Built for Giants: Emrack Engineers 12K Space Storage System for CAT Logistics

Engineered for endurance, designed for efficiency — Emrack built CAT’s Somerton hub to perform under pressure.

When global industrial giant Caterpillar Inc. set out to create a new parts distribution hub in Somerton, Melbourne, they needed a racking system that could match the scale, precision, and performance of their operations.

With millions of tonnes of earth moved daily by CAT machinery, their logistics arm — CAT Logistics — required a high-capacity, fully optimised warehouse solution built for both strength and efficiency.

That’s where Emrack came in.

Purpose-Built Racking for a Global Powerhouse

CAT Logistics operates one of the world’s most advanced distribution networks, servicing not only CAT dealers but also major automotive clients including Mercedes-Benz and Harley-Davidson. With over 60 locations across Australia, New Zealand, and the South Pacific, the company needed a storage system for their Somerton facility capable of handling a diverse inventory — from radiator fans and filters to bucket assemblies, windscreens, and motor heads.

The brief called for a solution that could accommodate an extensive range of SKUs, each with unique weight and size requirements. The goal: maximise capacity, streamline handling, and deliver a safer, smarter environment for warehouse staff.

Engineering Efficiency from the Ground Up

Caterpillar’s global data analysts and planners travelled from across the world to collaborate with Emrack’s engineering team. Together, they developed a custom layout design optimised to support peak performance with minimal on-floor staffing — just 12 operators per shift.

Drawing on a proven layout model from CAT’s Tullamarine facility, Emrack worked closely with Caterpillar’s visiting design and operations teams from India and the US to refine every detail.

The final configuration achieved maximum density and accessibility, with each racking bay precisely dimensioned to the assigned product group. Beam spacing, clearance heights, and aisle widths were calibrated to accommodate high-reach forklifts while reducing dead space across more than 12,000 pallet positions.

Selective Pallet Racking with Custom Mesh Decking

Although the system design was based on Selective Pallet Racking, the execution went far beyond standard. Each level was fitted with custom-designed mesh decks, eliminating the need for traditional pallets altogether — a model now used by CAT globally.

This innovative approach provided multiple benefits:

• Reduced storage height per item, freeing up space for additional product levels.
• Lower ongoing costs by removing pallet hire and replacement expenses.
• Enhanced safety and airflow, keeping components stable and visible.

With over 11,000 mesh decks installed, the Somerton facility achieved a long-term, low-maintenance solution with significant operational savings.

Partnership in Precision

Throughout the design and installation process, Emrack’s in-house engineers and draftspeople worked hand-in-hand with CAT’s project managers to ensure the system met global standards for durability, safety, and efficiency.

The result is a world-class parts distribution centre that embodies the Caterpillar commitment to performance and reliability — supported by Emrack’s expertise in engineered storage systems.

Built to Last

This project stands as a benchmark in large-scale industrial storage: an engineered environment where every beam, bolt, and bay serves a purpose. From high-density selective racking to long-term maintenance efficiency, the Somerton facility represents Emrack’s capability to deliver turnkey warehouse solutions for some of the world’s most demanding operations.

Ready to Optimise Your Storage?

Whether you’re managing mining parts, manufacturing components, or high-volume logistics, Emrack designs systems that keep your warehouse working smarter and safer.

Discover what Emrack can build for you — get in touch with our team today.