Large-Scale AP Refresh — Ontario Fulfillment Centres
Scarborough & Bolton, ON
1,586+ Access Points Replaced
2 Sites · 46 IDFs
24hr Shutdown Window · 0 Recorded Safety Incidents
Project Overview
A global e-commerce and fulfillment leader initiated a network refresh program, replacing aging wireless access points across approximately 24 North American sites including five Canadian facilities. AES executed the physical refresh at two Ontario locations: YYZ9 in Scarborough (476 APs across 23 network closets) and YYZ7 in Bolton (1,110 APs across 23 network closets), replacing over 1,586 access points in total.
The Challenge
Warehouse ceilings reached 40 feet across four mezzanine levels, requiring scissor lifts maintained at full charge throughout each shift. Labelling was exacting: every AP required port identifier, logical name, serial number, and MAC address for the client's asset database. YYZ9 had a non-negotiable 24-hour shutdown window. YYZ7, with more than twice the AP count, demanded extended windows and a larger workforce.
How AES Executed
- 1
Pre-staging day before each shutdown: technicians visited each site the day prior to inventory APs, confirm scissor-lift availability, and pre-stage all equipment including fall-protection gear. This became standard practice across the program.
- 2
YYZ9 Scarborough (24-hour window): A three-shift crew of 10-11 technicians rotated continuously. Shift 1 handled the top mezzanine and roof structures. Shift 2 covered lower mezzanine levels and main floor with labelling. Shift 3 ran a full verification sweep, qualification testing, and documentation sign-off.
- 3
YYZ7 Bolton (extended window): A greater proportion of APs were pre-labelled before deployment. Scissor lifts and fall-protection gear were pre-staged. Work was divided by mezzanine level for parallel crew operation, with all Scarborough lessons applied directly.
- 4
Real-time iPad-based tracking: each AP was logged in a shared spreadsheet as completed, ensuring no device was missed and enabling clean shift hand-offs with direct client engineering team communication.
- 5
Safety enforcement: full PPE including safety shoes, high-visibility vests, hard hats, and gloves; harnesses and lanyards above 6 feet; mandatory spotters for all scissor-lift operations; VCO contractor orientation completed by every technician.
Outcome
All 1,586+ access points were replaced across both Ontario sites. YYZ9 was completed within the 24-hour window. Warehouse staff reported improved wireless coverage, fewer drop-offs, and faster scanning speeds. Zero safety incidents were recorded at either site. The pre-labelling strategy, real-time documentation, and flexible staffing model were carried forward to the remaining facilities in the broader North American program.
Lessons Learned
Pre-planning is critical
A dedicated inventory and staging day before each shutdown allows the team to confirm lift availability and identify hazards in advance.
Labelling strategy matters
Pre-labelling APs before arrival reduces on-site labour and minimises errors. Where not feasible, technicians must have clear per-port instructions on hand.
Safety is non-negotiable
Zero incidents at both sites was achieved through consistent PPE, harnesses, lanyards, mandatory spotters, and contractor orientation.
Real-time documentation drives accountability
iPad-based progress tracking ensured no AP was left behind and enabled clean shift hand-offs across a 24-hour window.
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