Blogs & Case Studies

A Canadian mining and heavy equipment company faced a challenge many growing businesses encounter: their hand-picking operation was outpacing their storage setup. As their parts and service division expanded, they needed a way to store significantly more SKUs without adding square footage or compromising safety and efficiency. 

Challenges Faced

Growing Operations: 

The client’s pallet racking worked for their initial needs, but as their hand-pick parts business grew, they were running out of space. With only 25 bays of rack and roughly 200 shelf locations occupying 5,600 sq ft, they had reached capacity.

Limited Vertical Access:

Their initial approach was to add extra beam levels to existing racking and use forklift cages to move workers up and down for picking. While this would add some capacity, it introduced concerns about pick speed and worker safety during busy periods.

Space Efficiency:

The client needed to dramatically increase their parts storage without expanding their facility footprint or disrupting daily operations.

Solutions

A Consultative Approach to Storage Design

Having reviewed our client’s initial plan, our project manager took time to understand the operation before proceeding. We shared examples of similar operations we had worked with and walked through how we solved comparable challenges for those businesses. The conversation shifted away from adapting existing racking and toward a purpose-built solution designed specifically for high-density parts picking.

The recommendation was a two-level shelving mezzanine that would transform how the client approached vertical space. 

High-Density Shelving Mezzanine

We designed a system spanning approximately 1,960 sq ft with over 1,700 shelf locations across a total storage footprint of 10,200 sq ft. The mezzanine stands 15 feet tall with an 8-foot clear height to the first level, creating two full working levels for parts storage and retrieval.

Dense shelving with narrow aisles allowed the client to move from under 500 shelf locations in their original 5,600 sq ft setup to 1,700 shelf locations. Workers can now access parts quickly on both levels without waiting for forklift transport.

Perforated Steel Shelving for Fire Code Compliance

The shelving uses perforated steel decking to meet fire code requirements. The perforations allow proper air circulation and sprinkler coverage throughout the system, keeping the installation compliant while maintaining load capacity. Back and side panels were added to the top level to prevent products from accidentally falling off shelves.  

ResinDek Flooring for Efficient Movement

Flooring choice made a practical difference. We specified ResinDek for the mezzanine surface because it provides a smooth, solid surface for pushing carts. Steel grating can catch cart wheels and slow workers down during restocking. The ResinDek eliminates that friction, letting staff move quickly between pick locations.

Other features include a pivot gate for pallet loading, guard rails and stairs for safe access between levels.

Results and Impact

The shelving mezzanine delivered a measurable transformation, giving our client the capacity that matched their pace of growth. We increased their shelf locations by 240%, allowing them to serve their customers more effectively and positioning their hand-pick operation for continued expansion.

The real value came from the collaborative and open-minded discussions between our client and project manager that led to us being able to present an alternative solution that would significantly improve operational efficiency and safety while staying true to the client’s vision.

We approach these conversations by learning how your team works, applying what we’ve seen succeed before, and designing systems that support both immediate needs and future growth. If your current setup is reaching capacity, we can help you explore solutions tailored to your unique operation.

Setting out to expand their national footprint and strengthen service in Eastern Canada, 18 Wheels Logistics sought a warehousing solution that could support their timeline, budget, and evolving customer needs. The result was a new 220,000 sq ft facility in Brampton, Ontario. Serving a diverse client base across beverage, furniture, and other sectors, the new space required high-density pallet storage that would integrate smoothly into active operations and allow for reconfiguration as SKUs changed. 

Challenges Faced

Live Site Conditions: 

The Brampton site was already live when the project began, with operations underway and bulk storage in use. To stay on schedule and within budget, installation needed to be staged around product movement and day-to-day warehouse activity without restricting access to inventory or disrupting fulfillment. 

Customer-Specific Storage Needs:

As a 3PL managing varied client inventory, including food-grade products and furniture, 18 Wheels needed a system that balanced selectivity with high density. Flexibility was essential, especially for inventory with expiry dates and shifting pallet requirements. 

Engineering considerations:

With the goal of maximizing performance without unnecessary material spend, we needed to carefully account for seismic codes, which would impact frame design and project cost. 

Solutions

Double Deep Racking with Operational Flexibility:

To address density and selectivity, North American Steel designed a double deep system—ideal for storing high volumes while still allowing for reliable inventory access. This configuration is especially well-suited to the food and beverage sector, where stock rotation and pallet tracking are critical. 

We also engineered the layout for future adaptability. As needs evolve, adjustments can be made quickly through our in-house engineering team. 

Phased Installation Around Active Operations:

To align with capital planning and immediate operational needs, we took a phased approach to installation: Phase 1 at 20,000 pallet positions, and Phase 2 adding another 10,000. Given the live environment, the installation was designed to keep operations moving. Specific zones were isolated for racking while adjacent areas remained operational, allowing 18 Wheels to continue moving and fulfilling product.  

The installation was completed in under eight weeks—a notable achievement given the size of the system and the added challenge of working within a live warehouse, highlighting the value of precise coordination.  

Cost-Effective Seismic Engineering:

Rather than rely on default seismic values, 18 Wheels provided us with a geotechnical investigation report containing a defined average shear-wave velocity (Vs₃₀) reading (a measure of ground stability across the upper 30 meters of soil).  

With that information, NAS was able to engineer the system to a lower seismic site class, resulting in lighter frames and meaningful cost savings without compromising structural integrity. This approach helped reduce material cost significantly, while maintaining structural integrity and code compliance across the racking system.  

Value-Engineered Custom Brace Pattern

We optimized the frame with a customized, 24-inch brace pattern at the base—eliminating the need for more expensive double-posting, with the design tailored to the project’s specific seismic classification. Based on the presence of a bottom beam, 18-inch clip-on post guards were installed, extending higher up the frame to ensure coverage where contact is most likely. 

Results and Impact

Phase 1 of the racking system delivered 88,740 sq ft of pallet storage, giving 18 Wheels a robust foundation as it scales operations in Eastern Canada. The system is designed for adaptability, with Phase 2 and reconfiguration options already accounted for in the layout. 

By using the client’s geotechnical report and responding quickly to evolving site needs, we reduced material costs and kept the project on schedule, resulting in a system designed to support fast-paced growth. Projects like this demonstrate how tailored engineering and thoughtful phasing can support both immediate operations and long-term growth. 

We continue to deliver systems that fit the way today’s dynamic industries operate—efficient, adaptable, and built to keep up with change. If you’re planning a new facility or working through an upgrade, we can help you build a solution around your unique space, timeline, and goals. 

Our client, a leader in the construction and building products industry, approached us to facilitate the transition from their existing Illinois distribution center to a new, larger, integrated facility to meet growing demand. Known for their extensive selection of industry-leading brands in the USA, they aimed to enhance their distribution capabilities and service delivery with this new integrated distribution center (DC). While the Chicago project was underway, the client presented a second project: the construction of a new DC in Los Angeles. We worked on both projects simultaneously at different stages, optimizing design and functionality to meet their unique operational needs.

Challenges Faced

Complex Product Requirements:

The client’s diverse product range posed significant challenges, requiring high selectivity and specialized storage solutions. With products varying greatly in size, weight, and shape, the need for a mix of racking systems became apparent.

Geographical and Seismic Considerations:

With the construction of a new distribution center in Chicago and a smaller one in Los Angeles, each location presented distinct challenges. The Chicago facility, located in a low to medium seismic zone, required a design accommodating a wide range of products. In contrast, the Los Angeles facility was situated in a high seismic zone, necessitating specialized engineering solutions to ensure safety and compliance.

Compliance Constraints:

Navigating different regulatory standards and permitting processes for each location required strategic planning and coordination with local municipality. Each facility had to comply with specific local standards, which involved detailed coordination with sprinkler, lighting, and regulatory teams.

Solutions

Early Project Involvement:

Our involvement from the project’s inception allowed us to work closely with building engineers, facilitating seamless integration of racking systems, safety features, and compliance with city regulations. This early collaboration ensured that every aspect of the design, from the slab to lighting and sprinklers, was aligned with the client’s goals, including budget.

Customized Design and Engineering:

• Chicago Facility: A sprawling 1.02 million sq. ft. warehouse with a 40-foot clear building height and 35-foot frames. The design incorporated: 
  • Selective VNA (Very Narrow Aisle): Optimized for high selectivity. 
  • Multiple Elevation Bays: Based on product history, these were incorporated to increase the density of the selective system. 
  • Drive-In and Cantilever Systems: Provided flexibility for bulk storage and irregularly shaped items. 
  • Additional Capacity: Added extra threshold space to accommodate potential future inventory increases, boasting ~65,000 pallet positions in racking and 25,000 in bulk storage. 

• Los Angeles Facility: A more compact 125,000 sq. ft. warehouse, featuring:
  • Single Selective System: Enhanced efficiency for fast-moving products. 
  • Custom Engineering Solutions: Addressed seismic considerations, with modifications like custom braces and base plates to ensure stability and safety, offering ~4,000 pallet positions in racking and 3,000 in bulk storage. 

Cross-Functional Coordination:

Collaborating with slab engineers, North American Steel optimized the racking design based on product weight and seismic factors. This included providing engineers with the highest post load data to ensure the slabs met safety requirements before pouring. Adjustments were made to designs, such as custom beam connections, to align with engineering feedback. 

Permitting and Compliance 

Through meticulous coordination with sprinkler, lighting, and regulatory teams, we ensured compliance with local standards for each distribution center. This proactive approach mitigated delays and streamlined the permitting process, overcoming specific compliance hurdles unique to each location. 

Results and Impact

Operational Efficiency and Capacity 

The new Chicago DC now supports more than three times the capacity of the previous facility, with improved operational efficiency and the ability to handle a larger proportion of inventory. The transformation to an integrated distribution center has positioned the client to better serve regional markets, reducing shipping times and costs. 

Safety and Compliance 

Both facilities were designed to meet the highest safety standards, particularly the Los Angeles DC, which adheres to stringent seismic requirements. The successful navigation of compliance challenges ensured safe and efficient operations. 

Strategic Market Positioning 

By strategically locating their distribution centers, the client enhanced service delivery across major population centers, reinforcing their position as an industry leader. The new integrated facilities reflect their commitment to high-quality service and operational excellence. 

Are you thinking about or in the process of acquiring a new facility? Get in touch with North American Steel early in your planning process. Our expert team can provide customized solutions that optimize your distribution center from the ground up, ensuring maximum efficiency, safety, and compliance. Contact us today to see how we can support your new facility’s success from the very beginning. 

A prominent bottling company recently expanded with a brand new 261,600-square-foot facility in Richmond, BC. This Richmond, BC site required a cutting-edge warehousing solution to manage its extensive inventory and optimize its operations. Enter North American Storage Equipment (NASECO), Western Canada’s leading pallet racking and shelving manufacturer for 20+ years. Leveraging our longstanding partnership, the client was confident in our ability to provide a comprehensive and customized solution for their complex needs.

Challenges Faced

High Storage Density Needs:

• With 7,750 pallet positions plus floor storage, the Richmond, BC location needed to maximize density without compromising accessibility.

Efficiency and Speed:

• Given the high volume of beverage distribution, it was crucial to design a system that allowed for quick and efficient pallet retrieval and placement.

Accommodating Consumption Spikes:

• To handle the increased consumption during holidays and major sporting events, a robust racking system was essential for this Richmond, BC-based operation.

Reuse of Old Racking:

• Additionally, the client wanted to incorporate and reuse old racking from their previous facility, requiring innovative solutions for integration and optimization.

Solutions

1. Deep Pushback Racking:

• Supporting high-density needs, this solution allowed pallets to be stored up to six deep, effectively utilizing space and enhancing inventory management at the Richmond, BC plant.

2. Deep Double-Wide Drive-In Racking (Twinlode):

• This unique system, popular in the beverage industry, is known for high pallet density than standard drive-in setups. It enables pallets to be stored two wide on a single pair of rails, significantly increasing storage capacity.

3. Selective Pallet Racking with Netting:

• The installation of selective racking with netting improved safety and organization by preventing pallet spillage and cross-contamination. It ensured secure storage, easy accessibility, and optimized vertical space while maintaining a clean and efficient warehouse environment.

4. Seamless Permit Coordination:

• Leveraging our extensive experience and knowledge, we facilitated the client’s permit application process in Richmond, BC. We ensured all documentation was accurately completed and submitted, guiding them through regulatory requirements to obtain necessary approvals efficiently.

Summary

NASECO’s strategic implementation, leveraging the capabilities of the client’s material handling equipment vendor, successfully addressed immediate warehousing challenges while providing a scalable solution for future growth at the Richmond, BC, site. The result is a seamlessly integrated warehousing facility that optimizes space, enhances operational efficiency, and meets the rigorous demands of the bottling industry. This collaboration highlights NASECO’s commitment to innovative solutions tailored to each client’s unique needs, demonstrating excellence in storage solutions and customer service by prioritizing client satisfaction and fostering enduring relationships.

Transform your warehousing challenges with a solution designed just for you. Contact Us today to find out how our customized approach can make a difference in your operations!

An electrical distributor expanding into the Squamish, BC area sought to elevate its storage capabilities for various electrical solutions—from automation and controls to LED lighting, datacom, and more. Recognizing the need for expertise in designing a tailored solution that seamlessly integrated these diverse elements, it turned to North American Storage, Western Canada’s largest pallet racking and shelving storage manufacturer.

Are you curious about the innovative storage solutions that powered our client’s success in Squamish? Dive into the details of our customized system, which elevated their operational capacity and productivity!

Challenges Faced

• Ensuring the racking fit and finish meets the buyer’s standards for presentation.
• Maintaining consistency in aesthetics across multiple locations with similar requirements.
• Accommodating specialized items including unique heavy-duty wire mesh decks and reel racking.
• Managing vendor packaging dimensions and weights posed a significant challenge due to the warehouse’s seismic nature, requiring expert analysis and precision for effective handling.

Solutions

1. Conduit Bundle Racking Solutions:

• Implemented a roll formed Selective Pallet Racking system, wire and reel racking system, and a structural Cantilever Racking system tailored for efficient storage and picking of electrical conduit bundles.
• The roll-formed selective rack and wire and reel rack systems were installed inside the facility at a height of 21 feet with a total number of 307 pallet positions. These pallet locations stored a range of product lines to support the electrical and network industry.
• The cantilever rack, situated outside and standing approximately 14 feet, allowed for storing 10-foot bundles of conduit tubing.

2. Timely & Budget-Friendly Branch Setup:

• Met the client’s urgent need to establish the branch by delivering and installing within a timeframe crucial for coordinating with other trades leading up to the grand opening.
• This commitment resulted in the successful completion of the project on time and within the allocated budget.

Summary

Through a blend of innovative design and precise execution, North American Storage successfully elevated the storage capabilities of an electrical distributors newest branch in Squamish, BC. By addressing the challenges of aesthetic consistency, handling unique load requirements, and accommodating the warehouse’s seismic nature, we delivered a tailored solution that significantly boosted operational efficiency and productivity.

Our customized system, featuring a roll-formed selective racking system, wire and reel racking system, and structural cantilever racking system, effectively organized and stored various electrical solutions.

The timely and budget-friendly setup ensured the client’s new branch was ready for operation, meeting their urgent requirements and aligning with their grand opening plans.

This project showcases our expertise in designing and implementing advanced storage solutions and reinforces our commitment to exceeding client expectations through quality, accuracy, and proficiency. We understand that every warehouse is unique, and our commitment to customization ensures that your specific storage needs are met with precision. Contact Us today to transform your storage capabilities and enhance your warehouse productivity!

In the dynamic landscape of warehouse management, challenges arose for a longstanding beverage distributor in Edmonton, AB, balancing scalability, and accessibility. This experienced industry leader, distributing canned and bottled liquids and concentrates to vendors across Alberta, turned to North American Storage to seek storage solutions for their expansive 150,000 sq ft warehouse. Join us as we explore how this top distributor tackled challenges, boosted efficiency, and strengthened its brand with North American Storage’s comprehensive services.

Challenges Faced

The beverage distributor faced various challenges, including ensuring scalability for SKU inventory and meeting the usability requirements of existing forklifts, such as minimum aisle widths, lift heights, and clearances. Also, positive experiences with installing stacking storage systems at the client’s other locations prompted a review for improved density options and floor stacking. With a more efficient storage solution becoming paramount, the company began exploring innovative options to optimize its warehouse space, leading them to partner with North American Storage.

Solutions

1. Structural Drive-In Racking System:

• Implemented a structural drive-in system, which offers the ability to group SKUs efficiently and provides the flexibility to assign tunnel locations to specific items and adjust allocation based on current demand.
• This system features 1745 pallet positions and stands at an impressive height of 23 feet, ensuring optimal use of vertical space while maintaining accessibility and adaptability.
• Its durability prevents accidental damage to racking, thus preventing storage locations from being taken out of service.

2. Corporate Branding:

• Using custom corporate colours helped the visibility of the racking and enhanced the client’s brand presence within the warehouse.

3. Client-Focused Integration:

• Collaborated closely with the client to comprehensively understand the specific product types and dimensions that needed to be accommodated.
• Additionally, we meticulously considered the delivery and installation time frame to ensure seamless execution.

Summary

The partnership with North American Storage yielded significant results for the prominent beverage distributor in Edmonton, AB. Implementing a structural drive-in racking system provided an impressive 1745 pallet positions, effectively increasing the distributor’s storage capacity within the same warehouse footprint. Maximizing vertical space usage allowed for more efficient grouping of SKUs, reducing the time and effort required for picking and restocking.

Moreover, integrating the client’s corporate branding into the racking improved visibility and strengthened the distributor’s brand presence within the warehouse. The durability of the structural drive-in racking system was also a notable benefit, as it minimized downtime caused by damaged racking, assuring that storage locations remained operational.

One of the key successes of the project was the seamless execution. Close collaboration with the client ensured that the delivery and installation of the new system were completed within the specified timeframe, minimizing disruptions to warehouse operations.

Don’t let storage challenges hold you back. Contact North American Storage today to explore how our comprehensive services can achieve your objectives, enhance efficiency, and fortify your brand identity within your warehouse.