- Total pallets stored: 10,600
- Building size: 260,000 square feet
- Installation includes selective rack, carton flow, shelving (baby rack), and floor-mounted pallet flow
- 10-week completion from time of order
A New Facility with a Narrow Window
Ryder Logistics operates this warehouse on behalf of a major telecommunications client, supporting the storage and movement of a broad mix of inventory within a newly established distribution environment. Unlike a retrofit project, this was a clean-slate facility that needed to be equipped quickly, accurately, and in a way that could support multiple storage and picking functions from day one.
The size of the building and the variety of inventory requirements called for more than a standard rack layout. From the outset, the project involved a mix of storage systems designed to support pallet storage, carton picking, smaller-parts storage, and flow-through movement in key areas of the operation.
Building the Layout Around the Operation
The customer came to 3D Storage Solutions with a conceptual vision for how the warehouse should function. From there, 3D worked through the practical realities of translating that vision into a coordinated storage layout that could be manufactured, delivered, and installed on an aggressive schedule.
The final design incorporated:
- Selective pallet racking for primary storage
- Selective rack with pick levels below in designated areas
- Carton flow for box and tote picking
- Shelving (baby rack) for smaller parts and items
- Floor-mounted pallet flow in areas intended to support automated movement
This combination made the installation somewhat unique. While many facilities may combine one or two storage types, this project brought together four distinct systems within one integrated warehouse layout.
Speed as a Competitive Advantage
One of the defining aspects of the project was timing. 3D was awarded the work in part because it could move faster than competing suppliers. From the time of order, the first trucks began arriving on site in roughly five weeks, well ahead of what would more typically be a 12-week lead time.
That speed continued through installation. The full project moved from order to completion in just 10 weeks, including an approximately five-week install window. For a warehouse of this scale, with multiple storage systems and evolving layout considerations, that timeline was especially aggressive.
Designing Around Change and Site Constraints
Although the warehouse was new, the project still came with its own design complexities. The building included X-bracing between columns, which influenced how aisles and rack runs needed to be aligned to preserve forklift clearance and reduce the risk of impact.
Given the large-scale integration, the design required continuous calibration as the project progressed. The layout was refined through necessary revisions as the customer finalized space requirements in certain areas, particularly where automation would interact with the storage systems. 3D Storage Solutions responded swiftly, coordinating drawing changes, material planning, and installation sequencing to keep momentum and maintain the schedule.
That ability to adapt was a key part of the project’s success. Rather than treating changes as a barrier, the team worked through them while keeping delivery and installation on track.
A Coordinated Storage Solution for a Complex Warehouse
The completed facility now includes a coordinated mix of storage systems designed to support a high-volume logistics operation within a 260,000-square-foot footprint. With capacity for 10,600 pallets and dedicated areas for case picking, parts storage, and flow-based movement, the warehouse was built to support both immediate operational needs and future process integration.
The result is a large-scale, multi-system installation delivered under tight timelines and changing requirements, while still maintaining the level of precision needed for a new distribution environment. For Ryder, the project provided a storage foundation tailored to the realities of a modern warehouse operation. For 3D, it demonstrated the ability to deliver speed, flexibility, and execution across a complex build.
