Home Improvement Retailer’s Distribution Center Design Stacks Up the Wins | Apex Project Spotlight
From Bulk to Brilliant: Distribution Center Design Boosts Efficiency for Global Retailer
Reimagining warehouse performance starts with a smart foundation. That’s exactly what this major home improvement retailer set out to build—and they partnered with Apex to make it happen.
This ambitious new construction project consolidated three older distribution centers into two side-by-side, state-of-the-art Stocking Distribution Centers (SDCs) totaling 1.3 million square feet.
The Apex team led the design and engineering of the storage racking systems and handled the project management and installation for both facilities. This project focused on building high-capacity storage for seasonal, imported, and oversized inventory.
The Challenge: Space, Access & Compliance
The retailer’s previous facilities were outdated and tight on space. Floor stacking limited access and made SKU management a headache—especially for oversized or oddly shaped items. The goal? Build smarter and consolidate with efficiency.
- Maximize storage space to efficiently access a high number of SKUs and oversized/hard-to-stack products, improving the previous bulk floor stacking method.
- Consolidate inventory from three outdated facilities into two co-located SDCs.
- Ensure compliance with current fire and insurance code requirements through properly engineered storage solutions.
The Apex Solution: High-Density, Code-Compliant Storage
Back-to-Back Double-Deep Pallet Rack
To get the most out of every inch, Apex designed a selective pallet racking system with back-to-back, double-deep configurations—creating a large number of SKU facings without sacrificing access or pick efficiency.
Key features include:
- Double-deep racking in back-to-back rows for efficient use of vertical and horizontal space.
- In-rack sprinkler systems with protective horizontal beams to safeguard pipes and equipment.
- Pallet backstops to maintain proper flue space between rack rows and satisfy fire safety codes.
- Overhead dock door racking to capture unused vertical space and extend capacity.
The result? Each building now supports roughly 37,000 pallet positions, with 98% of those in single- or double-deep selective racking.
Over Dock Door Racking
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The Payoff: Streamlined, Scalable Distribution
A new distribution center design brought three DCs together into two side-by-side facilities on one campus, delivering:
- Simplified logistics with reduced facility transfers.
- Higher SKU density and faster access to inventory.
- A scalable footprint ready for future growth and seasonal surges.
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| Double Deep Racking | Loaded Racking |
Warehouse Design That Works for You
This project proves that with thorough planning and expert distribution center design, you can hit your efficiency, safety, and long-term growth goals. Whether building new or retrofitting, Apex Companies brings the design, engineering, project management, and installation support to make it happen.
Let’s build smarter. Contact the Apex team to schedule your free consultation.
In-Rack Sprinkler & Piping Behind Rack Beam
