All items in their storage system are now easily accessible and manageable.
- Custom workbenches were designed for the shipping and processing department. The new workbenches now allow for more efficient processing and packaging.
After completely redesigning their warehouse layout and professionally installing their pallet racking and boltless shelving mezzanine to meet all proper city codes, QMH created a safer and more efficient environment. The new storage system allows for much safer forklift use, improved inventory management, and increased storage by maximizing the facility’s work area.
What to evaluate before redesigning a warehouse racking layout
Before a redesign like this one, it helps to map your current forklift travel paths from the dock to storage, measure existing aisle widths against your forklift turning radius, and note where shelving is undersized or damaged. This gives your racking provider a clear picture of where inefficiency and safety risk are coming from, rather than guessing at a fix.
Permitting and code considerations for pallet racking projects in San Diego County
Projects like this one need to meet local city code for seismic bracing, aisle width, and fire/life safety clearance, especially in California where seismic requirements are more stringent. Working with an installer familiar with San Diego County permitting can help avoid delays or rework after inspection.
Our experience: With over 32 years of experience in material handling, QMH has redesigned warehouse layouts across Southern California to improve safety, storage capacity, and forklift efficiency, and we’re happy to evaluate your facility’s current layout.
Learn more about Pallet Racking
Talk to a Pallet Racking Specialist
Frequently Asked Questions
Common questions about pallet racking installation projects in Escondido and San Diego County.
The facility had heavy duty pallet racking arranged vertically that created long, inefficient forklift travel paths, narrow aisles that limited safe forklift use and damaged upright frames over time, and undersized shelving that wasted valuable floor space.
QMH performed a complete teardown of the existing pallet racks and boltless shelving, installed new higher-capacity pallet racking with more storage positions, added a boltless shelving catwalk mezzanine, and designed custom workbenches for the shipping and processing department.
Yes, pallet racking installations must meet local city code requirements for seismic bracing, aisle width, and fire and life safety clearance. California’s seismic requirements are generally more stringent than other regions, so working with an installer familiar with San Diego County permitting helps avoid delays.
It’s a raised platform built from boltless shelving components that adds a second level of storage above the main floor, with a walkway (catwalk) for staff to access items on the upper level. It’s a common way to add storage capacity without expanding a building’s footprint.
Compare your current aisle widths to your forklift’s rated turning radius. If forklifts frequently scrape racking, struggle to turn fully loaded, or operators have to make multiple maneuvers to position a pallet, your aisles are likely too narrow for safe, efficient operation.
Yes, QMH works with warehouses throughout Southern California and beyond, providing pallet racking design, installation, and layout redesign services similar to this Escondido project.
