Engineering Performance in the Most Demanding Environments
Where Temperature Control Meets Structural Performance
Cold storage facilities are among the most complex industrial buildings being developed today. From frozen food distribution and temperature-controlled logistics centers to automated storage and retrieval systems (ASRS), these facilities require careful coordination between structural systems, refrigeration equipment, building enclosures, and operational requirements.
At Bennett & Pless, we provide specialized structural engineering services for cold storage facilities, helping owners, developers, architects, and contractors deliver efficient, durable, and high-performing facilities. Our team understands the unique challenges associated with freezer warehouses, refrigerated distribution centers, food processing facilities, and cold chain infrastructure, including thermal movement, moisture control, heavy equipment loads, racking systems, and future operational expansion.
Whether designing a new cold storage facility or expanding an existing operation, we develop practical structural solutions that support long-term building performance while helping our clients control cost, schedule, and risk.
Why Cold Storage Facilities Require Specialized Structural Engineering.
Cold storage buildings are not simply warehouses with refrigeration equipment added after the fact. Successful cold storage facilities require integration between refrigeration systems, structural framing, building enclosure systems, slab design, and facility operations from the earliest stages of planning.
Temperature-controlled environments create unique structural challenges that must be addressed from day one:
- Thermal movement and temperature transitions between freezer, cooler, and ambient zones
- Equipment support for refrigeration systems, condensers, evaporators, and piping
- High-bay racking and automated storage and retrieval systems (ASRS)
- Freezer slab design and frost heave mitigation
- Structural support for insulated metal panel (IMP) systems
- Maintenance access platforms and equipment structures
- Long-span roof systems and clear height requirements
- Future facility expansion and operational flexibility
Our team works closely with project stakeholders to ensure these challenges are addressed early, reducing costly changes during construction and improving long-term facility performance.
Our Approach to Cold Storage Facility Design
We understand that every cold storage facility serves a unique operational purpose. Whether the project supports food distribution, grocery fulfillment, food processing, pharmaceutical storage, or logistics operations, our designs are driven by the owner’s operational goals.
Our approach focuses on:
- Structural Integration: Coordinating structural systems with refrigeration equipment, piping routes, maintenance requirements, and operational workflows.
- Thermal Performance: Designing structures that accommodate temperature-related movement while supporting energy-efficient building performance.
- Automation & ASRS Support: Creating structural systems that accommodate high-bay storage, automated retrieval systems, robotics, and the floor tolerances required for modern logistics operations.
- Building Enclosure Coordination: Working alongside BPL Enclosure to support moisture control, vapor continuity, insulated metal panel systems, and overall building performance.
- Long-Term Flexibility: Designing facilities that can adapt to future expansion, changing operational needs, and evolving technologies.
What we deliver
- 01.
A highly responsive team dedicated to delivering an unparalleled client experience.
- 02.
Structural engineering for cold storage warehouses, distribution centers, and freezer facilities.
- 03.
ASRS and high-bay racking system coordination and support.
- 04.
Freezer slab design, floor performance evaluation, and frost heave mitigation strategies.
- 05.
Refrigeration equipment support structures, platforms, and maintenance access systems.
- 06.
Warehouse expansions, facility retrofits, and operational upgrades.
- 07.
Cost-effective, energy-efficient designs tailored to industrial operations
- 08.
Integrated structural and enclosure solutions (with BPL Enclosure) that enhance facility performance and efficiency.
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.
To learn more about how we approach industrial design and view some of our past projects, download our brochure.
Contact our team
Let’s build for the future of industry.
Whether you’re developing a cold storage facility, a new warehouse, or a state-of-the-art distribution center, our team is here to provide the structural engineering services for industrial facilities that meet your goals.
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