Construction: Where Precision Engineering Meets On-Site Reality

The most elegant design, the most thoroughly planned project, the most precisely manufactured equipment—all converge at a single point of truth: the construction site. This is where engineered drawings become three-dimensional reality, where components fabricated thousands of miles away are assembled into functioning systems, where the vision that launched the project is finally validated—or challenged.

Construction is not merely installation. It is the critical discipline of translation—converting specifications into sequences, drawings into alignments, components into systems. It requires not only technical competence but project management rigor, safety discipline, and the ability to adapt when reality deviates from plans. A project perfectly designed but poorly constructed will fail. A project with design challenges but expert construction will succeed.

KINGSHELVING approaches construction with a fundamental conviction: installation is not an afterthought—it is a core competency. Our construction teams are not subcontractors assembled for each project; they are permanent, trained, and experienced professionals who have erected thousands of automated systems across dozens of countries. They bring to your site not only tools and skills, but the accumulated knowledge of decades of successful implementations.

• Core Positioning: The critical discipline of translation where engineering designs become operational reality; the on-site expertise that validates—or challenges—every prior project phase.

• Strategic Value: Converts precision manufacturing into functional systems; manages the complexity of site conditions, schedules, and coordination; delivers the project as designed, on time, and safely.

• KINGSHELVING Philosophy: Construction is not an afterthought—it is a core competency. Our teams are permanent professionals, not temporary subcontractors, bringing decades of accumulated experience to every site.

I. The Construction Imperative: Why Installation Defines Success

The Point of No Return
Construction is the phase where theoretical risks become real consequences. A clearance assumed in design but not achievable in the field becomes a collision. A sequence planned but not executed correctly becomes a delay. A safety procedure documented but not followed becomes an incident. There is no opportunity for redesign, no chance to revisit assumptions—only the immediate need to solve problems, maintain progress, and deliver quality.

The Coordination Challenge
A construction site is a complex ecosystem of activities:

• Multiple trades: Structural erectors, mechanical installers, electricians, controls technicians, general contractor crews

• Sequential dependencies: Racking must be installed before cranes can be erected; cranes before conveyors can be aligned; conveyors before controls can be tested

• Shared space: Equipment, materials, and personnel competing for limited space and access

• Dynamic conditions: Unforeseen site conditions, weather impacts, material delays, design clarifications

Successful construction manages this complexity through rigorous planning, clear communication, and disciplined execution.

The Quality Determinant
The quality of installation directly determines long-term system performance:

• Alignment: A rack that is plumb within tolerance ensures smooth crane travel for decades; one that is out of tolerance causes accelerated wear and premature failure

• Connections: Bolts torqued to specification transfer loads as designed; loose connections create stress concentrations and fatigue points

• Cleanliness: Debris left in conveyor paths causes jams; contamination in control panels causes failures

• Adjustments: Systems properly aligned and adjusted at installation require minimal ongoing maintenance; those rushed or skipped create chronic operational issues

The Safety Imperative
Construction is inherently hazardous. KINGSHELVING’s commitment to safety is absolute:

• Zero-incident culture: Every team member empowered to stop work if conditions are unsafe

• Comprehensive training: Site-specific safety orientation, task-specific training, regular refreshers

• Rigorous procedures: Documented safe work practices for all high-risk activities—lifting, working at height, electrical work

• Continuous oversight: On-site safety supervision, regular audits, incident investigation and prevention

• Point of no return: Construction is where design assumptions meet field reality—problems must be solved immediately, not redesigned.

• Coordination challenge: Multiple trades, sequential dependencies, shared space, dynamic conditions—managed through planning and discipline.

• Quality determinant: Installation quality—alignment, connections, cleanliness, adjustments—directly determines long-term system performance.

• Safety imperative: Absolute commitment to zero incidents through culture, training, procedures, and oversight.

II. The Construction Process: From Site Preparation to Mechanical Completion

Phase 1: Site Preparation and Mobilization
Before any equipment is installed, the site must be ready:

• Site assessment: Verification of site conditions against design assumptions—floor flatness, column locations, overhead clearances, utility availability

• Safety setup: Establishment of site safety protocols, emergency procedures, personal protective equipment requirements

• Mobilization: Delivery of tools, equipment, and materials; setup of site office, storage, and staging areas

• Coordination: Alignment with general contractor and other trades on schedule, access, and interfaces

Phase 2: Racking Installation
The structural foundation of the automated warehouse is erected first:

• Layout and marking: Precise layout of rack footings using laser instruments; column locations marked to ±2 mm accuracy

• Floor preparation: Verification of floor flatness; grinding or shimming as required to achieve specified tolerances

• Anchor installation: Drilling and setting of anchor bolts; torque verification; chemical anchors where specified

• Frame erection: Upright frames erected and temporarily braced; plumbness verified; final bolting

• Beam installation: Beams installed at specified levels; safety locks engaged; level verified

• Rail installation: Crane rails, shuttle rails installed and aligned to exacting tolerances

• Quality verification: Continuous inspection throughout; final survey of completed rack system

Phase 3: Equipment Installation
With the rack structure complete, automated equipment is installed:

• Crane installation: Masts, carriages, and drive systems erected; guide rails aligned; safety systems installed

• Shuttle installation: Shuttle vehicles placed on rails; commissioning mode verified; communication established

• Conveyor installation: Conveyor sections positioned, connected, and aligned; drives and sensors installed

• Lift installation: Lift towers erected; carriages installed; guide rails aligned; safety systems verified

• Workstation installation: Operator workstations positioned; ergonomic adjustments made; interfaces connected

Phase 4: Electrical and Controls Installation
The nervous system of the automated warehouse is installed:

• Power distribution: Main switchgear, panelboards, and branch circuits installed; proper grounding verified

• Control panels: Panels positioned, mounted, and connected; wiring verified against schematics

• Field wiring: Motors, sensors, and actuators wired to control panels; continuity and insulation tested

• Network installation: Switches, cabling, and wireless access points installed; network connectivity verified

• Safety system wiring: Emergency stops, light curtains, and safety interlocks wired and tested

Phase 5: Mechanical Completion and Handover to Commissioning
When installation is complete, the site is prepared for commissioning:

• Cleanliness verification: All debris removed; equipment cleaned; work areas restored

• Documentation: As-built drawings, test reports, and certifications compiled

• Punch list: Identification and resolution of any incomplete or non-conforming items

• Safety sign-off: Final verification of all safety systems and procedures

• Handover: Formal transfer of responsibility to commissioning team

• Phase 1 – Site preparation: Assessment, safety setup, mobilization, coordination.

• Phase 2 – Racking installation: Layout, floor prep, anchor installation, frame/beam erection, rail installation—continuous quality verification.

• Phase 3 – Equipment installation: Cranes, shuttles, conveyors, lifts, workstations positioned and aligned.

• Phase 4 – Electrical/controls installation: Power distribution, panels, field wiring, network, safety systems.

• Phase 5 – Mechanical completion: Cleanliness, documentation, punch list, safety sign-off, handover to commissioning.

III. Construction Management: Orchestrating Complexity

Project Planning
Every successful installation begins with a comprehensive plan:

• Schedule development: Detailed timeline showing all activities, dependencies, and milestones; integrated with overall project schedule

• Resource planning: Staffing plans, equipment requirements, material delivery schedules

• Risk assessment: Identification of potential challenges—site access, weather, coordination risks—with mitigation strategies

• Quality plan: Inspection and test plans for all critical activities; acceptance criteria defined

Site Management
On-site execution requires constant coordination and control:

• Daily coordination meetings: Alignment with general contractor and other trades on schedule, access, and issues

• Progress tracking: Daily reporting against plan; early identification of deviations; corrective action

• Material management: Receiving, storage, and handling of materials; inventory tracking; damage prevention

• Documentation control: Drawing revisions, specifications, and submittals managed; current versions available to all team members

Quality Management
Quality is not inspected in—it is built in through disciplined processes:

• Inspection and test plans: Defined hold points for critical activities; inspection before proceeding

• First-piece verification: First installation of each type inspected comprehensively; subsequent installations verified to standard

• Continuous inspection: Ongoing verification of alignment, torque, connections, and cleanliness

• Documentation: Complete records of all inspections, tests, and verifications

Safety Management
Safety is non-negotiable. KINGSHELVING’s safety program includes:

• Site-specific safety plan: Hazards identified; controls defined; emergency procedures documented

• Daily safety briefings: Toolbox talks covering day’s activities, hazards, and precautions

• Permit systems: Formal permits for high-risk activities—hot work, confined space, lifting

• Regular audits: Site safety inspections by supervision; third-party audits as required

• Incident reporting: Immediate reporting and investigation of all incidents and near-misses

• Project planning: Schedule, resource planning, risk assessment, quality plan.

• Site management: Daily coordination, progress tracking, material management, documentation control.

• Quality management: Inspection plans, first-piece verification, continuous inspection, documentation.

• Safety management: Site-specific plan, daily briefings, permit systems, regular audits, incident reporting.

IV. Specialized Construction Capabilities

High-Bay Installation
Automated warehouses increasingly reach heights of 25 meters and above. KINGSHELVING’s construction teams are equipped and trained for high-bay work:

• Specialized equipment: Scissor lifts, boom lifts, and mast climbers rated for high-bay access

• Fall protection: Comprehensive fall arrest systems; 100% tie-off required for all elevated work

• Precision alignment: Laser instruments and total stations for verifying plumb and level at height

• Sequenced erection: Systematic approach ensuring stability during construction

Cold Storage Construction
Freezer and cold storage environments present unique construction challenges:

• Cold-rated equipment: Tools and equipment rated for continuous -30°C operation

• Condensation control: Procedures to prevent moisture ingress and ice formation

• Personnel protection: Cold-weather gear, warm-up breaks, monitoring for cold stress

• Material handling: Materials staged to prevent freezing; special procedures for adhesives and coatings

• Phased work: Coordination with refrigeration system installation to minimize temperature excursions

Brownfield Installation
Installing new automation in operating facilities requires special approaches:

• Phased implementation: Work sequenced to maintain partial operations during construction

• Temporary protection: Barriers, dust screens, and protective covers to separate construction from operations

• Off-shift work: Night and weekend work to minimize impact on operations

• Logistics coordination: Material deliveries coordinated with operational schedules

• Communication: Constant coordination with facility management to manage expectations and address concerns

Multi-Site Rollouts
For clients deploying automation across multiple facilities, KINGSHELVING offers coordinated installation programs:

• Standardized processes: Consistent methods across all sites; lessons learned applied continuously

• Dedicated teams: Core teams that move from site to site, building expertise and efficiency

• Central coordination: Program management office overseeing all sites; consistent reporting and communication

• Supply chain synchronization: Coordinated material deliveries to multiple sites

• Knowledge transfer: Best practices documented and shared across sites

• High-bay installation: Specialized equipment, fall protection, precision alignment, sequenced erection for heights 25m+.

• Cold storage construction: Cold-rated equipment, condensation control, personnel protection, phased coordination with refrigeration.

• Brownfield installation: Phased implementation, temporary protection, off-shift work, logistics coordination, constant communication.

• Multi-site rollouts: Standardized processes, dedicated teams, central coordination, supply chain synchronization, knowledge transfer.

V. Quality Assurance in Construction

Pre-Installation Verification
Before installation begins, critical conditions are verified:

• Site readiness: Confirmation that site conditions match design assumptions—floor flatness, column locations, utilities

• Material verification: All materials checked against specifications; damage identified and addressed

• Foundation verification: Anchor bolt locations, projections, and alignment checked

• Coordination confirmation: Interfaces with other trades verified; conflicts resolved

In-Process Inspection
Quality is verified continuously throughout installation:

• Rack alignment: Plumb and level verified for every upright; beam elevations checked; rail straightness measured

• Connection verification: Bolt torques verified; welds inspected; safety locks engaged

• Equipment alignment: Crane rails checked for straightness and level; shuttle rails verified; conveyor alignments measured

• Electrical verification: Wiring checked against schematics; continuity and insulation tested; grounding verified

Testing and Validation
Before commissioning begins, systems are tested:

• Mechanical testing: Manual operation of moving equipment; clearance verification; interference checks

• Electrical testing: Power-up of control panels; motor rotation checks; sensor verification

• Safety system testing: Emergency stop functions; light curtain operation; interlock verification

• System integration testing: Communication between controllers and equipment; handshake verification

Documentation
Complete records are maintained throughout construction:

• Daily reports: Activities, progress, issues, and resolutions documented daily

• Inspection records: All inspections and tests documented with results

• As-built documentation: Record drawings showing actual installed conditions

• Material certifications: Certificates of compliance for all materials and components

• Pre-installation verification: Site readiness, material verification, foundation checks, coordination confirmation.

• In-process inspection: Rack alignment, connection verification, equipment alignment, electrical verification.

• Testing and validation: Mechanical, electrical, safety, and integration testing before commissioning.

• Documentation: Daily reports, inspection records, as-built drawings, material certifications.

VI. Safety: The Foundation of Everything

Safety Culture
KINGSHELVING’s safety approach is not just about rules—it is about culture:

• Leadership commitment: Management visibly demonstrates commitment to safety; safety performance is a key metric

• Worker empowerment: Every team member has authority and responsibility to stop work if conditions are unsafe

• Continuous learning: Incidents and near-misses investigated; lessons learned shared across all teams

• Recognition: Safe behavior recognized and celebrated; safety champions acknowledged

Hazard Identification and Control
All construction hazards are systematically addressed:

Training and Competency
Every team member is trained and qualified for their role:

• Site-specific orientation: All personnel trained on site rules, hazards, and emergency procedures

• Task-specific training: Operators trained on specific equipment; technicians trained on specific tasks

• Certification: Required certifications maintained—crane operation, rigging, electrical, welding

• Regular refreshers: Periodic training updates; toolbox talks on relevant topics

Emergency Preparedness
Every site is prepared for emergencies:

• Emergency plan: Documented procedures for fire, medical emergency, severe weather, other scenarios

• Emergency equipment: First aid kits, fire extinguishers, eyewash stations, emergency communication

• Drills: Regular emergency drills to ensure readiness

• Medical support: Trained first aid providers on site; emergency medical services contact information posted

• Safety culture: Leadership commitment, worker empowerment, continuous learning, recognition.

• Hazard control: Systematic identification and control of working at height, lifting, electrical, heavy equipment, confined space, chemical hazards.

• Training: Site orientation, task-specific training, certification, regular refreshers.

• Emergency preparedness: Emergency plan, equipment, drills, medical support.

VII. The KINGSHELVING Construction Advantage

Permanent, Experienced Workforce
Many construction teams are assembled for each project—temporary workers hired, trained, and dispersed. KINGSHELVING’s construction teams are permanent employees, not temporary subcontractors. They have installed thousands of systems across dozens of countries. They bring to your site not only skills but judgment—the ability to anticipate problems, adapt to conditions, and maintain quality when the unexpected occurs.

Integrated with Engineering
Because our construction teams work alongside our engineers daily, they understand not just how to install, but why systems are designed as they are. When field conditions require adaptation, they make informed decisions that preserve design intent. When they identify opportunities for improvement, that feedback flows directly back to engineering. This integration—rare in the industry—delivers better outcomes on every project.

Global Capability, Local Execution
KINGSHELVING constructs projects worldwide, but we execute them locally. Our teams include local personnel familiar with local codes, practices, and conditions. We maintain relationships with local subcontractors where needed. We understand the regulatory environment in every region where we work. You get the capability of a global organization with the responsiveness of a local partner.

Safety Record That Matters
Safety is not a slogan—it is a measurable outcome. KINGSHELVING’s safety record is among the best in our industry. We have completed millions of work-hours without a lost-time incident across multiple sites. This record is not accidental; it is the result of systematic investment in training, procedures, and culture. When you choose KINGSHELVING, you choose a partner that prioritizes your people’s safety as much as you do.

Schedule Reliability
Construction delays are the most common source of project overruns. KINGSHELVING’s construction teams deliver on schedule, consistently. Our detailed planning, experienced workforce, and integrated approach minimize the surprises that derail other projects. We understand the cost of delay to your operation, and we share your commitment to timely completion.

Your Design. Our Construction. Your System, Realized.

The automated warehouse that performs flawlessly for decades is not built by accident. It is built by disciplined, experienced construction—teams that understand the equipment they install, the designs they execute, and the operations they enable. It is built by people who take pride in alignment measured in millimeters, connections torqued to specification, and systems that function exactly as intended from the first day of operation.

KINGSHELVING’s construction capability delivers that disciplined execution. It takes the designs created by our engineers and the equipment manufactured in our facilities and transforms them into a functioning, reliable, high-performance automated warehouse. It manages the complexity of the site, the coordination of trades, and the challenges of the unexpected—delivering your project on time, on quality, and on safety.

When you entrust KINGSHELVING with construction, you are not merely hiring installers. You are investing in certainty—the confidence that your project will be executed by professionals who have done it before, who understand what success requires, and who share your commitment to quality, safety, and schedule.

Your design, our construction, your system—realized.