How to Maximize Storage for Pattern Boxes and Alloy Castings at a Steel Valve Manufacturer in Costa Mesa, California

CUSTOMER DESCRIPTION

World-Leading Designers & Manufacture of Automatic Control Valves

Since 1936, Cla-Val has been a global leader in the design and manufacture of automatic control valves for waterworks, fire protection, and industrial applications. Known for superior quality and engineering expertise, Cla-Val provides mission-critical solutions to municipal water utilities, shipbuilders, and military airbases. Their commitment to excellence and continuous innovation has made them a trusted partner in the most demanding fluid control environments worldwide.

PROJECT SCOPE OF WORK

Optimizing Every Cubic Foot of New Warehouse

The customer’s primary objective was to overhaul the storage capabilities of their new warehouse to accommodate massive, heavy-duty industrial piping. Given the extreme weight of the inventory, the project required a solution that balanced structural integrity with maximum density. Drawing on decades of engineering experience, we developed a custom-configured pallet racking system that optimized vertical height and aisle width.

Our precision design not only ensured 100% seismic and structural safety but also outperformed competitor quotes by delivering 18% more storage capacity within the exact same warehouse footprint. We ensured the system was not only space-efficient, but also fully compliant with rigorous California seismic and high-pile fire safety regulations for heavy industrial inventory.

CUSTOM SOLUTION

Designed Custom High-Value Storage Space

To handle the substantial weight of the inventory, we utilized structural steel components with high-capacity ratings, ensuring long-term durability and safety. The design prioritized utilizing all vertical space using custom frame heights that reached the building's maximum clear height, effectively turning "air" into high-value storage space. We optimized aisle widths to maintain a balance between high-density storage and forklift maneuverability, ensuring that Cla-Val’s team could access inventory quickly and safely.

A key part of our technical contribution was the integration of seismic engineering tailored for the Costa Mesa region. We provided heavy-duty base plates and specialized anchoring to meet strict local building codes. Furthermore, our design accounted for high-pile fire storage requirements, ensuring proper flue spaces and clearances were maintained to meet safety standards.

By applying our engineering expertise, we transformed a challenging product—heavy, awkward piping—into a streamlined, organized palletized system. This custom configuration successfully addressed the customer’s need for maximum density while providing a future-proof foundation for their growing distribution needs. The final installation delivered over 2,500 pallet positions, providing a level of efficiency that standard "out-of-the-box" racking solutions simply could not match.

OUTCOMES

Empty Warehouse to Optimized Distribution Hub

The project successfully transformed an empty warehouse into a high-performance distribution hub tailored for heavy-duty industrial inventory. By prioritizing structural integrity and spatial efficiency, we provided Cla-Val with significant long-term return on investment and the operational flexibility needed to manage their global supply chain. Our design turned a challenging footprint into a highly organized facility that exceeds all local safety standards.

THE C&SS DIFFERENCE

Tailored High-Density Storage Hub

We successfully transformed the empty warehouse into a high-density storage hub tailored for industrial loads:

• Custom engineered high-capacity pallet racking system

• Over 2,500 pallet positions optimized for heavy piping.

• 100% compliant safety and structural certification for the Costa Mesa facility.

• 18% higher storage capacity than competitor designs

• Streamlined inventory flow for mission-critical fluid control components