A comprehensive industrial warehouse transformation featuring state-of-the-art loading dock systems, 3-phase electrical upgrades, high-bay LED lighting, climate-controlled storage zones, and full OSHA compliance — delivered on time in 14 weeks.
Tell Projects TX was engaged to execute a full-scale renovation of a 25,000 sqft distribution warehouse in Katy, TX serving a regional logistics operator. The facility had reached the end of its functional life cycle — aging dock equipment, undersized electrical infrastructure, and inadequate lighting were impacting throughput and worker safety.
Our team delivered a phased renovation plan that allowed the facility to maintain reduced operations throughout the project. Structural reinforcements supported an expanded mezzanine for 3,000 sqft of modernized office space, while ground-floor operations received automated dock levelers, 3-phase power upgrades, and a complete high-bay LED lighting system.
Climate-controlled storage zones were carved out using VRF HVAC technology, enabling the client to store temperature-sensitive inventory without offsite rental costs. Fire suppression was upgraded to a wet-pipe NFPA 13 system covering all bays and the new mezzanine office.
The project was delivered on schedule in 14 weeks with zero recordable safety incidents, achieving 100% OSHA compliance and a 45% reduction in energy costs against baseline.
From loading dock upgrades to high-bay LED installation — a visual record of the transformation.
Every system in this Katy, TX warehouse was assessed, upgraded, and brought to modern operational standards.
Installed 8 automated dock levelers with hydraulic lip plates, weatherseals, and safety lights. Added dock bumpers, wheel restraints, and leveler control panels meeting OSHA 1910.178 standards.
Upgraded service entrance to 1,200A 3-phase, installed new switchgear, ran dedicated circuits for fork lifts and heavy machinery, and added EV charger infrastructure for fleet electrification.
Replaced 400W metal halide fixtures with 240W UFO LED high-bays achieving 50fc average floor illuminance. Added motion-sensing controls and emergency backup lighting throughout all zones.
Constructed 3,000 sqft mezzanine office space with open-plan workstations, private conference rooms, break area, ADA-compliant restrooms, and data/telecommunications infrastructure.
Created four climate-controlled storage zones using VRF HVAC technology. Zones maintain 55–75°F independently, enabling temperature-sensitive inventory storage and reducing spoilage.
Repaired and reinforced existing slab, applied 3-coat industrial epoxy flooring system rated for 8,000 lbs/sqft. Painted aisle markings, forklift lanes, and safety zones per OSHA standards.
Installed NFPA 13 wet-pipe sprinkler system throughout the warehouse floor and mezzanine. Upgraded fire alarm panel, added smoke/heat detectors, and completed fire marshal inspection sign-off.
Installed IP camera network with 64-channel NVR, access control on all dock doors and personnel entry points, perimeter lighting, and remote monitoring integration for 24/7 visibility.
Every large-scale industrial renovation presents unique engineering and logistical challenges. Our team anticipated each obstacle and deployed proven solutions to keep the project on track.
The client required 40% operational capacity throughout construction. We implemented strict work zone partitioning with temporary barriers, maintained clear forklift lanes at all times, and scheduled concrete and electrical work during weekend shutdowns.
Delivering and staging industrial electrical switchgear, dock leveler components, and HVAC rooftop units required precise crane scheduling and temporary road closures coordinated with Katy city traffic control to avoid disrupting adjacent tenants.
Upgrading from single-phase to 3-phase power while maintaining live production circuits required meticulous load calculations, temporary generator supply, and close coordination with CenterPoint Energy for the new service entrance installation.
Engineering four distinct climate zones within one open warehouse required thermal break wall systems, vapor barriers, and precise airflow modeling to prevent condensation, cross-contamination, and thermal bridging between adjacent zones.
Only commercial-rated, long-life materials were specified for this Katy, TX warehouse project to ensure decades of reliable performance under heavy industrial use.
Our phased construction methodology ensured minimal disruption to the client's operations while maintaining strict quality controls and safety standards throughout the 14-week renovation of this Katy, TX distribution warehouse.
Talk to a Project ManagerStructural assessment, load calculations, electrical design drawings, HVAC engineering, fire suppression plans, and permitting with the City of Katy Building Department. Procurement orders placed for long-lead items including switchgear and dock levelers.
Mezzanine steel erection and concrete deck pour, electrical service entrance upgrade with CenterPoint coordination, 3-phase switchgear installation, and underground conduit runs. Dock pit modifications and floor slab repairs completed.
High-bay LED fixture installation, climate zone wall framing and VRF HVAC rough-in, fire suppression piping, office interior build-out, epoxy flooring application, security system rough-in, and dock door installation with automated levelers.
System commissioning and testing, fire suppression flow tests, electrical load testing and arc flash study, HVAC balancing across all climate zones, fire marshal inspection, final walkthrough, punch list completion, and Certificate of Occupancy issuance.
"Tell Projects TX transformed our aging warehouse into a world-class distribution facility. The phased approach meant we never fully shut down, and they delivered every milestone on schedule across all 14 weeks. The new loading dock system alone cut our truck turnaround time by 60%. Our energy bills dropped 45% thanks to the LED lighting and VRF HVAC zones. Most importantly, our team feels genuinely safe in the facility now. If you have a warehouse project in Katy, there is no one else to call."
Quantified improvements measured 90 days post-completion compared to pre-renovation baseline.
Reduction in monthly utility costs from LED lighting upgrade and VRF HVAC system efficiency.
Improvement in truck turnaround time from automated dock levelers and optimized dock workflow.
Increase in usable storage capacity from climate zone optimization and improved racking layout.
Full compliance achieved on first inspection — zero deficiencies cited by the OSHA inspector.
A structured four-phase process refined over 15 years of industrial construction in the Katy, TX area.
We conduct a comprehensive site survey covering structural integrity, electrical capacity, fire code compliance, and operational workflow to identify every improvement opportunity.
Licensed engineers produce stamped drawings for all systems. We handle all permitting with the City of Katy and Harris County, and coordinate utility upgrades with providers.
Our phased approach allows your operations to continue at reduced capacity. Dedicated site supervisors provide daily progress updates and manage all subcontractor coordination.
Before handover, every system undergoes full commissioning and operational testing. We resolve all punch list items before Certificate of Occupancy and final sign-off.
Common questions from Katy, TX business owners planning industrial warehouse upgrades.
Join the Katy, TX businesses that have transformed their industrial operations with Tell Projects TX. Licensed, insured, and experienced in large-scale warehouse and industrial renovations. Free consultation — no obligation.
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