Roush Delivery Service
PEMB optimized for 360° dock flow
2019
Roush Delivery Service
The Project
A 30,000-square-foot pre-engineered metal building (PEMB) tailored for distribution and logistics, Roush Delivery Service combines a generous clear-span warehouse with 3,500 square feet of heated and cooled office space arranged over two stories. The facility features dock-high access on all sides (“360” dock configuration), multiple 12-foot overhead doors with edge or pit levelers, translucent light panels to brighten the warehouse, and a concrete ramp from parking into the building to streamline receiving. The design maximized PEMB economy while customizing circulation, access, and interior environment to suit intensive delivery operations and varied truck types.
The Challenge
The project demanded squeezing high operational flexibility and occupant comfort from a cost-effective PEMB shell. Typical PEMB limitations—column spacing, wall penetrations, and standard anchorage—needed creative mitigation to provide full dock-high access around the building, accommodate varied truck heights and levelers, incorporate a two-story office within the shell, and introduce daylight without compromising wall strength or thermal performance. The client also required efficient circulation for rapid truck turnaround, robust slab design for heavy loading, and detailing that supported quick erection and long-term maintenance in a coastal climate.
The Solution
By treating the PEMB as a highly adaptable platform, the design team customized door layouts, leveler types and a concrete ramp to create multiple practical approaches for loading and unloading. The office suites were thoughtfully sited and stacked to minimize interference with warehouse operations while maintaining clear sightlines for supervision. Translucent roof and wall panels were strategically placed to introduce daylight deep into the building without weakening critical load paths, and the slab and foundation detailing were reinforced in high-traffic zones to resist concentrated wheel loads and prevent differential settlement. Anchor and hold-down designs accounted for local wind demands and coordinated with the PEMB manufacturer to ensure accurate field alignment. The result balanced PEMB cost-efficiency with operational, thermal, and durability upgrades meaningful for a high-throughput distribution hub.
The Improvements
Operational throughput was improved through full-perimeter dock access, a variety of leveler solutions, and a site ramp that offers alternate receiving paths. Daylighting panels reduced reliance on artificial light during daytime hours, improving working conditions for staff and lowering energy use. Reinforced slab zones and considered jointing helped the floor withstand heavy forklift and truck traffic, lowering maintenance needs. The two-story office build-out provided climate-controlled administrative space with direct visual connection to warehouse activity, enhancing management and safety. Coordination with the PEMB vendor and contractor minimized field changes and sped erection.
The Results
Roush Delivery Service opened as a high-functioning distribution facility that leverages PEMB affordability while meeting the practical demands of modern logistics. The dock-high “360” configuration, combined with varied leveler options and a receiving ramp, increased truck handling capacity and reduced turnaround times. Improved daylighting and dedicated office space supported a safer, more comfortable workplace for staff. Durable slab and anchorage design reduced anticipated lifecycle repairs, and the coordinated design-delivery approach helped the project meet schedule and budget expectations.
