Warehouse1 Material Handling Case Studies

The National Archives and Records Administration (NARA) retrofitted a library facility in Lewisville, Texas, to house millions of pages of official records and artifacts from the two-term administration of President George W. Bush. Given the irreplaceable nature of these materials, NARA required shelving that was both dust-free and capable of withstanding seismic activity. Warehouse1 provided and installed 1,850 sections of steel document storage shelving with an electrostatic powder-coated finish. Each unit was thoroughly cleaned using electrostatic cloths, and custom bracing was added for seismic stabilization. The completed shelving system exceeded NARA’s stringent “near perfect condition” requirements.

The National Archives and Records Administration’s Federal Records Centers in Lee’s Summit and Lenexa are 60 feet below the surface in excavated limestone caves. The constant low-60s temperature creates an ideal environment for preserving government records. To support expanding storage needs—both from the fully utilized 800,000 cubic feet at Lee’s Summit and the consolidation of records from the recently closed Bannister Road facility—NARA turned to Warehouse1. We designed, supplied, and installed compression shelving systems for both facilities, 4,000 sections in the Lee’s Summit Center and 4,700 sections in the Lenexa Center. The result: a stable, space-maximizing solution built for long-term archival storage.

The Florida Department of Health operates a 295,000-square-foot emergency response warehouse in Orlando to store and distribute relief supplies across the state during natural disasters. At full capacity—5,000 pallet positions of bottled water—the facility needed a smarter storage solution. Warehouse1 delivered. We designed, supplied, and installed a high-density drive-in pallet rack system that doubled storage capacity to 10,000 pallet positions—without increasing the building footprint. The result: 2x the storage and a 50% reduction in cost per pallet position. A full turnkey solution. Delivered on time. Built to scale. Now, the Department can respond faster—and store more—when every second counts.

The 159th Wing of the Louisiana Air National Guard identified a critical need for an integrated receiving, storage, and distribution system to support its operations at England Air National Guard Base (ANGB) in Alexandria, Louisiana. This initiative aimed to enhance the base’s logistical efficiency and optimize the handling of mission-critical equipment and supplies. Warehouse1 furnished and installed a pallet racking system designed to meet the base’s storage specifications, ensuring durability and optimal load capacity. To further enhance space efficiency, a mobile aisle shelving system was implemented, allowing for high-density storage with streamlined access and improved operational workflows.

This facility plays a critical role in supporting military readiness by packing supply bags for service members preparing for deployment. To meet the high-volume, precision needs of this operation, the project included tall, narrow aisle pushback racking systems. These racks optimize vertical space and enable efficient storage and retrieval, improving throughput and organization. To streamline the transition from storage to shipment, a custom conveyor system was also integrated. It moves the filled bags into 463L pallet containers—standardized cargo units for air transport—ensuring they are securely packed and ready for rapid loading onto aircraft.

The Kansas Air National Guard reached out to Cogan Wire & Metal Products Ltd. to explore the possibility of installing a small mezzanine to expand their functional space. Recognizing the need for a local partner to execute the project, Cogan brought in Warehouse1 as their trusted regional dealer. The Warehouse1 team consulted with the Kansas Air National Guard to define the project scope, funding parameters, and operational needs. We then designed and delivered a durable, code-compliant mezzanine tailored to space and load requirements, managing the project from start to finish.

The Hawaii Air National Guard Base faced recurring citations for failing to meet mandated organizational storage standards, highlighting the need for a more efficient solution. warehouse1 supplied materials and installed a custom mezzanine system designed by Wright-Patterson Air Force Base engineers, allowing 463L pallets to be stored both above and below the structure to maximize vertical space. We also provided and installed a secure cage area featuring a mobile aisle shelving system and pallet racking for organized, secure storage of sensitive materials. With the upgraded systems in place, the base is now fully compliant and utilizes its warehouse space effectively and efficiently.

Warehouse1 delivered and installed a fully integrated storage aid system to enhance efficiency, organization, and security across the facility. The solution included mobile aisle shelving for high-density storage, as well as pallet and selective racking to accommodate various material types. Expanded conveyor systems streamlined the movement of goods, while issue counters and totes improved the picking and distribution process. A secured storage area was also added to protect sensitive or high-value inventory. The system significantly improved storage capacity and overall workflow efficiency.

This project featured the installation of two Vertical Lift Modules (VLMs) manufactured by Diamond Phoenix Co.—the first units ever procured and installed through the Wright-Patterson contracting office. These high-density storage systems function similarly to vertical carousels but with enhanced automation and efficiency. The VLMs utilize integrated light beam sensors to measure the dimensions of loaded trays and automatically determine the most space-efficient storage position within the system. In addition to the VLMs, Warehouse1 installed a mobile aisle system with pallet racking to support organized storage of tools and supplies, further enhancing overall facility efficiency.

This project supported the Nevada Air National Guard at their newly constructed $9 million facility in Reno, NV, which houses the Telecommunications Corps on one side and the Security Forces Corps on the other. Warehouse1 was awarded a $140,000 contract for the design and installation of specialized storage solutions. Our scope included four mezzanines—two structural and two rack-supported—along with short pallet racking, three Lyons industrial cabinets, and five sets of heavy-duty removable casters for large multi-use pallets, each valued at $1,800. The base, along with the contracting officer and project engineer, was extremely satisfied with the outcome, and the project was delivered three weeks ahead of schedule.

Ramstein Air Base, headquarters for U.S. Air Forces in Europe, had reached capacity in its storage facilities, prompting the need for expanded and reconfigured material handling systems across two buildings. In the first, warehouse1 converted existing pallet racking into a narrow aisle system with order pickers and reach trucks. Custom guide rail joints eliminated welding or drilling, reducing installation time. The team also installed a portable office, issue counter, bar and pipe rack, 22 flammable cabinets, and a secure cage for high-value items. In the second building, warehouse1 installed 61 sections of cantilever racking for long and irregular materials. The project finished ahead of schedule and earned an A+ rating for execution.

Warehouse1 was awarded this project through the Department of Defense’s competitive bid process, demonstrating our ability to deliver value under strict federal standards. The scope included installing 104 sections of pallet racking to store mobility bags—deployment-ready supply kits for soldiers—along with upgraded fluorescent lighting for improved visibility and energy efficiency. We also built a 2,000-square-foot security cage and provided 44 heavy-duty worktables to support operations. After reviewing the original plans with Wright-Patterson project managers, Warehouse1 enhanced the design and upgraded materials to ensure long-term durability.

In partnership with Speedrack West, Warehouse1 delivered a customized three-level full/split case pick module for one of Mexico’s largest commercial bakeries near Mexico City. The rack-supported system features integrated multi-tier racking and conveyor designed to manage both full and broken case picking. The system was engineered to handle the bakery’s diverse SKU mix efficiently, reducing labor demands while offering modular flexibility for future scalability. This project reflects Warehouse1’s strength in deploying high-performance fulfillment systems in demanding, high-volume environments.

Blount International of Kansas City, a subsidiary of Oregon Cutting Systems Group, consolidated its Portland and Kansas City distribution operations into an expanded, centralized facility—doubling Blount Industrial’s footprint. The project required nearly $1 million in material handling equipment, including 500 pallet rack sections, 5,000 beams, 5,000 wire decks, 140 closed bin shelving sections, two mezzanines totaling 18,000 square feet, and two floor-to-mezzanine conveyors. With only 60 days from purchase order to completion, Warehouse1 delivered on time, meeting an aggressive deadline that few competitors could match. Blount International remains a valued customer and this project highlights Warehouse1’s ability to execute large-scale installations with speed and precision.

Chegg.com, a leader in online textbook rentals, expanded its distribution capacity with a new, state-of-the-art Distribution Center in Louisville, KY. Committed to environmental stewardship, Chegg not only recycles textbooks through its rental model but also plants a tree for every book rented. To align with these priorities, Chegg partnered with Warehouse1 to implement a green, cost-effective storage solution, installing 2,700 sections of reconditioned shelving and 20 steel-topped work benches made from pre-owned materials. By selecting Warehouse1’s reconditioned equipment, Chegg secured high-quality infrastructure while keeping valuable resources out of landfills.

Excelligence, a leading provider of learning materials for primary grade schools, selected Kansas City as the site for its new distribution center, drawn by the city’s central location and optimized shipping reach. To outfit the facility, Excelligence chose Warehouse1 over national competitors, citing exceptional service, flexibility, and deep product knowledge as key differentiators. Warehouse1 supplied a full range of material handling equipment including pallet racking, column guards, conveyors, packing stations, forklifts, pallet jacks, dock equipment, ladders, service carts, and personnel carts. Every solution was tailored to support fast-moving order fulfillment and safe material handling in a high-volume environment.

Houston’s Inc.—a distributor of restaurant equipment—relocated to a new distribution center in Kansas City, doubling its previous storage capacity. To support the expansion, Warehouse1 designed and installed a cost-effective selective pallet rack system. By integrating Houston’s existing racking with high-quality used racking sourced from Warehouse1’s inventory and partner network, we delivered substantial savings over the cost of a fully new system. The result exceeded expectations. Mike Buddrius, Houston’s Warehouse Operations Manager, flew in from corporate headquarters in Wilsonville, Oregon, and confirmed the system’s performance was on par with new—at a fraction of the cost.

Following its acquisition of a competitor, McCall's Patterns faced the challenge of absorbing additional inventory and fulfillment operations into its existing facility. To support this integration, the company partnered with Warehouse1 to design and install a two-level, shelf-supported pick module that maximized space and efficiency. Each level spans 6,000 square feet, providing a total of 12,000 square feet of high-density storage. McCall's reused shelving components from both facilities, supplemented with materials from Warehouse1’s inventory. Warehouse1 also engineered and furnished the catwalk, railings, and stairs, ensuring safe, efficient movement between levels while minimizing operational disruption.

MCR Safety, a leader in personal protective equipment, expanded its logistics footprint with a new distribution center just outside Memphis, in Piperton, Tennessee. To support the scale and complexity of the facility, the company partnered with Warehouse1 for full project management and systems integration. Warehouse1 managed the procurement and installation of over 3 million pounds of pallet rack and allied material, coordinating across four manufacturers to ensure seamless execution. The project delivered optimized storage, product accessibility, and scalability—demonstrating Warehouse1’s ability to execute complex, high-volume distribution solutions.

As Plastic Enterprises experienced significant growth, the company needed to expand storage capacity by adding a new warehouse to its manufacturing facility and consolidating a separate offsite warehouse 10 miles away. To support the project, Plastic Enterprises and McCownGordon, the general contractor, invited Warehouse1 and three other material handling firms to submit proposals for the design, furnishing, and installation of a pallet storage system. Warehouse1’s solution exceeded pallet storage requirements by 15%, offering a more efficient and scalable system than competing bids. Impressed by the results, Plastic Enterprises also asked Warehouse1 to optimize the storage layout in their original warehouse.

In a multi-phase project, Warehouse1 supported NAPA’s growing operational demands by optimizing multiple warehouse areas. The project began with the installation of new pallet racking in a newly constructed warehouse, providing increases in storage capacity. Next, existing shelving in the primary warehouse was reconfigured, and a two-level mezzanine system with bar grating and integrated catwalks was installed to create safe, elevated storage access. Then, additional shelving was deployed on an existing mezzanine platform, further maximizing vertical space. To complete the upgrade, conveyor systems were installed to streamline material handling—enhancing opperational speed, accuracy, and throughput.