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Innovative Warehouse Design

Innovative Warehouse Design. Council of Supply Chain Management Professionals Global Conference Warehousing Innovations Track 20 Session E-1 Doug Pope. Overview. Green is gold

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Innovative Warehouse Design

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  1. Innovative Warehouse Design Council of Supply Chain Management Professionals Global Conference Warehousing Innovations Track 20 Session E-1 Doug Pope Innovative Warehouse Design

  2. Overview • Green is gold • All engineering disciplines are trying to develop strategies to reduce energy use and to create sustainable designs • The future is a big place • Designing in as much flexibility as possible to accommodate future developments Innovative Warehouse Design

  3. Overview of Sustainable Design & Construction • LEED – What is it?Leadership in Energy & Environment Design US Green Building Council (USGBC) System for integrating sustainable design strategies into building projects Types of Projects that can be LEED Certified: • New Construction • Existing Buildings • Commercial Interiors • Core & Shell • Schools, Retail, Health Care LEED Accredited Professionals (LEED AP)

  4. Overview of Sustainable Design & Construction • Sustainable Sites 26 points • Water Efficiency 10 points • Energy and Atmosphere 35 points • Materials and Resources 14 points • Indoor Air Quality 15 points • Innovation and Design Process 6 points • Regional Priority Credits 4 points 110 points

  5. Overview of Sustainable Design & Construction • Sustainable Design & the LEED Score Card Platinum 80-110 Gold 60-79 Silver 50-59 Certified 40-49 Not Certified 0-40 Points

  6. Site Considerations • Brownfield vs. Greenfield • Site specific seismic analysis • Costs $5,000 to $12,000 • Not always a benefit (ask a geo-tech engineer) • Yields less steel • Ripples through other disciplines • Get the results early so they can be inexpensively incorporated in design Innovative Warehouse Design

  7. Orient building to capture as much sunlight as possible Orienting windows to the South maximizes sunlight entering the building Stopping summer sun from penetrating the building through overhangs and landscaping Vents in the roof allow rising heat to escape Integrated with the building’s electrical system Site Considerations Innovative Warehouse Design

  8. Using natural vegetation Limiting the use of grass to eliminate mowing and irrigation Collecting rainwater in cisterns for irrigation and toilets Landscaping Innovative Warehouse Design

  9. Landscaping • Graywater Processing • All waste water except toilet • Usually used for subsurface irrigation of non-edible plants • Acceptable uses depend on the amount of treatment • Sometimes hard to get permitted

  10. Landscaping • Using pervious materials • Pervious pavers in parking areas • White pavers to lower heat island effect • Using concrete instead of asphalt to lower heat island effect • The goal is to have storm water runoff volumes equal to predevelopment levels • Collecting rainwater in cisterns for irrigation and toilets • Pre-ponds • Underground separation tanks Innovative Warehouse Design

  11. Landscaping • Reducing the amount of disturbed area through the use of underground parking or parking decks • Waste diversion • Trees to mulch Innovative Warehouse Design

  12. Landscaping • Light trespass • No light off the site • Down lighting so you don’t illuminate the night • Night sky compliant fixtures Innovative Warehouse Design

  13. Vertical Axis Wind Turbines Helix wind turbine testing Smaller footprint than typical wind turbines Generates enough electricity to power a battery room Landscaping Innovative Warehouse Design

  14. Building Envelope • Roofs • Single ply white PVC roof • Mechanically installed • Heat welded seams • R-12 insulation in roof Innovative Warehouse Design

  15. Roofs The Tesco photovoltaic roof Building Envelope Innovative Warehouse Design

  16. Building Envelope • Roofs • Grass roofs Innovative Warehouse Design 16

  17. Building Envelope • Walls • Insulated metal panels particularly in temperature controlled spaces • Requires curbing for protection • R-30 insulation in walls • Reflective ceilings • High level windows Innovative Warehouse Design

  18. Building Envelope • Slabs • Shrink compensated flooring • Particularly in high traffic areas • Continuous pour • No control joint • A hardener is recommended • Selection of a reputable slab contractor is critical Innovative Warehouse Design

  19. Building Envelope • Slabs • Fiber reinforced floors • Micro-fibers are adding to the concrete • Eliminates steel reinforcement • May not need dowels at joints • Allows the truck to drive on the site eliminating pumping • Super flat floors Innovative Warehouse Design

  20. Building Envelope • Door Systems • Impactable knockout doors • Hydraulic or airbag levelers • Vertical dock levelers in temperature controlled docks • Design of controls for safety • Air curtain doors to prevent vapor infiltration in temperature controlled areas Innovative Warehouse Design

  21. Lighting • Daylighting • Decreasing energy use by installing skylights in combination with smoke vents Innovative Warehouse Design

  22. Lighting Interior Electrical Lighting • Fluorescent Lighting except in freezers • T-5 or T-8 Innovative Warehouse Design 22

  23. Lighting • Lighting Controls • Computer controlled timers for all areas • Motion sensors Innovative Warehouse Design

  24. HVAC Equipment and Systems • Cooling Equipment Efficiencies • Night flush air vents for summer Innovative Warehouse Design

  25. HVAC Systems start of night flush heat release from mass end of night flush heat gain by mass Innovative Warehouse Design 25

  26. Heating Equipment Efficiencies Radiant heat system with ceiling mounted radiant panels HVAC Equipment and Systems Innovative Warehouse Design

  27. HVAC Equipment and Systems • Supply Fans Innovative Warehouse Design

  28. Refrigeration • Ammonia vs. Freon • Smaller ammonia based systems are being installed • Ammonia is the least expensive refrigerant in terms of acquisition, operating expense, and replacement cost • Requires RMP reporting • Refrigeration system needs to be isolated using a secondary coolant to provide cooling to the space (propylene glycol) • Some energy penalties associated with the secondary coolant Innovative Warehouse Design

  29. Refrigeration • Ammonia vs. Freon • 300 tons is the current limit • 404 and 410 are the main remaining Freon types Innovative Warehouse Design

  30. Refrigeration • Variable Frequency Drives • Based on sensor feedback • Potential for hot spots • Inexpensive to install • Compressors • Evaporators • Drives Innovative Warehouse Design

  31. Refrigeration • Carbon dioxide refrigerant used in conjunction with ammonia • Effective at very low temperatures • Benefit can be obtained by raising or lowering equipment operating temperatures as product is being chilled (blast freezing) • IIAR in conjunction with several other organizations are studying the potential application of ammonia and CO2 cascade systems • There are some successes but the conditions for success are very specific Innovative Warehouse Design

  32. Refrigeration • Other topics • Use of motorized valves to control refrigerant flow and to provide a more stable operating environment • Coatings on piping and vessels to reduce future corrosion • LED lights are being examined • Thicker insulation Innovative Warehouse Design

  33. Low Flow Toilets Waterless fixtures Gray water treatment Plumbing Innovative Warehouse Design

  34. Upright sprinkler heads Supplied from a wet system in a heated space Eliminates the need for in-rack sprinklers in temperature controlled areas Fire Protection Innovative Warehouse Design

  35. Material Handling Design Considerations • Building dimensions • Distribution center • Storage facility • Dock Depths • Maximizing floor to truss storage density • Avoiding future expense through design • Application of automation Innovative Warehouse Design

  36. Material Handling Design Considerations • Column spacing and flexibility Innovative Warehouse Design

  37. Material Handling Design Considerations • Column spacing and flexibility Innovative Warehouse Design

  38. Material Handling Design Considerations • Column spacing and flexibility Innovative Warehouse Design

  39. Material Handling Design Considerations • Column spacing and flexibility Innovative Warehouse Design

  40. Material Handling Design Considerations • Application of automation • Look for where it fits • Avoiding future expense through design Innovative Warehouse Design

  41. Other Considerations BIM (Building Information Modeling) 3-dimensional design Facilitates collaboration between disciplines on design Highly efficient Enables earlier design visualization Program identifies design conflicts Saves time and money by eliminating need for re-design Innovative Warehouse Design 41

  42. Other Considerations BIM (Building Information Modeling) Innovative Warehouse Design 42

  43. Other Considerations Charge in place systems Innovative Warehouse Design

  44. Other Considerations Recycling waste through anaerobic digestion Innovative Warehouse Design 44

  45. Economic Benefits of Sustainable Design Initial Cost Premiums - Certified 1% to 3 % - Silver 3% to 6% - Gold 5% to 8% - Platinum 10% to 15% Due to the “menu based” LEED system it is possible to select a slate of credits that has very little first cost impact an a 3 -5 year payback on any first cost premiums Overall Cost Premiums - Certified 1% - Silver 2% - Gold 4% - Platinum 7% Innovative Warehouse Design 45

  46. In Conclusion • There are a number of innovative techniques being developed that have potential to positively impact distribution center and manufacturing plant design • Integrating a well designed facility with effective material handling processes and methods yields the lowest life cycle distribution costs Innovative Warehouse Design

  47. In Conclusion • There are a number of environmentally sensitive strategies being considered in all engineering disciplines • Careful study will determine which strategies meet corporate profitability and corporate responsibility goals Innovative Warehouse Design

  48. Thank YouDoug PopeKennesaw Advisory Groupdoug.pope@kennesawadvisorygroup.com770-330-4172 Innovative Warehouse Design 48

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