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Google Maps image of large distribution centre

Apr

2020

500,000 sq ft emergency distribution warehouse — UK (confidential 3PL)

Delivering a resilient Cisco network to a fixed go-live deadline

Network & Wi‑Fi design + build (warehouse + offices)

The problem (a site that had to be operational in weeks)

A brand-new warehouse needed to go from “empty shell” to a live, 24×7 operation on a non-negotiable deadline — with multiple trades on-site, a moving design, and no opportunity for the usual survey-and-build sequence.

The client had been a long-term 3PL partner, and we’d already delivered networks across dozens of their warehouses — but this engagement was different. The facility was new, and there was no racking, no comms infrastructure, and no existing network to extend.

The build programme was compressed. The warehouse layout evolved during the project (including changes to racking orientation), which meant network and Wi‑Fi decisions had to be made with incomplete physical context.

At the same time, the wider supply chain was under strain. Lead times were uncertain, site access needed tight coordination, and the usual “wait for the previous contractor to finish” approach wasn’t viable. Workstreams had to run in parallel without creating safety risks or rework.

What “good” looks like (outcomes)

A resilient Cisco LAN/WLAN that supports a 24×7 operation across warehouse and offices
Network and Wi‑Fi ready for go-live on the agreed date, despite layout changes and parallel trades
Structured comms spaces and cabling that scale as the site grows and operational processes mature
Evidence via validation: commissioning checks, post-install verification, and documented handover

Risk & Challenges

Compressed programme with a fixed “open the doors” deadline
Dependencies on other contractors (racking, electrical, fire suppression, CCTV/PA) working in the same zones
Layout changes mid-project (including racking re-orientation) affecting coverage assumptions and pathways
Limited ability to do a traditional predictive/active wireless survey before installation (the physical environment didn’t yet exist)
Working at heights and maintaining safe, clearly controlled work areas
Pre-agreed documentation for change control and approvals

Our approach (designing for reality, then validating in the finished space)

We treated this as a deadline-driven delivery programme: design from constraints, build a resilient core, keep the access layer modular, and validate once the environment was physically real — without relying on wishful assumptions or “rip-and-replace” thinking.

Rather than waiting for a finished warehouse that might arrive too late, we used a desktop-led design approach informed by real-world warehouse deployments we’d already delivered for the client. That allowed us to make practical decisions early (cabling pathways, comms-room strategy, cabinet locations, and resilience) while retaining the flexibility to adapt as the layout changed.

We built a high-availability core and distribution design first, then connected outlying areas via diversely routed fibre, so critical services could be commissioned early and expanded safely as zones became available.

On-site delivery was run as coordinated “handover windows” with other contractors: as soon as an area was released, the next trade moved in. That kept progress moving without compromising safety, documentation, or quality.

Deliverables (what the customer actually receives)

Core network design and implementation to support resilient 24×7 operations
Two main comms rooms with resilient power and structured cabling approach
Fibre backbone with diverse routing to reduce single points of failure
Distributed access switching across outlying wiring closets/cabinets
Warehouse and office Wi‑Fi design and installation, with post-install validation
Segmentation for third-party / tenanted networks (VRF configuration)
Installation, commissioning, and handover documentation aligned to change control
Weekly project coordination with the client team and on-site contractors