The Challenge
A major goods distributor in Ontario was experiencing significant wireless connectivity issues inside its 400,000 square foot distribution centre.
Their operations depended heavily on reliable wireless coverage for handheld picking devices and autonomous machinery navigating warehouse aisles. As staff moved throughout the facility, intermittent signal dropouts led to operational inefficiencies, frustration, and potential fulfillment delays.
The client needed a fully redesigned wireless network capable of delivering stable, seamless coverage across the entire facility.
The Solution
CORE Cabling Inc. was engaged to lead a full redesign and rebuild of the facility’s wireless infrastructure.
The process began with an on-site Ekahau wireless site survey, capturing detailed measurements to create a data-driven design. Once the client confirmed their Cisco Meraki access point (AP) and antenna models, CORE’s engineering team integrated the equipment specifications into Ekahau’s design software. This allowed for highly accurate propagation modelling based on the specific hardware selected.
The initial design proposed approximately 160 APs to achieve 100% coverage at an aggressive signal threshold. However, upon budget review, CORE worked closely with the client to adjust coverage expectations. Areas of lower operational importance were identified where full redundancy wasn’t critical, allowing the design to be revised to approximately 100 APs while still ensuring reliable connectivity in all key operational zones.
Building a Scalable Backbone
The redesign also required a full overhaul of the structured cabling system to support the new wireless deployment. CORE installed new OM4 fibre optic cabling (10Gb capacity) from the Main Distribution Frame (MDF) to seven strategically placed Intermediate Distribution Frames (IDFs) throughout the facility.
Each IDF was fed via dedicated home-run fibre, eliminating daisy-chaining to ensure network integrity and simplify troubleshooting. Category 6 copper cabling was installed to support the APs, each limited to industry-standard 300-foot cable runs for performance certification.
Seamless Execution
A key requirement was to execute the cutover with minimal operational disruption. CORE developed a fully documented migration plan, mapping every connection to allow rapid rollback if necessary. The cutover was performed over a weekend, transitioning the entire facility to the new network without incident.
Following installation, CORE conducted a post-installation validation survey using Ekahau’s real-time monitoring tools. The post-survey heat maps confirmed that the deployed solution was performing as designed, delivering consistent coverage and stability.
Results
• Reliable, seamless wireless connectivity throughout critical operational zones
• Reduced AP count while meeting operational needs and budget constraints
• Fibre backbone providing 10Gb scalable capacity for future expansion
• Smart, adaptive Meraki system capable of real-time performance optimization
• Zero downtime during cutover; no service calls or issues since deployment
“This project demonstrates the kind of comprehensive, collaborative approach CORE brings to every client engagement,” says Ed Darlington, CEO of CORE Cabling Inc. “From wireless design and cabling infrastructure to seamless execution, our team ensures that every solution we deliver is engineered for long-term reliability and client confidence.”
CORE Cabling Services Featured:
• Ekahau wireless site surveys & design
• Cisco Meraki wireless deployment integration
• OM4 fibre optic backbone installation
• Structured cabling design & installation
• Post-deployment wireless validation surveys
Contact the CORE Team
For more information on CORE’s Structured Cabling and wireless network solutions, or to discuss your project with our team of professional installers, contact us today!
