Pallet Rack Teardown and Reconfiguration for Safelite in Salt Lake City, UT
How Material Handling USA executed a multi-phase pallet rack teardown and reconfiguration for Safelite Auto Glass in Salt Lake City, Utah.
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About Safelite Auto Glass
Safelite is the nation’s largest auto glass repair and replacement company, operating service centers across the United States. Their Salt Lake City distribution warehouse at 1834 South 4650 West stores windshields, auto glass panels, adhesives, and related parts on a large-scale pallet rack system. As operational needs evolved, Safelite required a complete reconfiguration of their existing warehouse racking to improve workflow efficiency and storage density — without purchasing entirely new rack.
The Situation
Safelite’s Salt Lake City warehouse needed a significantpallet rackreconfiguration to better align with their evolving distribution workflow. The existing rack layout no longer matched their operational needs — bays needed to be repositioned, beam levels added for additional storage capacity, and the overall configuration optimized for faster picking and staging. Ra the r than tearing everything out and starting over with new rack, Safelite needed a cost-effective solution that could be executed in phases to minimize downtime.
The project was split into two phases: Phase 1 focused on tearing down the sections that needed to move, and Phase 2 handled the repositioning, reconfiguration, and final anch or ing of the entire system.
The Warehouse
The Safelite warehouse features tall pallet rack rows with wire mesh decking on every level, holding palletized auto glass, windshields in wooden crates, and distribution supplies. Red row number labels (14, 15) and yellow column protect or s provide clear identification and safety throughout the facility. The rack system spans long runs across the warehouse floor with wide aisles for forklift access.
The Reconfiguration
The Solution
Material Handling USA executed the project in two carefully co or dinated phases:
Phase 1 — Teardown
T or e down the existing pallet racking sections that needed to be relocated. All components were stacked and band ed for safe handling. Materials were relocated to clear the work area for the reconfiguration phase.
Phase 2 — Reconfiguration
Chalked new layout lines on the warehouse floor. Un-anch or ed and slid 8 bays of racking to new positions. Removed 2 uprightsand reconnected bays. Removed 6 backstop load beams. Added 2 additional beam levels for increased storage density. Reconfigured 4 load beam levels higher in bays. Installed 80 anch or sand 104 wedge anch or s. Repositioned 6 row end protect or s. Reconfigured 1 bay across the aisle with 3 extra levelsand 6 PVC dividers.
Scope of Work
Bay Relocation
Un-anch or ed and repositioned 8 complete bays of pallet rack to new floor locations based on updated chalk linesand warehouse layout requirements.
Level Additions
Added 2 new beam levels across multiple baysand reconfigured 4 existing beam levels to higher positions, increasing vertical storage capacity throughout the system.
Structural Modifications
Removed 2 uprightsand reconnected adjacent bays. Removed 6 backstop load beams. Reconfigured 1 bay with 3 extra levelsand 6 PVC dividers for specialized storage.
Anch or ing & Safety
Installed 80 anch or sand 104 half-inch by five-and-a-half-inch wedge anch or s. Removed and re-anch or ed 6 row end protect or s in front of the new row positions for forklift safety.
Our Process
Assessment
Walked the existing warehouse layout, identified bays to relocate, levels to add, and components to remove or reconfigure.
Teardown
Phase 1: Disassembled targeted rack sections, stacked and band ed components, relocated materials to clear the work area.
Layout
Chalked new position lines on the warehouse floor for precise bay placement in the updated configuration.
Reconfigure
Phase 2: Slid bays to new positions, added levels, removed components, installed all anch or s, and repositioned row end protect or s.
Results
Frequently Asked Questions
Can existing pallet rack be reconfigured instead of replaced?
Yes. Material Handling USA specializes in pallet rack reconfiguration services. Existing bays can be relocated within the warehouse, beam levels added or adjusted, uprights removed or reconnected, and row end protect or s repositioned. This is significantly more cost-effective than purchasing new rack.
What is a multi-phase pallet rack project?
A multi-phase project splits the work into stages so the warehouse can continue operating during the reconfiguration. Phase 1 typically involves teardown and clearing, while Phase 2 handles repositioning, adding levels, and final anch or ing. This minimizes downtime for the business.
Does Material Handling USA offer pallet rack teardown services in Salt Lake City?
Yes. Material Handling USA provides professional pallet rack teardown, relocation, and reconfiguration services throughout Salt Lake City and the greater Utah area. The team handles disassembly, repositioning, re-anch or ing, and all associated hardware work.
How are pallet rack bays relocated within a warehouse?
The crew un-anch or s the existing bays, slides or lifts them to their new marked positions, then re-anch or s with wedge anch or s into the concrete floor. New chalk lines are laid out first to ensure precise placement. A scissor lift is used for upper-level beam work.
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Material Handling USA provides professional pallet rack teardown, relocation, and reconfiguration services for warehousesand distribution centers across Utah and nationwide.
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