Project Summary
Crate & Barrel Distribution Centers

Teaming with The Keith Corporation, Choate completes multiple tilt wall distribution facilities to serve Crate & Barrel's east coast retail facilities.

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The Space
Square Footage 1,468,000
Location Newton, NC; Lincolnton, NC

Crate & Barrel Newton

Faced with climbing product demands, repeat client Crate & Barrel required a large-scale distribution facility in Newton, NC to meet its goals, maintain customer satisfaction, and drive profits. Working under a tight, 7.5-month schedule, the project team builds the concrete tilt wall and steel framed distribution warehouse, as well as 12,000 SF of upfitted office space.

Battling Weather Conditions

The 68-acre site is part of the Newton Corporate Center business park and required roughly 643,000 cubic yards of cut and fill operations before construction could begin.

At the commencement of construction and mass-grading operations in October, the project team encountered the damp, blustery weather late Fall provides. To combat the conditions – not to mention the remnants of several named storms that passed through the area – the team implemented more than 117,000 square yards of lime stabilization to treat the soil and maintain operations on track with the already-tight schedule.

Nailing Down the Proper Approach

Through a detailed logistics plan designed to meet an aggressive schedule, the team was able to proactively erect the steel core of the building before the perimeter tilt walls were complete. The team then executed a split tilt erection plan, wherein half of the tilt walls on the building were erected and connected to the steel. This strategy allowed the roofing process to begin on the first half of the building while the remaining tilt walls were placed.

Crate & Barrel Lincolnton

Crate & Barrel Distribution Center: This distribution for Crate and Barrel consists of structural steel and tilt walls. The steel has a 36-foot clear height and tilt panels approaching 45’ in height. There is 2,000 SF of office space and area for a future retail/outlet center within the facility.

Crate & Barrel Expansion: This project is constructed in two phases. The first phase includes earthwork to complete the expansion. The building construction, phase two, begins seven months later. This addition keeps the same structure as the original and includes 25 loading docks with 36-foot clearing and 2,000 SF of office space. This distribution center is used exclusively for Crate and Barrel’s furniture lines, most of which are manufactured in western North Carolina.

Crate & Barrel Distribution Center II: This Crate and Barrel distribution center is 360,000 SF and expandable to 600,000 SF. For the site development, 500,000 CY of soil was moved. The building is also fitted for a possible future retail store in its base. This project was the first distribution center for Choate that has received LEED Silver certification from the USGBC.

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