Project Spotlight: From Parking to Operational Power - Warehouse Layout

A Wisconsin beverage manufacturer needed more trailer capacity — but had no room to expand. See how Benchmark unlocked 25 additional slips by rethinking existing space.

CLIENT Challenge

The site was experiencing a shortage of trailer slips within its trailer lots, limiting operational flexibility and creating pressure on daily logistics. At the same time, the facility had no ability to expand the overall lot footprint, making traditional expansion options both costly and disruptive.

With space at a premium, the challenge was to increase capacity without expanding the site or significantly impacting ongoing operations.

Benchmark Insight

Benchmark evaluated the broader site layout and took a closer look at how space was being used across the facility. This included reviewing staffing levels and parking utilization trends.

Through this analysis, the team identified that an adjacent employee parking lot was no longer being fully utilized following staffing changes. What was once a necessary parking area had become underused space, presenting an opportunity to address the trailer capacity issue without expanding the site footprint.

Solution Implemented

Benchmark recommended and supported a targeted solution focused on making better use of existing space, including:

• Expanding the trailer lot 60 feet into the underutilized employee parking area

• Optimizing the layout to increase the number of trailer slips

• Removing and relocating existing security fencing to accommodate the new configuration

• Installing concrete dolly pads to properly support trailer landing gear

The solution avoided major pavement reconstruction and instead focused on strategic, low-cost modifications that delivered immediate operational benefits. 

Results & Value Delivered

• Added 25 trailer slips without expanding the overall site footprint

• Delivered a cost-effective solution with minimal construction scope and disruption

• Improved yard efficiency and trailer staging flexibility

• Repurposed underutilized space to better align with current operational needs

Why It Matters

This project demonstrates how thoughtful site analysis and cross-functional thinking can unlock value without the need for expensive expansion.

By aligning pavement design with operational needs and evolving staffing realities, Benchmark helped the client achieve meaningful improvements in capacity and efficiency while minimizing cost and disruption.

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