Amazon Distribution Center – Kenosha

Kenosha, Wisconsin

The facility allows Amazon the greatest product density while keeping the building footprint to a manageable size.

This distribution and sortation project for Amazon includes a 1,017,879-square-foot fulfillment facility with 1,418,106 square feet of mezzanine and 514,000-square-foot sortation facility constructed on a 200 acre site.

Previously an active farm field, the site contained 180,000 cubic yards of over burdened topsoil, which was hauled off-site. Clayco overcame a brutally cold winter with frost depths up to 5’ and an excessively wet spring to complete the project on time and on budget.

This facility allows Amazon the greatest product density while keeping the building footprint to a manageable size by utilizing a series of stacked mezzanines in order to take advantage of all the available interior vertical space and the two buildings are connected via conveyor bridge.

The sortation facility is constructed of precast concrete walls, sloped TPO roof and a bridge to connect with the adjacent AR sort fulfillment center. The bridge was constructed following completion of the sortation center complete with fire rated coiling doors and wrapped in insulated metal panels. The sortation center comes complete with an MDF Room, an extensive security entrance, a battery charging area, and 110 dock positions. Coordination was key as drawings for the MHE came later in construction. The fire protection contractor had to add sprinklers underneath the conveyors in order for temporary occupancy to be achieved. The conveyors were installed by a contractor directly hired by Amazon and they didn’t begin construction until roughly 1 month before the temporary certificate of occupancy was scheduled. Many evenings and weekends were worked in order to maintain the TCO date and this was a huge accomplishment.

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Key Facts

Client:  Amazon
Project Value:  $113.5 M Fulfillment / $33.3 M Sortation
Size: 2,435,985 SF Fulfillment / 514,000 SF Sortation
Completion:  June 2015
Architect:  Ford & Associates Architects