Lego

Designed and built for DHL, the Lego warehouse is a nearly 1.5-million-square-foot distribution facility.

This 1,440,000 SF distribution facility built for a global toy manufacturing company was successfully completed in just 8 months from the start of piers to the owner's move-in, demonstrating efficient project management and construction techniques.

The warehouse boasts a 36-foot clear height, maximizing vertical storage capacity and allowing for efficient racking and product handling. An ESFR fire protection system is installed throughout the facility to ensure safety, capable of quickly responding to fire hazards in a high-storage environment. The 7-inch reinforced concrete floor slab is engineered to withstand heavy equipment and constant forklift traffic, providing long-term durability for industrial use.

The facility is equipped with 150 dock positions, making it well-suited for handling a large number of inbound and outbound shipments. These docks are designed to ensure fast and efficient loading and unloading, which is essential for the rapid turnover required in the toy distribution industry. Additionally, there are 350 trailer parking positions to accommodate extensive trailer storage needs, ensuring flexibility in fleet management.

The roof system includes a 60-mil mechanically fastened TPO membrane with R-20 insulation, designed to provide weather protection and energy efficiency. The insulation helps maintain interior climate control, ensuring that products are stored in optimal conditions while reducing energy costs. The site also features a fully enclosed and fenced truck court, which adds an extra layer of security to the logistics operations. A dedicated guard house is positioned to monitor entry and exit, ensuring secure access for all vehicles.

The foundation is constructed on a 10-foot moisture-conditioned pad, ensuring stability and longevity of the structure. The exterior of the facility includes approximately 900,000 SF of 8-inch reinforced dock paving, designed to handle the heavy wear and tear from constant truck traffic. This paving provides durability for trailer maneuvering and loading operations, reducing maintenance needs over time.