Scalable RF Design for a Multi-Use 1.8M+ sq. ft. Facility
Client Profile
- Client Type
- Chemical Manufacturer
- Region
- AMER
- Industry
- Manufacturing
Categories
Overview
A client engaged TDI Vertical to architect and deploy a scalable, high-performance wireless network across a massive 1.8 million+ square foot facility. The space encompassed diverse use zones—including warehousing, offices, industrial operations, and expansive outdoor environments—all requiring seamless, reliable wireless coverage.
The goal was to deliver enterprise-grade wireless connectivity to support mission-critical workflows, mobility, voice services, and emerging IoT needs. TDI Vertical developed a comprehensive RF architecture to provide full coverage, withstand environmental challenges, and scale for future innovation.
Business Challenge
The client was building a new, multi-use site with a range of technical and architectural complexities:
- RF Interference & Structural Variability
The presence of metal racking, machinery, variable ceiling heights, and outdoor elements created difficult RF conditions. - Diverse Use Cases
Wireless support was required for everything from ruggedized warehouse devices and IoT sensors to voice-over-WiFi, video surveillance, and guest access. - Mobility & Roaming
Seamless indoor/outdoor roaming was essential for uninterrupted workflows and user satisfaction. - High Density & Coverage Requirements
The network needed to support thousands of devices, with optimized throughput and minimal latency across all zones.
The client needed a full-service wireless design partner capable of engineering a future-ready RF solution that delivered reliable performance from day one.
Solution & Design
TDI Vertical delivered an end-to-end RF and wireless infrastructure solution tailored to the facility’s size, complexity, and use cases. Key components of the engagement included:
- Active Wireless Site Survey
Conducted a real-world, on-site wireless survey across over 1.5 million square feet using enterprise-grade tools to measure signal strength, channel overlap, noise floor, and roaming behavior. - Indoor RF Design
Engineered access point (AP) placement and antenna types optimized for each zone—accounting for obstructions, ceiling structure, and client device density. - Outdoor Mesh Design
Created a wireless mesh architecture for courtyards, loading docks, and remote exterior zones using directional antennas and rugged APs. - Hardware Selection & Environmental Optimization
Chose hardware matched to environmental demands, including weatherproof enclosures and high-capacity APs for high-density zones. - Documentation & Deployment Planning
Delivered CAD-integrated RF heatmaps, performance simulations, channel plans, and controller templates to streamline implementation.
A phased deployment and validation process allowed for iterative optimization, ensuring strong performance and eliminating post-deployment rework.
Unique TDI Vertical Contributions
TDI Vertical brought a holistic and engineering-first approach to the RF challenge, backed by:
- Deep RF Design Expertise
Experience designing for complex environments with interference-heavy zones, mobility demands, and mixed device types. - Vendor-Agnostic Strategy
Focused on performance outcomes rather than specific technologies, aligning solution components to exact environmental and business needs. - Scalable Planning & Documentation
Provided futureproofed blueprints, including AP layout files, controller configs, and capacity planning for future IoT and user growth. - Field Validation & Real-World Modeling
Applied live testing and empirical validation techniques rather than relying solely on predictive models.
Results & Impact
The project delivered measurable and lasting value, including:
- 100% Targeted Coverage Achieved
Seamless wireless access across indoor and outdoor zones with performance above design thresholds. - 500+ Access Points Deployed & Validated
Strategic placement and tuning of indoor and outdoor APs for optimal client density support and reliability. - Mesh Mobility & Redundancy
Outdoor mesh network enabled seamless handoff and coverage continuity with built-in failover. - Operational Support Impact
Wireless-related helpdesk tickets dropped by over 75%, reducing IT burden and boosting workforce satisfaction. - Future-Ready Architecture
The RF blueprint supports upcoming initiatives including IoT, environmental sensors, and smart facility features.
The wireless infrastructure designed by TDI Vertical now forms the backbone of the client’s broader smart facility roadmap. With seamless coverage and robust performance in place, the organization is accelerating IoT adoption and connected workforce programs. TDI Vertical continues to support ongoing health assessments, tuning, and coverage extensions for new operational zones.
Leadership has recognized the project as a strategic enabler of efficiency, reliability, and employee satisfaction across the campus.
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