Location: Fort Worth, Texas
Industry: Medical Equipment Distribution
Project Duration: 2 Weeks
Rental Term: Seasonal (May 1 – September 30)
The Challenge
A Fort Worth–based medical equipment distributor operates a 2 million square foot warehouse serving as a major distribution hub. The facility is older and relies on an outdated HVAC system that cannot adequately cool the most heavily utilized work zones.
With employees working long shifts in high-traffic areas, heat became a growing concern — especially during peak Texas summer months.
The customer needed:
- A cost-effective spot cooling solution
- Minimal equipment footprint
- Equipment that would not interfere with forklift traffic
- Installation within strict space limitations
The constraints were significant. 1Source Rentals was allotted:
- Two dock doors for equipment transitions
- A 10’ x 20’ space on the north end of the warehouse
The scale of the building combined with limited installation space required a carefully engineered solution.
The 1Source Solution
To maximize cooling capacity while minimizing footprint, 1Source deployed:
- (4) 25-Ton Units
- (2) 12-Ton Units
- (20) 1.5-Ton Spot Coolers
- 1,400 feet of layflat ducting
- House power supplied for all units
This combination created a large-scale, targeted cooling system designed specifically for the most occupied areas of the warehouse.
Installation Strategy & Execution
25-Ton Units – Dock Door Deployment
The team began by identifying the two dock doors designated for the 25-ton installations.
Once positioned, supply and return ducting was routed through the dock transitions. From there, the team moved vertically.
Because of the large amount of suspended layflat ducting required, the installation utilized:
- Two scissor lifts
- Teams of three per lift
- Two technicians in the lift (one dropping straps, one feeding layflat)
- One ground technician directing traffic and ensuring consistent tie-off height
Ducting was suspended high enough to avoid interference with the customer’s tall forklifts while still delivering effective airflow to occupied zones.
This configuration created a large-scale cooling station for the most active portion of the warehouse.
Once the 25-ton systems were operational, the team transitioned to the 12-ton units.
12-Ton Units – North-End Cooling Station
The customer provided a 10’ x 20’ footprint on the north end of the building for this portion of the system.
For these units:
- Condenser ducting was routed 35 feet up the wall
- Exhaust was vented through an existing louver
- Layflat was suspended with forklift clearance in mind
- Condensation lines were routed beneath the dock door
After wiring and commissioning (“wire and fire”), these units provided additional stationary cooling for fixed workspaces.
1.5-Ton Units – Flexible Spot Cooling
The 20 smaller 1.5-ton units were deployed as flexible spot cooling stations.
Because this warehouse does not have a typical grid tile ceiling, the solution incorporated exhaust stacks for proper ventilation.
This setup gave the customer flexibility to place units wherever cooling demand shifted — without being locked into a fixed configuration.
The Results
- Installation completed in approximately two weeks
- Large-scale targeted cooling delivered to high-traffic work areas
- Minimal operational disruption
- No interference with forklift traffic
- Cost-effective seasonal rental solution
The customer opted for a seasonal rental agreement (May 1 – September 30) to manage peak summer temperatures without investing in permanent HVAC upgrades.
The Impact
Cooling a 2 million square foot warehouse with limited installation space requires more than equipment — it requires strategy.
By combining large-tonnage units, extensive layflat distribution, and flexible spot coolers, 1Source Rentals delivered a scalable solution that improved working conditions while respecting space and operational constraints.
When permanent systems fall short, temporary solutions can make a major operational difference.