We spearheaded the design, engineering, site development, and construction of a monumental 750,000 sf freezer distribution warehouse, executed in six distinct phases over 24 years. This state-of-the-art facility stands as one of US Cold Storage’s largest and their second fully automated warehouse, featuring a sophisticated 180,000-pallet Automated Storage and Retrieval System (ASRS) freezer.
In Phase 6, we significantly expanded the facility’s capacity by adding 26,000 pallet positions to the existing 55,000. We also introduced advanced central ammonia refrigeration systems and a cutting-edge ASRS equipped with 13 high-efficiency cranes and a comprehensive inbound and outbound conveyor system. The ASRS features a 100-foot clear height, a multi-level automation system for both layer and case picking operations, and in-rack sprinklers to enhance operational efficiency and safety.
Innovative Structural Strategies for Cold Storage Automation
To support the complex ASRS system, we developed innovative structural strategies tailored to automated cold storage. We installed 2’x2’x2’ concrete piers on top of the slab to satisfy seismic requirements without cutting into the slab or impacting the glycol system beneath the freezer floor. We also built a mezzanine over the dock that reverses the typical warm-to-cold layout with an insulated metal panel ceiling, engineered to withstand heavy forklift traffic and support a gantry crane system. The mezzanine’s sawtooth slab edge required precise coordination with the ASRS contractor, and we implemented a custom snow load design to accommodate elevation changes between high and low roofs, ensuring long-term structural integrity.
