No WAPS Without Wires: Facts About Wireless Access Points and Cabling Infrastructure at Manufacturing Facilities

No wires, no WAPS: Requirements for WiFi and Access Points at Large Scale Facilities

When planning a new manufacturing plant or large commercial facility, it’s common to hear requests like, “We’ll need wireless access points installed so our teams and machines can connect across the site.” But here’s the truth: wireless doesn’t exist without wires.

Access points are only as strong as the cabling and network infrastructure that support them. Without a structured cabling backbone, power delivery, and coverage planning, wireless performance will fall short—especially in heavy machine manufacturing environments.

The Important Role of Wireless Access Points (WAPS) Cabling in Modern Facilities

Wireless access points aren’t just about convenience—they’re now mission-critical in today’s large facilities and manufacturing plants all across the booming industrial industry of South Carolina and North Carolina.

• Mobile Workforce: Employees rely on tablets, handheld scanners, and mobile devices to track production, inventory, and logistics in real time.

• Connected Machinery & IoT: Sensors, robotics, and smart machines use Wi-Fi to send performance data and receive commands.

• Streamlined Operations: Wireless supports warehouse management systems, barcoding, and automated inventory control across massive spaces.

• Real-Time Monitoring: High-bandwidth Wi-Fi enables video monitoring, safety systems, and quality control cameras without relying solely on hardwired connections.

• Flexible Security: Access points integrate with mobile credentials and cloud-based systems for flexible, secure access control.

  
  

In short: wireless is the nervous system of modern industrial facilities—but without the “bones” of structured cabling, it simply can’t function.

180,000 sqft industrial facility cabling infrastructure by GenX Security Solutions

Building WAPS Cabling the Right Way

If you’re building a new large-scale facility, don’t think of wireless access points as a quick add-on. They’re the visible tip of a much larger system that includes:

• Structured cabling (Cat6A or fiber)

• PoE-capable switches

• Site surveys and heat mapping

• Integration with enterprise-grade security systems

Without this foundation, Wi-Fi simply won’t deliver the reliability and performance needed to support heavy machine manufacturing and connected technologies.

Why Cabling Always Comes Before Wireless

📡 Every Access Point Needs a Wire

Wireless access points (WAPs) don’t function alone. Each one connects back to a switch through structured cabling—typically Cat6A or fiber—to ensure reliable speed and performance.

• Backbone infrastructure is critical

• Adequate structured cabling ensures coverage, speed, and reliability across the facility.

⚡ Power and PoE

Most enterprise-grade WAPs draw power through the network using PoE+ or PoE++. Without properly designed switches and cabling, access points can’t even turn on. Shielded cabling, proper grounding, and strategic AP placement help maintain signal integrity.

🏭 Industrial Interference & High Bandwidth Demand

Heavy machinery, motors, and steel infrastructure can disrupt wireless signals. A strong cabling plan paired with a professional site survey ensures access points are strategically placed to overcome interference.

• Applications like CAD uploads, robotics control, ERP systems, and video feeds from production lines require high throughput.

• Wi-Fi 6/6E is becoming the standard in new construction for handling dense device environments.

🌐 Coverage and Capacity

Manufacturing plants and warehouses often cover hundreds of thousands of square feet. Properly placed access points require backbone cabling to eliminate dead zones and handle high device density.

• Manufacturing plants have high ceilings, wide open bays, and physical obstructions (machines, cranes, steel walls).

• Site surveys and heat mapping are essential to determine placement and quantity of WAPs.

🔐 Security and Segmentation

Access points must integrate with enterprise-level security, often separating employee devices, production equipment, and guest users into secure network segments.

• WAPs must integrate with enterprise security (VLANs, firewalls, and access control systems).

• Manufacturing environments often require segregated networks (production machines vs. corporate users vs. guests).

📈 Future Growth

IoT, robotics, and automation demand ever-increasing connectivity. Designing infrastructure with 30–50% expansion capacity upfront prevents costly retrofits later.

• Plants usually expand device usage over time: sensors, robotics, handheld scanners, and IoT devices.

• Cabling and switch capacity should be designed with 30–50% growth in mind.

FAQs About Wireless Access Points for Large Facilities

❓ What do I need at a bare minimum to install wireless access points in a large facility?

• Structured cabling (Cat6A or fiber backbone)

• Enterprise-grade switches that support PoE+ or PoE++

• A coverage plan based on a professional site survey

• Proper grounding and shielding for industrial environments

❓ How many access points do I need based on square footage?

As a general rule of thumb:

• 2,000–3,000 sq. ft. per access point in open office or retail settings

• 1,200–2,000 sq. ft. per access point in industrial or high-density manufacturing areas

• Exact numbers vary based on ceiling height, wall materials, machinery, and device density—so a wireless site survey is essential.

❓ Can I just add Wi-Fi later if I’m not ready for full cabling now?

Wireless is only as strong as the wired backbone beneath it. Without structured cabling and switch capacity, future Wi-Fi installation will require tearing into finished walls and ceilings, making it far more costly.

❓ What’s the difference between Wi-Fi 5, 6, and 6E for a plant?

Wi-Fi 6/6E supports higher device density, faster speeds, and better reliability in interference-heavy environments—making it the preferred choice for new construction.

Partner With the WAPS & Building Infrastructure Experts: GenX Security Solutions

When you request wireless access points for a large facility, a licensed low-voltage cabling company like GenX Security Solutions doesn’t just install equipment. We begin with discovery questions that uncover what’s already in place, what’s missing, and what needs to be built to fully support your wireless network.

Some of the key questions include:

• Facility Size & Layout: How many square feet is the building? What’s the ceiling height, and are there multiple floors, mezzanines, or outdoor areas that need coverage?

• Construction Materials & Machinery: Are there steel walls, concrete barriers, or heavy equipment that may block or weaken wireless signals?

• Device Density: How many devices—laptops, handhelds, scanners, IoT sensors, machinery, and cameras—will connect at the same time?

• Power & Switching: Do you have PoE-capable switches available, or will you need to upgrade infrastructure to power the access points?

• Existing Cabling Infrastructure: What type of structured cabling do you currently have in place (Cat5e, Cat6, Cat6A, or fiber)? Is it properly terminated, tested, and certified?

• Build-Out Requirements: If no cabling infrastructure currently exists, where will cable pathways, conduits, and cable management systems need to be installed? What’s the most efficient route to run backbone cabling throughout the facility?

• Scalability & Growth Plans: Will you be expanding operations, adding new production lines, or increasing automation that may require more access points and cabling in the near future?

• Network Segmentation Needs: Will you require separate wired and wireless networks for production machines, employees, visitors, or contractors?

• Performance Goals: Is wireless primarily needed for staff mobility, or will it also support robotics, video monitoring, and real-time production systems?

  
  

By asking these questions, GenX Security ensures you don’t just get Wi-Fi; you get a network designed for your operations, your environment, and your future growth.

👉 Ready to talk about your upcoming project? Contact us today. GenX Security installs wireless access points at facilities across South Carolina, North Carolina, and Georgia from our office locations in Greenville, SC, Myrtle Beach, SC, Charleston, SC, and The Piedmont Triad of North Carolina.

Related: Wired For Success - Cabling Infrastructure Design by Business Type

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With custom security integration solutions come custom quotes designed for your needs. Please contact us by clicking here or calling 866-598-4369.

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At GenX Security Solutions, we proudly serve businesses in all locations across South Carolina, North Carolina, and Georgia with cutting-edge commercial security systems, access control solutions, structured cabling, fire alarms, and professional audio/visual integration. From bustling cities like Greenville and Raleigh to growing industrial hubs like Winston-Salem to hospitality hot spots like Myrtle Beach, our team delivers tailored solutions to meet your business’s unique needs.

Please visit our state-specific pages for more information on our services in various industries. We serve all cities in the Upstate and surrounding, including:

SOUTH CAROLINA	NORTH CAROLINA	GEORGIA
Aiken, SC	Asheville, NC	Alpharetta, GA
Anderson, SC	Burlington, NC	Athens, GA
Beaufort, SC	Cary, NC	Atlanta, GA
Charleston, SC	Chapel Hill, NC	Augusta, GA
Columbia, SC	Charlotte, NC	Carrollton, GA
Florence, SC	Concord, NC	Columbus, GA
Goose Creek, SC	Durham, NC	Dalton, GA
Greenville, SC	Fayetteville, NC	Douglasville, GA
Greenwood, SC	Gastonia, NC	Gainesville, GA
Greer, SC	Goldsboro, NC	Hinesville, GA
Hilton Head Island, SC	Greensboro, NC	Macon, GA
Lexington, SC	Hickory, NC	Marietta, GA
Mount Pleasant, SC	High Point, NC	Newnan, GA
Myrtle Beach, SC	Jacksonville, NC	Peachtree City, GA
North Charleston, SC	Kannapolis, NC	Rome, GA
Orangeburg, SC	Raleigh, NC	Roswell, GA
Piedmont, SC	Rocky Mount, NC	Sandy Springs, GA
Rock Hill, SC	Wilmington, NC	Savannah, GA
Spartanburg, SC	Wilson, NC	Valdosta, GA
Summerville, SC	Winston-Salem, NC	Warner Robins, GA