How Atlantic Air-Cooled Engines Doubled Their Storage Capacity in Moncton Without Expanding Their Building: A Stor-It Systems Case Study

When a facility runs out of storage capacity, the instinct is to look outward: add onto the building, lease additional space, or plan a new facility. What rarely gets examined carefully enough is whether the existing building is actually full, or whether it just feels that way because the space above the floor is being ignored.



At Atlantic Air-Cooled Engines in Moncton, New Brunswick, the answer was the latter. The facility had room. It was just the wrong dimension. The floor was at capacity. The air above it was not. Working with Stor-It Systems, president Robert Buzzell and operations manager Suzanne McLaughlin found a solution that delivered a 50 percent improvement in storage capacity, added bulk pallet storage and additional picking locations, stayed on budget, and finished ahead of schedule — all without adding a single square foot to the building footprint.

This is the story of how that outcome was achieved, why going vertical was the right answer, and what it means for industrial, distribution, and engine service operations across Atlantic Canada facing the same capacity pressure.

About Atlantic Air-Cooled Engines

Atlantic Air-Cooled Engines is a Moncton, New Brunswick-based operation specializing in small engine parts distribution and engine rebuilding. By early 2019, the company was approaching its 100th anniversary, a milestone that brought both pride and a heightened sense of responsibility. A century of operation in Atlantic Canada represents an extraordinary legacy. For Robert Buzzell, that anniversary was not just a moment to celebrate the past. It was a moment to demonstrate that the company's commitment to its customers and its standard of excellence would carry forward into the next generation of the business.

That commitment required a plan. Atlantic Air-Cooled Engines was growing. New product lines were being introduced. Customer demand was increasing. The parts inventory needed to support that growth was expanding. And the facility in Moncton that had been purpose-built for the operation when it was constructed was already showing signs of constraint. Within a relatively short time of opening the new facility, the parts storage area was running out of capacity.

The Challenge: A New Facility Already Running Out of Room

The capacity challenge at Atlantic Air-Cooled Engines had a particular edge to it. This was not a decades-old facility that had gradually been outgrown over time. It was a relatively new building, purpose-built for the operation, and it was already struggling to accommodate the inventory levels needed to serve a growing customer base. That situation creates pressure that goes beyond the purely logistical. For a business approaching its 100th anniversary and committed to demonstrating continued innovation and customer service excellence, running out of storage capacity is not just an operational problem. It is a strategic one.

Robert Buzzell understood that whatever solution was chosen needed to meet a demanding set of requirements. It needed to deliver a 50 percent improvement in parts storage capacity, the minimum required to support both the current operation and the new product lines being planned. It needed to preserve the existing workflow that the team had developed and relied on for years, since disrupting a well-functioning operation to accommodate a storage upgrade would undermine the very efficiency the upgrade was meant to support. And critically, it needed to allow the operation to continue running without interruption throughout the implementation. Downtime was not an option for a business whose customers depended on reliable, timely access to parts.

The initial instinct was to look at expanding the building. When that option was evaluated against the timeline, the cost, and the disruption it would create, the conversation shifted. Buzzell and McLaughlin arranged an on-site consultation with a product specialist from Stor-It Systems to explore whether there was a better path forward.

The Consultation: Finding Space in Thin Air

The on-site consultation at Atlantic Air-Cooled Engines began, as all Stor-It Systems consultations do, with an examination of the existing facility rather than a presentation of products. The storage challenge was real. But the question was whether the constraint was genuinely a lack of space, or a lack of vertical utilization.

Atlantic Air-Cooled Engines had an advantage that was not immediately obvious: they were already Stor-It Systems customers. When the facility was originally built, they had purchased Rousseau shelving through Stor-It Systems. That existing infrastructure was in good condition and performing well. Any solution that built on that foundation rather than replacing it would preserve the operational continuity Buzzell had identified as a non-negotiable requirement.

Several options were discussed during the consultation. A shelf-supported mezzanine structure would use the existing Rousseau shelving as part of the supporting infrastructure for an upper level. Adding modular drawers to the existing shelving would increase density within the current footprint. Each option had merit. Each was evaluated against the specific requirements of the operation.

The option that best addressed every requirement was the Cogan Clear Span Work Platform. Rather than building on top of existing shelving or adding density at the floor level, the Clear Span platform is a free-standing structural work platform that creates an entirely new floor level within the building's existing ceiling height. It does not depend on the existing shelving for structural support. It does not require the existing shelving to be relocated or replaced. It uses the vertical space above the current floor level that had been present all along but going entirely unused. The tagline from the original case study says it simply: when floor space is at a premium, go vertical.

The Solution: The Cogan Clear Span Work Platform

The Cogan Clear Span Work Platform is a pre-engineered, structurally independent raised work platform designed to create usable space at height within an existing facility. Unlike shelf-supported mezzanines that rely on the shelving below for structural support, the Clear Span design uses its own column and beam structure to carry the load of the upper level independently. This means the existing Rousseau shelving beneath could remain in place, fully operational, undisturbed throughout the installation.

For Atlantic Air-Cooled Engines, this was the decisive advantage. The lower level continued to function exactly as it had before, with no reorganization, no temporary displacement of inventory, and no disruption to the workflow the team depended on. The upper level was being built above them, in vertical space that had never been productively used, while the operation below ran without interruption.

The structural engineering of the Clear Span platform allowed the upper level to be configured for the specific requirements of the operation. Bulk pallet storage could be accommodated on the upper level, freeing floor-level space for the active picking and parts access that happens most frequently throughout the day. Additional picking locations on the upper level expanded the total number of accessible storage positions within the facility. And the platform's versatility meant that the upper level configuration could evolve as the operation's requirements changed over time, rather than locking the facility into a single layout permanently.

The Cogan system's pre-engineered design also contributed to the project's timeline and budget performance. Pre-engineered structural components arrive with precise specifications already established, reducing the design and engineering work required on site and allowing installation to proceed more efficiently than custom-fabricated alternatives. This is one of the reasons the Atlantic Air-Cooled Engines project came in on budget and finished ahead of schedule. Explore mezzanine and structural platform solutions available through Stor-It Systems.

Why Going Vertical Was the Right Answer

The decision to go vertical rather than outward at Atlantic Air-Cooled Engines reflects a principle that applies to a wide range of industrial, distribution, and service operations across New Brunswick and Atlantic Canada: floor space is expensive and difficult to add, but vertical space within an existing building is often available and significantly less expensive to utilize.

Building construction in Atlantic Canada carries a meaningful cost. Every square foot of new construction represents a capital expenditure that must be justified against the operational value it delivers and the time required to design, permit, and complete the work. A structural work platform within an existing building, by contrast, delivers usable square footage at the upper level at a fraction of the cost of new construction, in a fraction of the time, without the permitting delays and site disruption that building additions typically involve.

The vertical space in most industrial facilities is among the most underutilized asset in the building. It is present from day one. It does not require land, foundation work, or exterior construction. It requires a structural platform capable of using it safely and productively. When that platform is the right solution for the operation, as it was at Atlantic Air-Cooled Engines, the economics are compelling and the timeline is significantly faster than any building expansion alternative. For more on evaluating vertical versus floor-level storage strategies, see our guide on maximizing warehouse capacity without expanding your building.

The Outcome: 50 Percent More Capacity, On Budget, Ahead of Schedule

The results Atlantic Air-Cooled Engines achieved through the Cogan Clear Span Work Platform project delivered on every objective Buzzell and McLaughlin had set out to meet.

Storage capacity improved by 50 percent, the target Buzzell had identified as the minimum required to support the operation's growth and new product line expansion. That improvement was achieved without adding to the building footprint, without displacing the existing Rousseau shelving infrastructure, and without disrupting the workflow the team had developed over years of operation in the facility.

The upper level of the platform added bulk pallet storage capacity that had not previously been possible within the floor-level layout. It also created additional picking locations that expanded the range of parts accessible without floor-level reconfiguration. The combination of increased density and new picking positions addressed both the storage volume challenge and the operational efficiency requirements the project had been designed to meet.

Staying on budget reflected the quality of the pre-project planning and the precision of the pre-engineered Cogan system specification. Finishing ahead of schedule reflected the project management discipline of the Stor-It Systems installation team and the thoughtful preparation by Buzzell and McLaughlin. Both outcomes together represent the standard that a well-executed industrial storage project should produce.

Robert Buzzell, President of Atlantic Air-Cooled Engines, described the full relationship, including both the original Rousseau shelving installation and the subsequent mezzanine project, in his own words:

"When we were building our new warehouse, we looked for a company to sell us and install new warehouse shelving. Dwayne and his team went above and beyond to get this done. After a few years, we were running out of space, and again, we turned to Stor-It Systems for a mezzanine. Stor-It Systems came to our rescue with a solution that made sense. Working with Dwayne and his team was a pleasure. We would highly recommend Stor-It Systems to anybody looking for a new warehouse solution."

That testimonial captures something important beyond the specific project outcomes. Atlantic Air-Cooled Engines trusted Stor-It Systems with the original facility fit-out and returned when the next challenge arrived. That repeat relationship reflects the long-term value of working with a storage partner who understands the facility, the operation, and the people running it — not just the dimensions of the space. Additional examples of industrial and distribution projects completed across Atlantic Canada are available in our project gallery.

What This Means for Industrial and Distribution Operations in Atlantic Canada

The Atlantic Air-Cooled Engines project speaks directly to industrial operations, engine service facilities, parts distributors, manufacturing companies, and distribution centres throughout New Brunswick, Nova Scotia, Prince Edward Island, and Newfoundland that are managing the same pressure: growing inventory requirements, fixed building footprints, and the need to find more capacity without the cost and disruption of new construction.

The critical insight from this project is that the capacity constraint many operations experience is a floor-level constraint, not a building constraint. Most industrial facilities in Atlantic Canada were designed and built with ceiling heights that accommodate the installation of a structural work platform. The vertical space is available. The question is whether the operation's inventory profile, workflow requirements, and building specifications make a platform the right solution for the specific situation.

Answering that question requires the kind of on-site consultation that preceded the Atlantic Air-Cooled Engines project. Not a catalogue review, not a phone call, but a physical evaluation of the facility, the workflow, the existing storage infrastructure, and the growth requirements that are driving the capacity pressure. That evaluation is what allows a genuine solution to emerge rather than a standard recommendation applied without regard to the specific situation.

For operations that already have industrial shelving from Stor-It Systems, a platform solution may integrate with that existing infrastructure in ways that make the economics even more compelling, as it did at Atlantic Air-Cooled Engines. For operations starting fresh, the combination of floor-level shelving or racking and an upper-level platform can be designed together from the outset to maximize the full cubic volume of the facility from day one. See our related case study on how Bayview Trucks avoided a building expansion through a different but equally effective approach to the same pressure.

The Stor-It Systems Advantage

Stor-It Systems has been helping industrial operations, distributors, and service businesses across Atlantic Canada solve storage and capacity challenges since 1978. We serve organizations throughout New Brunswick, Nova Scotia, Prince Edward Island, and Newfoundland, and the Atlantic Air-Cooled Engines project represents something we see consistently across the region: the best solution to a capacity challenge is often already inside the building, waiting to be found through the right consultation process.

Our relationship with Atlantic Air-Cooled Engines began with the original facility fit-out using Rousseau industrial shelving and continued with the Cogan Clear Span Work Platform project when the next capacity challenge arrived. That continuity reflects how we approach every client relationship: not as a one-time sale but as an ongoing partnership that supports the operation as it grows and changes over time.

As an authorized dealer for both Rousseau and Cogan, we have direct access to two of the most trusted product lines in the Canadian industrial storage market. The Rousseau shelving system's compatibility with Cogan structural platforms made the Atlantic Air-Cooled Engines project possible in the way it was executed. That product knowledge, combined with the consultation-first process that identified the vertical solution in the first place, is what produces outcomes that a product-first supplier cannot replicate.

Our consultation and design services, professional installation, and preventative maintenance programs are all structured to support the complete lifecycle of a storage system, from initial design through ongoing performance. Our industrial shelving and racking solutions complement mezzanine and platform installations as part of integrated facility storage strategies. If your operation is facing capacity pressure and you have not evaluated the vertical space in your facility, that evaluation should be the first conversation.

Frequently Asked Questions

• What is a Cogan Clear Span Work Platform and how does it differ from a standard mezzanine?
• A Cogan Clear Span Work Platform is a free-standing, pre-engineered structural work platform that creates a full upper level within an existing facility using its own independent column and beam structure. Unlike shelf-supported mezzanines that rely on the shelving below for structural support, the Clear Span design carries its load independently of any existing infrastructure. This means the floor-level storage below remains fully operational and undisturbed throughout installation and after completion. The pre-engineered design also reduces on-site fabrication requirements, contributing to faster installation timelines and tighter budget performance compared to custom-fabricated alternatives.
• How much additional storage capacity can a structural work platform add to an existing facility?
• The capacity improvement depends on the available ceiling height, the floor area over which the platform is installed, and how the upper level is configured. At Atlantic Air-Cooled Engines in Moncton, the Cogan Clear Span Work Platform delivered a 50 percent improvement in total storage capacity while adding bulk pallet storage and additional picking locations. Facilities with generous ceiling heights can accommodate platforms that effectively double the usable floor area of the building. A professional facility assessment is the most reliable way to evaluate what a platform solution could deliver in a specific building.
• Can a mezzanine or work platform be installed without shutting down operations?
• Yes, and this was a non-negotiable requirement at Atlantic Air-Cooled Engines. The Cogan Clear Span Work Platform was installed above the existing Rousseau shelving while that shelving remained fully operational below. The installation was sequenced to allow the parts operation to continue without interruption throughout the project. Stor-It Systems plans and sequences all mezzanine and platform installations around the operational requirements of the facility. Uninterrupted operations is the standard expectation, not the exception, on projects of this type.
• Is a structural work platform a long-term investment or does it limit future flexibility?
• The Cogan Clear Span Work Platform is designed for long-term use and long-term flexibility. At Atlantic Air-Cooled Engines, the upper level was configured to accommodate both bulk pallet storage and picking locations, with the platform's versatility specifically noted as a factor in the decision. Pre-engineered platforms can be reconfigured, extended, and adapted as operational requirements change. They are not a fixed commitment to a single layout — they are a structural asset that grows with the operation, consistent with the long-term planning objectives that drove the Atlantic Air-Cooled Engines project from the outset.
• Does Stor-It Systems handle both the design and installation of mezzanine and work platform projects?
• Yes. Stor-It Systems manages the full project lifecycle for mezzanine and structural platform installations, from on-site consultation and layout design through product specification, delivery coordination, and professional installation. For operations with existing Stor-It Systems shelving or racking, our team's familiarity with that infrastructure informs the design of any additional platform solution. Contact us to arrange a consultation.
• Does Stor-It Systems serve industrial operations throughout Atlantic Canada?
• Yes. Stor-It Systems serves industrial facilities, distributors, engine service operations, manufacturers, and parts operations throughout New Brunswick, Nova Scotia, Prince Edward Island, and Newfoundland. Our team completed the Atlantic Air-Cooled Engines project in Moncton, New Brunswick, and has delivered storage and capacity solutions for industrial clients across all four Atlantic provinces. Book a consultation here.

Ready to Find the Capacity That Is Already in Your Building?

If your facility is experiencing capacity pressure and a building expansion feels like the only answer, the most valuable step you can take before committing to that investment is an on-site consultation with a storage specialist who will evaluate the full three-dimensional potential of the space you already have.

Atlantic Air-Cooled Engines found 50 percent more capacity in a building that felt full. That capacity was in the air above the floor level. It took the right consultation to find it, and the right product to use it. For nearly 50 years, Stor-It Systems has been having exactly that conversation with industrial and distribution operations throughout New Brunswick, Nova Scotia, Prince Edward Island, and Newfoundland.

Book a free facility consultation with our team today. We will evaluate your space, your workflow, and your growth requirements, and give you a clear picture of what is actually possible before any decision is made.