Warehouse Design & Space Planning in Irving, TX

Professional warehouse design & space planning for warehouses and industrial facilities in Irving, TX. Local expertise, OSHA-compliant work, free estimates.

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Warehouse Design & Space Planning Services in Irving, TX

Warehouse design in Irving has to accommodate the specific operational demands of each Irving submarket. Las Colinas corporate-distribution buildings often have higher-than-typical office-to-warehouse ratios because the tenant mix is corporate HQ with distribution attached — think pharmaceutical, consumer goods, or tech companies running regional distribution out of corporate facilities. SH 183 industrial buildings run more conventional warehouse-dominant layouts. DFW Airport cargo facilities are dock-heavy and staging-heavy with high-velocity pick operations.

Freeport property tax exemption drives design decisions on tenants claiming the exemption — inventory location tagging, slotting rules that separate Freeport and non-Freeport inventory, and WMS integration that documents the 175-day transit window. Those aren't structural requirements but they shape slotting and location-numbering schemes from day one.

FAA Part 77 imaginary-surface clearances can cap upper-bay rack heights on buildings within DFW approach paths. On projects in those corridors, we verify clearances before finalizing vertical design — there have been cases where a planned 40' clear rack layout needed to come down to 35' to stay under the surface. The check is done early so the rack spec, engineering package, and permit drawings all align. Related design work in Dallas and Grand Prairie on multi-site tenants uses the same hybrid-system framework.

About Our Warehouse Design & Space Planning Service

DFW Pallet Racking provides professional warehouse design and space planning services for businesses throughout the Dallas–Fort Worth metroplex. We begin with a thorough analysis of your current facility — measuring every inch, evaluating your inventory and workflow, and identifying underutilized zones and inefficiencies. From that foundation, our design team builds optimized warehouse layouts in detailed CAD drawings that maximize storage density, improve traffic flow, reduce picker travel time, and meet all applicable code requirements for egress, sprinkler clearance, and forklift aisle widths. Whether you are designing a new warehouse, expanding an existing one, or reconfiguring your current layout, we give you a data-driven plan and permit-ready drawings to execute it.

What's Included

Complete facility measurement and floor plan documentation
Inventory profiling, SKU slotting, and vertical space utilization analysis
Identification of underutilized zones and consolidation opportunities
Custom CAD warehouse layout drawings to scale
Traffic flow and forklift aisle planning for operational efficiency
Receiving, staging, and shipping zone design and optimization
Multiple layout options with comparative storage capacity analysis
Sprinkler clearance and egress path compliance built into all designs

Irving Warehouse Design Factors

Las Colinas corporate, SH 183 industrial, DFW Airport cargo, and FAA Part 77 — each shapes design differently.

Las Colinas corporate-distribution mix: higher office-to-warehouse ratios, moderate velocity, trained operators — design prioritizes flow and accuracy over raw cube density.
DFW Airport cargo: dock-heavy, staging-heavy, high-velocity pick — design prioritizes dock-side accessibility and fast throughput paths.
SH 183 industrial: conventional warehouse-dominant layouts, often in older 22'–26' clear buildings — selective on reach aisles is default.
Freeport compliance shapes slotting rules and location-numbering — tenants claiming Freeport need design-phase coordination with tax advisor and WMS.
FAA Part 77 imaginary surfaces cap upper-bay rack heights on specific buildings within DFW approach paths — verified before design finalization.
Newer Las Colinas and Pinnacle Park-adjacent buildings (2010s+) support 36'+ clear and hybrid systems; older stock caps lower.

Warehouse Design & Space Planning in Irving, TX: Common Questions

How does Las Colinas corporate-distribution design differ from conventional DC design?

Las Colinas corporate-distribution buildings typically have higher office-to-warehouse ratios (20%–35% office versus 5%–10% in conventional DCs), moderate velocity throughput, and trained career operators rather than rotating temporary labor. Design prioritizes flow accuracy and orderly pick paths over raw cube density. Selective rack on reach aisles is most common; deeper-storage systems rarely pencil because SKU velocity profiles don't justify them.

Can we maximize vertical cube in an Irving warehouse despite FAA Part 77?

On most Irving buildings, yes — the imaginary surfaces on most addresses sit well above typical rack heights. Where they do become a constraint (specific buildings in Las Colinas and the SH 114 corridor), we design to the maximum allowable height under the surface. On most Irving projects the vertical cube potential matches or exceeds comparable Dallas or Grand Prairie buildings.

How does Freeport compliance affect warehouse design?

Freeport compliance affects slotting and location-tagging more than structural design. Inventory claiming Freeport needs to be locatable by specific pallet position, dated by receipt and ship, and documentable as having moved through within 175 days. We design location-numbering schemes that support that level of documentation and coordinate with the tenant's WMS and tax advisor at design kickoff. Structural rack layout itself is typically unchanged.

What is design turnaround for a 500,000 sq ft Irving Las Colinas DC?

15–20 business days from site walk to permit-ready drawings for a 500,000 sq ft Las Colinas DC design with hybrid rack system, velocity-based slotting, dock-and-staging integration, FAA Part 77 clearance verification where applicable, and Texas-PE engineering package. Airport-property buildings add 1–2 weeks for DFW Airport Board document coordination.