Company Overview

East Coast Metal Distributors is a prominent leader in the metal roofing industry, offering high-performance roofing systems known for their durability, energy efficiency, and environmental friendliness. Their product line includes a variety of advanced features such as solar-ready panels, rust-resistant finishes, and integrated ventilation systems, making them a go-to provider for both residential and commercial clients seeking long-term roofing performance.

As their business continued to grow, East Coast Metal expanded its in-house fabrication capabilities to keep up with rising demand for custom metal components like roll-formed gutters and trims. With this growth came new logistical challenges. The company needed to store an increasing volume of aluminum sheet metal rolls — the raw material essential for producing many of their finished products. Recognizing that proper storage was critical to both productivity and safety, East Coast Metal partnered with Atlantic Rack to develop a customized solution tailored to the unique characteristics of their aluminum coil inventory and fast-paced production environment.

The Challenge

As East Coast Metal Roofing scaled up its operations, the limitations of their existing storage methods quickly became apparent. The company’s aluminum sheet metal rolls — large, heavy, and cylindrical in shape — posed a unique storage challenge. Traditional pallet racking systems were not designed to accommodate these types of loads, and makeshift storage solutions often resulted in instability, wasted floor space, and difficulty during handling.

Coils were sometimes placed directly on the floor or stacked insecurely, which not only created safety hazards for warehouse staff but also increased the risk of damaging the raw material before it even reached the fabrication stage. Moreover, the lack of an organized, purpose-built storage area led to workflow disruptions and delays in production, especially when employees had to spend extra time maneuvering around disorganized inventory or locating specific coils. With demand for roll-formed components rising, East Coast Metal Roofing needed a specialized system that would enhance safety, protect inventory, and keep pace with their accelerated production schedule.

East Metal Roofing

The Solution

To address the unique storage challenge, Atlantic Rack designed a custom Drum Coil Bed system tailored specifically for East Coast Metal’s aluminum sheet metal rolls. These beds were constructed using structural angle steel, shaped to create a secure cradle that holds each coil in place and prevents shifting, rolling, or deformation. Using pallet racks, the Drum Coil Beds support the full weight of the coil directly on the bed itself, providing maximum stability while eliminating the pressure points that can lead to material damage. The system also features an open-face design, allowing forklift operators to easily load and retrieve coils, which significantly speeds up handling and reduces labor effort. Each unit was customized to match the dimensions of East Coast’s materials and facility layout, ensuring the storage solution not only fit the physical space but also aligned with their production flow. This targeted approach improved both safety and efficiency while creating a cleaner, more organized storage area for their growing inventory.

The Implementation

Atlantic Rack began the implementation process with an on-site evaluation of East Coast Metal’s facility, carefully measuring the space available and assessing the dimensions and weight specifications of their aluminum coil inventory. This hands-on approach allowed the design team to fine-tune the Drum Coil Bed layout, ensuring that each unit would optimize floor space without interfering with existing workflows or equipment. Once the system was fabricated, Atlantic Rack coordinated delivery and installation around the client’s operating schedule to avoid disrupting production. The beds were strategically placed near the roll-forming area, reducing the distance and time required to move materials from storage to processing. Throughout the setup, Atlantic Rack worked closely with warehouse staff to make sure the new system aligned with their handling preferences and safety protocols. The installation was completed quickly and efficiently, allowing East Coast Metal Roofing to put their upgraded storage solution to use almost immediately.

East Metal Roofing
East Metal Roofing

The Result

The installation of the Drum Coil Bed system brought immediate and measurable improvements to East Coast Metal Roofing’s warehouse operations. By securing each aluminum coil in a designated cradle, the system dramatically increased safety, eliminating the risk of rolls shifting or tipping during storage or handling. Employees reported smoother and faster workflows, as forklift access to materials became more direct and efficient. The improved organization helped reduce time spent locating specific coils, which translated into quicker production prep and reduced downtime on the shop floor. In addition, the coils were better protected from floor damage and stacking-related deformation, extending their usable lifespan and minimizing waste. With their raw materials now stored safely and systematically, East Coast Metal Roofing gained the confidence to scale up production, knowing their storage system could support both current demands and future growth. The result is a cleaner, safer, and more productive environment that strengthens every step of their manufacturing process.

Conclusion

By partnering with Atlantic Rack, East Coast Metal successfully solved a critical operational challenge with a solution tailored precisely to their needs. The custom Drum Coil Bed system not only addressed immediate concerns around safety and storage efficiency but also laid the groundwork for sustained growth in their fabrication operations. This project highlights the value of specialized storage solutions in industrial environments where conventional racking falls short. With increased organization, safer handling, and faster material access, East Coast Metal is now better positioned to meet rising demand while maintaining the high standards that define their brand. The collaboration between both teams demonstrates how thoughtful design and expert implementation can transform warehouse logistics into a true strategic advantage.