John Levar, P.E.
Cold storage facilities have never been more expensive, important, or more complex.
Driven by increasing consumer demand, supply chain expectations, and automation technology, today’s refrigerated and frozen distribution facilities bear little resemblance to the warehouses of the past. What was once a relatively straightforward industrial building is evolving into a highly specialized operational environment where refrigeration, automation, structure, and enclosure systems are all interconnected.
As a result, many of the challenges owners face today are coordination driven rather than constructability focused.
In cold storage development, refrigeration, automation, and building design cannot be addressed independently. These key elements influence multiple aspects of the facility design. Refrigeration systems affect structural loading, equipment support requirements, roof design, maintenance access, and operational workflows. Automation systems influence building configuration and height, floor requirements, foundation design, electrical and cooling demands, and long-term operational performance.
For owners, this interconnectedness creates both opportunity and risk.
The projects with the best outcomes are the ones where critical decisions are made early by experienced stakeholders who understand how to anticipate outcomes, and the project team understands how those decisions affect the facility as a whole. The projects that struggle are those where key decision makers lack an understanding of system interactions, and coordination occurs too late in the process. When this occurs, changes become expensive, schedules become compressed, and compromises begin to impact long-term operations.
Automation continues to amplify this reality. Modern Automated Storage and Retrieval Systems (ASRS) place demanding requirements on floor slabs, foundations, and overall building geometry. Selection of the automation vendor and operational strategy drives many of the facility’s key design parameters. Owners who understand those requirements early can make informed decisions that improve constructability and reduce risk throughout the design and construction process.
At the same time, operational performance is a major concern for Owner/Operators. Refrigeration systems often receive the most attention, but building enclosure performance plays a significant role in the facility’s long-term success. Air leakage, thermal bridging, and poorly coordinated transitions can increase refrigeration demand, create moisture-related issues, and drive higher operating costs for years after construction is complete. These are not problems that can be solved through equipment alone. They require coordination between structural, enclosure, and refrigeration systems from the outset of design.
Through the addition of AST to Bennett & Pless, our team has expanded its experience supporting refrigerated distribution facilities, freezer buildings, and highly automated cold storage campuses for some of the nation’s largest food and grocery operators. Owners who bring together experienced teams early in the process are better positioned to control costs, improve facility performance, and avoid surprises during construction and operations.
Click here to learn more about our experience in the cold storage market.
Frequently Asked Questions About Cold Storage Structural Engineering
What makes cold storage facilities different from traditional warehouses?
Cold storage facilities must maintain precise temperature-controlled environments while accommodating specialized refrigeration systems, insulated building envelopes, freezer slabs, and operational equipment. Structural systems must account for thermal movement, moisture control, and heavy equipment loads that are not typically found in conventional warehouse facilities.
What structural challenges are unique to cold storage facilities?
Cold storage facilities present challenges including thermal expansion and contraction, freezer slab performance, frost heave prevention, refrigeration equipment support, high-bay storage systems, and integration with insulated metal panel (IMP) enclosures. These elements require early coordination between structural, architectural, refrigeration, and enclosure design teams.
What is ASRS and how does it impact structural design?
Automated Storage and Retrieval Systems (ASRS) use robotics and automation to store and retrieve products within high-bay warehouse environments. These systems often require extremely flat floor slabs, increased clear heights, specialized rack support considerations, and close coordination between structural systems and automation vendors.
Does Bennett & Pless have experience designing cold storage facilities?
Yes. Bennett & Pless has experience designing cold storage warehouses, refrigerated distribution centers, food processing facilities, freezer expansions, and temperature-controlled manufacturing environments across the United States.
What types of cold storage facilities does Bennett & Pless design?
Our experience includes:
- Freezer warehouses
- Refrigerated distribution centers
- Grocery fulfillment centers
- Food processing facilities
- Temperature-controlled logistics facilities
- Food and beverage manufacturing facilities
- Cold storage expansions and retrofitsHigh-bay
- ASRS storage facilities
How important is building enclosure design for cold storage facilities?
The building enclosure is one of the most critical systems in a cold storage facility. Proper design of insulated metal panels (IMPs), vapor barriers, thermal transitions, and moisture management systems helps maintain temperature control, minimize energy consumption, and reduce long-term maintenance issues. Bennett & Pless collaborates closely with BPL Enclosure to support overall facility performance.
What should be considered when designing freezer floors and slabs?
Freezer slabs must be designed to address temperature-related movement, loading requirements, joint performance, and frost heave risks. Floor flatness requirements become even more critical in facilities that utilize high-density racking or automated retrieval systems.
Can Bennett & Pless support cold storage facility expansions and renovations?
Yes. In addition to new facility design, we provide structural evaluations, renovations, freezer expansions, equipment support modifications, and facility upgrades to help owners adapt existing facilities to changing operational demands.
When should a structural engineer be involved in a cold storage project?
Structural engineers should be involved as early as possible during site selection, facility planning, and concept design. Early coordination helps identify potential challenges related to refrigeration equipment, enclosure systems, equipment loads, racking layouts, maintenance access, and future expansion opportunities before they impact cost and schedule.
How does structural design impact the long-term performance of a cold storage facility?
Proper structural design supports operational efficiency, equipment reliability, building durability, energy performance, and future adaptability. Effective coordination between structural systems, refrigeration systems, and enclosure components can significantly reduce lifecycle costs and operational disruptions.