When you’ve spent as many years in HVAC as I have, you start to realize something: air conditioning a warehouse is nothing like cooling a house, an office, or a storefront. Homes have walls, insulation, zoning, and ceilings low enough to touch without grabbing a ladder. Warehouses? They’re a different beast — high ceilings, metal construction, wide-open spaces, open dock doors, heat-producing machinery, and often a workforce stuck in the summer sweatbox wondering why management hasn’t figured out a better solution.
If you're reading this, there’s a pretty good chance you’re either responsible for the comfort and productivity of a large facility or you’re trying to figure out how to cool 20,000–100,000 square feet without setting the roof on fire — metaphorically or literally.
So today, I’m bringing you the complete Mark Callahan breakdown: a practical, straightforward, no-fluff, boots-on-the-concrete guide to picking the right warehouse AC unit, understanding warehouse HVAC design, and avoiding the biggest mistakes companies make when choosing warehouse air conditioning units.
And yes — we’re going to talk about the Goodman 3 Ton 14.5 SEER2 R32 Bundle, because it’s a workhorse solution for offices, packaging areas, and warehouse segments that need targeted cooling. You’ll find the full details on the product page here:
👉 Goodman 3 Ton 14.5 SEER2 R32 Bundle
Let’s get into it.
Why Warehouses Need Specialized AC Solutions
Cooling a warehouse isn’t optional anymore. When OSHA advises employers to consider heat-mitigation systems for industrial facilities and when modern processes depend on temperature control, the stakes go way beyond comfort.
Warehouses often require AC for:
-
Worker safety and compliance
-
Equipment longevity (especially electronics, packaging systems, conveyors)
-
Maintaining product integrity
-
Preventing heat-related downtime
-
Keeping logistics areas workable during peak season
But here’s the truth:
You can't throw a couple of rooftop units at a 50,000 sq ft metal box and expect miracles.
The physics don’t care about your budget.
The square footage doesn’t care about your guesswork.
And the summer sun definitely doesn’t care about your comfort.
That’s why choosing the right air conditioner for warehouse environments requires engineered planning — not just buying the biggest unit your supplier has in stock.
Heat Load in Warehouses: Bigger, Hotter, and More Complicated
Most warehouses experience:
-
Extreme heat gain from metal roofs
-
Constant door cycles at docks
-
Heat from forklifts, equipment, and lighting
-
Limited insulation
-
High cubic volume (not just square footage)
This means warehouse AC is about tonnage AND airflow.
It’s why organizations like the U.S. Department of Energy recommend industrial facilities adopt strategic zoning and energy-efficient mechanical systems rather than trying to brute-force cool the entire space — a resource you can check out here:
➡ U.S. Department of Energy – Commercial Cooling Guidance
Warehouses demand a unique approach because they’re among the most challenging spaces in the entire HVAC landscape.
Warehouse AC Units: What Are Your Options?
Let’s break down the leading categories used today.
**1. Central Split Systems (Targeted Zones)
The Most Common "Warehouse Office + Segment Cooling" Strategy**
If you’re cooling:
-
Front offices
-
Packaging lines
-
Inspection stations
-
Breakrooms
-
Supervisor areas
-
Temperature-sensitive corners of the warehouse
Then a high-performance central split system like the Goodman 3 Ton SEER2 R32 unit is a perfect fit.
These systems provide:
-
Strong cooling capacity
-
Tight climate control
-
Cost-effective installation
-
Energy-efficient performance
Most warehouses use multiple 2–5 ton split systems to create temperature-controlled islands. You’re not cooling the full 60,000 sq ft — you’re cooling where people work most.
And that’s smart HVAC.
**2. Warehouse HVAC Rooftop Units (RTUs)
The Industry Standard for Large-Scale Cooling**
Rooftop units dominate in large warehouses for one reason:
They can move a ton of air and deliver serious BTUs across huge spaces.
RTUs are popular because:
-
They’re easy to access for maintenance
-
They free up interior floor space
-
They come in large capacities (10–50 ton)
-
They deliver high airflow
-
They handle large-area ventilation and cooling effectively
The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) provides some of the most respected engineering standards for warehouse ventilation and load calculation — essential reading when planning RTUs:
➡ ASHRAE Commercial HVAC Standards
RTUs are the backbone of large-scale industrial comfort.
**3. Industrial Portable Cooling Units
Good for Temporary or Spot Cooling**
These units aren’t your home improvement store portable ACs. Industrial portable coolers can deliver 1–5 tons of cooling per unit.
Warehouses use them for:
-
Temporary cooling
-
Seasonal support during heat waves
-
Emergency spot-cooling for overheating equipment
-
Cooling loading docks
-
Solving hot spots due to machinery or layout changes
But they are not replacements for a real warehouse AC unit.
Think of them as tactical HVAC reinforcements.
**4. Evaporative Coolers (Swamp Coolers)
Widely Used in Dry Climates**
Evaporative coolers can drop temperatures significantly in dry regions and cost less to run than full refrigeration-based AC.
They’re often used in:
-
Southwest states
-
Industrial buildings with high airflow needs
-
Warehouses where moderate cooling is acceptable
The Department of Energy offers an excellent overview of evaporative cooling efficiency for large facilities, making it a valuable educational resource:
➡ Department of Energy – Energy-Efficient Cooling Technologies
But remember:
Evaporative coolers are useless in humid climates.
If your warehouse is in Florida, Texas (coastal), or the Gulf Coast, skip them.
**5. VRF/VRV Systems
High-Tech and Efficient, But Higher Upfront Cost**
Large VRF systems excel in:
-
Multi-zone warehouses
-
Facilities with mixed-use spaces (warehouse, offices, testing labs)
-
Sites requiring precise temperature control
They offer:
-
Very high efficiency
-
Modular expansion
-
Superior zoning
-
Quiet operation
These systems work exceptionally well when warehouse office areas need strict climate control while open warehouse areas require moderate cooling.
For deeper insights on commercial heat recovery and VRF technologies, the Energy Star commercial guidance is extremely helpful:
➡ Energy Star – Commercial HVAC Systems
How Much Cooling Does a Warehouse Actually Need?
Here’s where people get into trouble.
They assume they can use the same tonnage estimates used for houses or retail.
That does not work for warehouses.
A 3-ton unit may cool a 1,500–1,800 sq ft home…
…but a 3-ton unit in a 50,000 sq ft warehouse cools a small room or a single zone.
Warehouse cooling calculations include:
-
Cubic volume (height matters)
-
Roof construction and insulation
-
Number of dock doors
-
Heat-generating equipment
-
Climate zone
-
Ventilation requirements
-
Worker density
-
Product storage temperature needs
This is why professional HVAC load calculation — not guesswork — is essential.
Warehouse HVAC Layout Strategies That Actually Work
There are three proven approaches.
Strategy 1: Zoned Cooling (Most Common)
-
Offices cooled with 2–5 ton split systems
-
Packing lines cooled with 5–20 ton RTUs
-
Cooler zones within the warehouse
-
Minimal cooling in storage-only zones
This balances cost and comfort.
Strategy 2: Full-Facility Cooling (Premium)
Common in:
-
Pharmaceutical warehouses
-
Food storage
-
Electronics and tech logistics
-
Manufacturing with heat-sensitive processes
This can involve dozens of massive RTUs designed to maintain uniform temperatures across the entire interior.
Strategy 3: Spot Cooling + Air Movement
This hybrid includes:
-
Large HVLS fans
-
Portable industrial AC units
-
Strategic RTU placement
-
Targeted cooling for worker-intensive areas
This is often the most cost-effective approach for large, non-temperature-critical facilities.
Why the Goodman 3 Ton R32 System Works Well for Warehouse Zones
The Goodman 3 Ton 14.5 SEER2 R32 bundle is excellent for warehouse applications because:
-
It delivers strong cooling output
-
It’s efficient under SEER2 standards
-
R32 refrigerant is environmentally friendlier and more efficient
-
It handles commercial-grade duty in controlled spaces
-
It’s cost-effective compared to many commercial-grade systems
Most warehouse offices and adjacent operational rooms fall between 2–5 tons, making the Goodman 3 Ton a versatile option.
Common Warehouse AC Mistakes (That Cost Thousands)
Let me save you a year’s worth of regret.
❌ Mistake #1: Trying to cool the entire warehouse with residential units
I've seen businesses install sixteen 3-ton residential units thinking it would match two commercial 20-ton RTUs.
It won’t.
It never will.
Residential units are not built for industrial duty cycles.
❌ Mistake #2: Ignoring cubic footage
You’re not cooling floor space — you’re cooling a giant box.
❌ Mistake #3: Installing units with poor airflow distribution
If the air can’t move, the cooling is useless.
❌ Mistake #4: Forgetting about ventilation
Warehouses require fresh air.
Skipping ventilation leads to humidity, odor issues, and system inefficiency.
❌ Mistake #5: Assuming portable units can replace a real system
Portables supplement. They do not replace.
❌ Mistake #6: Not zoning
Zoning is the secret weapon of warehouse HVAC.
❌ Mistake #7: Not planning for future expansion
A good warehouse HVAC design outlives your current layout.
Warehouse AC and Energy Efficiency: Saving Money While Staying Cool
Cooling a warehouse can be expensive, but proper engineering reduces costs dramatically.
Here’s how:
1. Insulate the roof
Reduces heat load by 30–50%.
2. Use HVLS (High Volume Low Speed) fans
Spreads cooled air more efficiently.
3. Seal dock doors
The biggest source of heat gain.
4. Install programmable thermostats
Optimizes cooling schedules.
5. Use zoning
Only cool where needed.
6. Maintain your equipment
Dirty coils and filters destroy efficiency.
How Much Does a Warehouse AC System Cost?
Warehouse HVAC pricing varies massively.
Below are common ranges (estimates only):
Small warehouse zones (using 3–5 ton splits):
$2,500–$6,000 per zone
Medium warehouse with some RTUs:
$25,000–$120,000
Large warehouse full cooling:
$250,000–$1,000,000+
The Goodman split system used in offices and warehouse zones is far more budget-friendly and simple to maintain.
Is the Goodman 3 Ton R32 a Good Fit for Your Facility?
Yes — if you’re cooling:
-
Warehouse offices
-
Breakrooms
-
Packaging zones
-
Supervisor stations
-
Quality control rooms
-
Storage corners needing climate control
-
Any zone between 600–2,000 sq ft depending on insulation and design
It’s not meant to cool the entire warehouse — no single 3-ton unit is.
But as part of a well-designed warehouse HVAC strategy?
It’s a powerful tool.
Final Thoughts from Mark Callahan
Cooling a warehouse takes planning, strategy, and the right combination of units — not guesswork. You need zoning, airflow, commercial-grade equipment, and the willingness to approach the problem as an engineer, not a homeowner.
If you want a reliable, cost-effective unit for your warehouse’s offices or targeted cooling zones, the Goodman 3 Ton 14.5 SEER2 R32 Bundle is a solid choice. You can review all specs here:
👉 Goodman 3 Ton 14.5 SEER2 R32 Bundle
And remember — when it comes to warehouse HVAC, doing it right the first time is always cheaper than doing it twice.
