Summary
Building type: Large warehouse
Challenge: 5G coverage for forklift scanners
Product installed: Titan iR4 repeater
The Background
Ace Express Freight is an established freight and logistics company based in Lusk, Co. Dublin. The company provides a broad range of freight services by road, sea, and air. Its impressive global network of world-class partners spans over 173 countries, while its combined warehousing facilities accommodate approximately 25,000 pallets.
The management team is widely recognised for its excellence and has been awarded Deloitte’s Best Managed Company award 13 years in a row.
The Challenge
The company’s warehouse facilities have a combined capacity of over 235,000 square feet and can accommodate more than 25,000 pallets. To maintain tight operational schedules within such a large space, forklifts operate around the clock, continuously scanning pallets, stacking, moving, and loading goods. In this high-pressure environment, where every minute counts, efficiency is critical. Any delay in scanning or in receiving real-time updates from the server can result in shipment delays, frustrated customers, and potentially lost business.
Warehouse management identified that mobile signal coverage inside the facilities was extremely poor. Forklift operations rely heavily on 5G connectivity for scanning and real-time stock updates. However, modern construction materials — including triple-glazed windows, steel frameworks, and metal-clad walls — significantly block mobile signals from entering the building. In addition, pallets stacked from floor to ceiling further obstruct signal distribution throughout the warehouse. As a result, forklift operations slowed considerably, leading to costly delays.
The objective
Management decided to take immediate action to resolve the mobile connectivity challenges. Novatel, a trusted partner of Stella Doradus, was selected due to its proven expertise in delivering mobile signal repeater solutions.The requirement was clear: robust and reliable 5G coverage across the entire warehouse facility to ensure forklift scanners could operate efficiently at all times.
The requirement was clear: robust and reliable 5G coverage across the entire warehouse facility to ensure forklift scanners could operate efficiently at all times.
The Solution
As a first step, Novatel conducted a site survey using TestTool to assess the RF environment and mobile signal presence in different parts of the warehouse. Based on the survey findings and the client’s requirements, the Novatel team selected Stella Doradus Titan iR4 repeater for the installation.
The Novatel engineers then designed the full installation plan, including all required equipment, using StellaPlanner, the online installation design tool developed by Stella Doradus.
The following equipment was installed during this installation:
- The Titan iR4 repeater
- Indoor Yagi antennas
- External Yagi antenna
- Cable
All structured cabling throughout the warehouse was fully managed by Novatel.
The Titan iR4 captures strong mobile signal from nearby cell towers and amplifies coverage for all mobile operators within the building. Directional Yagi antennas, installed back-to-back at high level beneath the ceiling, were used to evenly distribute the mobile signal across all internal areas, ensuring consistent and reliable coverage throughout the facility.
The Result
Management was highly satisfied with both the speed of installation and the overall results delivered.
Once the iR4 repeater system was installed, strong and reliable mobile signal became available throughout the entire warehouse. Forklifts were able to move freely across the facility without any loss of connectivity, while scanners remained online at all times, enabling rapid scanning and real-time stock updates.