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How To Build a Hi-bay Warehouse Distribution Facility
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Business New Haven
11/11/2002
By: Anne-Marie Brungard
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Construction of a new warehouse or production facility is an increasingly complex endeavor. Sophisticated business owners demand considerable input into the design and material selection of the new building. Availability of land and improved quality of construction are persuading owners to consider custom build-to-suit facilities. The construction plan must maximize operational efficiencies as well as provide return on investment. “Value” is much more the issue than “price.”
The Process -
• Site Selection:
Choose a location that is in close proximity to major highways or main interstates. Transportation to and from your facility should flow as smoothly as possible, avoiding smaller roads or residential areas if at all possible.
Making adequate allowances for access by tractor-trailers allowing enough space for the functional maneuverability of all heavy vehicles.
Select land that is large enough to facilitate future expansion of the facility.
Verify the availability of, and access to, utility lines for new construction - municipal water and sewer lines should be in place; check access to adequate electrical power, natural gas, etc.
• Choosing your Contractor:
Thoroughly review and investigate your potential contractors' history and experience. Talk to past customers. Conduct site visits of other completed facilities in the area, and request references from owners with similar building projects. Ask questions: Did the team deliver the project on time and on budget? How easy was the process? Was the team responsive? Fair? Service-oriented. Check the company's capacity for bonding.
Your project requires a team of trained professionals. The Design Build team should have the capacity to expedite town and city approvals and the permit approval process. Some contractors can now offer design and construction services internally, bringing the key players together in a cohesive manner and reducing the communication issues encountered in the past.
Structure a sensible agreement meeting your needs as the owner - this can ensure the trusting and confident relationship essential to the project's construction process. Eliminating pricing risk is key, consider a fixed price contract. Note that “fixed price” is not synonymous with “lowest final price.” Some contingencies may be built into the construction budget. This approach allows for firm financing commitments.
• Planning & Design:
Initial meetings should include the company owner, his or her material handling consultant and the Design Build team.
A thorough assessment includes flushing out the owner's goals for anticipated use of the facility and growth projections. Commodity clarification involves identifying the essential elements and details about what the company produces, to determine what is being stored, racked and distributed. Systems for plastics and Styrofoam storage have different requirements than cardboard or metals. A discussion about anticipated usage will be a benchmark for determining building size and capacity.
A comprehensive plan that outlines the company's specific requirements for material storage and types of sophisticated material handling systems (automation, robotics, etc.) is developed. Storage rack layouts and systems are reviewed.
Obtain the appropriate approvals and permits from municipalities for land use, including planning and zoning department approvals and special permissions for wetlands, if applicable.
Expect to spend approximately three to four months in the design phase depending on the size and scope of the project.
•The Construction Project:
Anticipate that the actual construction may take between six and ten months. Consider the following:
Critical clear height - The roof structure and mechanical systems must be at the appropriate height to fully accommodate the rack systems. A taller building is actually less expensive to build than a larger building with more square footage. The product for storage is traditionally thought of in cubic feet to maximize space usage.
Column location - Structural support is a key element in any construction project, however, in the hi-bay distribution warehouse particular attention must be given to column sizing, spacing, locations and bay spacing. There must be some flexibility to allow for design around the parameters of the owners rack and handling systems.
Design of concrete floor slab - These days it is not the type of concrete that is used that counts, but how much is actually poured. The traditional industrial/commercial building would have a six-inch thick concrete floor. To adequately support the racks, machinery and storage systems, an eight- to ten-inch thick concrete floor with heavy wire mesh reinforcement (installed on chair supports) is required.
Fire Protection Sprinkler System - The product and commodity type (i.e. cardboard, metals, plastic) will dictate the fire protection system required for the job.
Early Suppression Fast Response (ESFR) - This particular sprinkler system is installed at roof level only. Generally less expensive, the system is typically adequate for storage of metals and corrugated cardboard.
In-Rack Sprinkler System - Sprinklers are installed at roof level with additional heads dropped directly into all racking systems. Consider this method of fire protection for storage of plastics and Styrofoam.
Construction and control joints - Careful planning must go into the placement and location of both sets of joints, they should not interfere with the rack supports.
Electrical - Lighting, electrical systems and types of fixtures will be matched to suitably fit the materials being stored, including underground installation if appropriate.
Security - Maintain a professional company to design, develop and install the security system. Construction considerations include ensuring that outside walkways and entryways are well lit. Adequate lighting and fencing on the facility's exterior must be part of the design considerations.
Remember that an impressive team at the start of the project is not as important as how impressive the team is at the end.
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