Atlantic Logistics Center.
Overview
No production downtime. Not on day one. Not on day fifty-two.
Atlantic Logistics runs a third-shift fulfillment operation that ships 11,000 packages a night. Their existing torch-down roof installed in 2003 had begun separating at seams above the high-bay forklift aisles, raising risk for inventory and ops floor. Replacement had been deferred for three years because nobody could imagine shutting it down.
We designed a 14-zone phased tear-off and SBS modified-bitumen rebuild over 52 working days. Every workday closed watertight; every shift change saw the same site they'd left. Zero packages delayed. Zero forklift incidents. Granulated cap-sheet finish, 20-year manufacturer warranty.
Approach
14 zones, 52 days, one set of dock doors that never closed.
What "no downtime" actually cost.
The premium for phased operations roofing is roughly 8–12% over a same-spec single-pour install a fraction of what a single shift of paused fulfillment would have cost.
Every zone required isolated tarping, dedicated dumpster routing, sequenced material delivery, and a cleanup pass that left the floor below clean enough for the third shift to start an hour later. Our foreman walked each zone with the ops manager at the start and end of every day.
Documentation
Selected frames
We told them "if a single package ships late we're out" and they delivered fifty-two days of perfect.
Related work
View archive →Operation can't stop?
Phased programs designed around your shift schedule. We'll engineer it before we quote it.