We are proud to work with Pepsi on protecting its distribution center with a flood control system customized to its specific site.
Warehouses like Pepsi’s distribution center are fast-moving hubs that keep products flowing to stores and communities every day. When severe weather threatens warehouses, the stakes are high: delays in delivery, disrupted supply chain, inventory loss, damage to expensive equipment, and costly downtime.
Every distribution center has its own nuances, including varying elevations, high-traffic dock doors, critical electrical systems, and constant forklift movement. That’s why this project required more than a standard solution. It required a carefully designed system tailored to the building’s layout, loading docks, door openings, and operational demands.
Our team worked closely with the facility to design a flood control system that integrates seamlessly into daily operations while standing ready to deploy when needed.
The Challenge: Protecting a High-Volume Distribution Hub
Pepsi distribution centers are fast-paced environments. Forklifts move continuously, loading docks cycle trucks in and out all day, large overhead doors remain operational, product is stacked high, and mechanical and electrical systems power refrigeration, lighting, and automation.
For this installation, the facility faced exposure to heavy rainfall events and storm-driven flooding with the most vulnerable areas including:
- Loading Docks - Large dock doors are frequent entry points for water. Custom barriers must accommodate the size of the entryway.
- Overhead Doors - Large warehouse doors require engineered flood panels or deployable barriers that maintain structural integrity under hydrostatic pressure.
- Personnel Doors - Even standard entry doors can become major points of intrusion during flood events.
- Utility Penetrations & Mechanical Rooms - Electrical rooms, refrigeration systems, and control panels must be protected to prevent catastrophic downtime.
- Perimeter Gaps - Uneven grading, expansion joints, and transitions between building materials create vulnerabilities that standard products cannot address.
Each of these areas requires precise measurement, engineering calculations, and tailored design.
The FRA Difference: Architectural Designers in Every Project
One of the defining elements of this Pepsi installation was FRA’s involvement of architectural designers from the start. Why does that matter? Our architectural designers bring a deep understanding of building codes, facility operations, and structural systems to every project. They:
- Analyze building elevations, thresholds, and drainage patterns
Evaluate industry-specific requirements and operational flow - Coordinate flood control system placements to maintain accessibility and logistics
- Ensure compatibility with existing structural elements
- Produce detailed shop drawings for custom flood panels to guarantee a precise, watertight fit
By combining technical knowledge with advanced flood prevention products, our team ensures every custom flood control system is engineered to fit exactly as intended - both structurally and operationally.
For the Pepsi distribution center, this meant delivering custom-fabricated barriers designed to accommodate dock height variations and reinforced door openings, all while preserving daily logistics and ensuring a secure, watertight seal.
The FRA Flood Panel
When it comes to protecting high-traffic facilities like distribution centers, speed and simplicity matter just as much as strength. The FRA Flood Panel is engineered for rapid deployment with minimal disruption, ensuring operations can continue soon after the storm passes with little to no recovery efforts.
At the Pepsi distribution center, the system was specifically designed so on-site staff could install it quickly and efficiently without the need for specialized crews or complicated procedures.
Key benefits of The FRA Flood Panel include:
- Lightweight Yet Durable Construction - Panels are easy to handle at 5lb PSF while maintaining structural integrity under flood loads.
- Minimal Operational Disruption - Unlike permanent flood walls or complex mechanical systems that interfere with daily operations, The FRA Flood Panel is designed to stay out of the way until it’s needed. Panels are stored efficiently, deploy only during storm events, and can be quickly dismantled once the storm passes.
- Rapid Deployment - Straightforward installation steps with easy-turn knobs reduce downtime and keep logistics moving.
- Engineered Watertight Sealing - Precision-designed gaskets and sealing systems ensure reliable water protection.
The result is a high-performance warehouse flood control system that activates quickly, protects critical assets, and integrates seamlessly into daily operations without slowing business down.
A Flood Control System That Protects Product, People, and Supply Chains
Flooding in a distribution center doesn’t just impact one building - it affects retailers, employees, and communities that rely on timely deliveries. By installing a custom flood control system, this Pepsi distribution center strengthened its resilience against severe weather events while safeguarding inventory, infrastructure, and operational continuity.
This project demonstrates that effective flood mitigation needs to be site-specific and backed by flood experts, not generic. At Flood Risk America, we design warehouse flood protection solutions for facilities where downtime isn’t an option. Contact us today to speak to a flood expert.