U.S. Coast Guard Moore Warehouse Complex
A critical logistics hub consolidates into a single modern facility, overcoming schedule pressure and active site constraints while delivering high-capacity storage, uninterrupted operations and daily fleet support.
Project
Overview
The U.S. Coast Guard needed a solution.
Parts, equipment and avionics supporting the Atlantic Coast fleet were housed across aging facilities that could no longer support modern inventory systems or high-rack storage.
At the same time, ongoing storage costs in the Baltimore area made speed of delivery essential. The solution had to consolidate operations, protect critical assets and be built without interrupting daily Coast Guard activity.
Butler® pre-engineered building systems formed the backbone of a fast-track approach that prioritized certainty and coordination.
The Coast Guard Facilities Design and Construction Center Atlantic was tasked with delivering a centralized warehouse, office and electronics laboratory capable of supporting state of the art logistics and testing.
The new complex would include a two-story office and lab facility totaling 24,000 square feet and an attached 116,000 square foot warehouse designed for high-rack storage and automated retrieval. The warehouse would ultimately store more than 3 million pieces of inventory valued at over $240 million.
The warehouse utilized a clearspan structural system to achieve a 40-foot clear height with long span column spacing, supporting efficient storage and material flow. The office and laboratory building was designed using another clearspan structural system, allowing flexible interior layouts for administrative and technical functions.
To maintain uninterrupted operations at the active yard, the project was executed in three carefully sequenced phases.
Phase I focused on construction of the new office and laboratory building, allowing administrative functions and avionics testing to relocate early.
Phase II included demolition of half of the existing warehouse and construction of the first portion of the new warehouse while operations continued nearby.
Phase III completed demolition and construction of the remaining warehouse area, allowing inventory to transition seamlessly into the new facility.
Throughout construction, base traffic was rerouted, hazardous materials were abated and nearby facilities such as the Yard Post Office and Base Entry Guardhouse remained fully operational.
The automated wire guided retrieval system required super-flat concrete floors, adding another layer of precision to execution. Existing steam from the Yard was repurposed for heating, and an unused geothermal sub ground system was relocated and integrated into the office building as a value-added solution.
The exterior envelope was completed using Shadowall™ metal wall systems and an MR-24® standing seam metal roof system. Together, these systems deliver durability, weather performance and long-term reliability suited to a coastal industrial environment.
From design through completion, the project was delivered in 16 months.
The facility now stands as the Coast Guard’s first state of the art high rack storage warehouse, built to perform under pressure while supporting the mission without interruption.
