Whether you are planning an expansion or a new distribution center with any level of Material Handling Equipment (MHE) and / or automation, there are many design factors to consider— way too many for a blog, so we’re going to focus on the biggies.
Size: Start by selecting the storage and handling concepts you will be utilizing. With the numerous options available, having an experienced design consultant will expedite the selection process and ensure your facility will be properly sized to meet the needs of your operation. This may seem obvious to most, but you really want to design the building from the inside out. Otherwise, you risk building unnecessary empty space or shoehorning the operation in, both of which result in less than desirable results. Analysis of the business, which includes processing and throughput requirements for each functional area, inventory levels, and a growth plan will help establish the operational solutions and ultimately the footprint and clear height(s) of the DC.
Building Column Spacing: Optimal column spacing is key to maximize cubic storage space. Often the storage rack and mobile equipment solutions will dictate how far apart building columns should be, with the goal of burying them in the flue space of back-to-back rack rows. Consideration for the dock areas (i.e. “speed bays”) is also necessary to determine column spacing to ensure enough clear space for dock levelers, vehicle traffic and product staging.
DC Floors: Several factors impact DC floor design. Storage rack and automation solutions can require a floor flatness, levelness and thickness/reinforcing above and beyond standard DC concrete floor design. Very Narrow Aisle (VNA) rack configurations and high-bay crane solutions are examples where special consideration is likely needed to ensure the floor design provides capability for mobile equipment and automated cranes to reach heights for storage and retrieval of product.
Storage rack / pick module loads can also impact the DC floor design. Calculations should be established early on so that the floor design can adequately support the loads, avoiding costly changes.
Additional Structural Support: Depending upon the MHE and automation solutions, it may be best to look at alternative ways to support equipment. For instance, it may be desirable to support conveyors from the ceiling versus floor supports to aid in clear pathways for vehicle and personnel traffic below. A cost-benefit analysis assists in making these types of decisions.
Egress: OSHA and local codes require personnel egress to not exceed certain distances. Often overlooked until it becomes a hot topic, this requirement needs to be considered early in the design process, as it can impact the facility layout and overall dimensions of the DC.
Fire suppression: Most new or expanded DCs will be outfitted with Early Suppression Fast Response (ESFR) sprinkler systems. With the proper water pressure and design, ESFR sprinklers can release more water over a given time period than sprinkler systems / designs of the past. However, in some cases, such as with storage of hazardous and / or flammable product, in-rack sprinklers are generally required. Getting a handle up front on product commodity class and the amount of storage required for each is critical for building and in-rack (if necessary) sprinkler design.
Electrical: It is important to establish total requirements for a DC to ensure the building’s power grid can handle the anticipated loads. Power loads for MHE and automation equipment are a big part of the equation to establish the overall DC loads. Often, the estimates are needed for the building ahead of final procurement and engineering of the MHE / automation solutions. It is critical to work with an experienced team to ensure estimates are as accurate as possible to reduce risk (and cost) down the road.
Other key electrical considerations include strategically locating power distribution panels, DC lighting requirements, ensuring enough convenience outlets and energy conservation.
IT: A DC design with any level of sophistication will need to rely heavily on the IT infrastructure. RF scanners, Automated Guided Vehicles (AGVs) and Goods-To-Person (GTP) and Autonomous Mobile Robots (AMRs) will need a reliable WiFi network for wireless communication. Storage racks can impact signals, so a WiFi survey is recommended in many instances to determine the location and quantity of access points for adequate coverage.
Even with the trend of software solutions navigating to the cloud, there still may be server requirements within an automated DC. AGVs, AMRs and GTP solutions along with more complex conveyor systems will likely require a server and ethernet or fiber runs to local HMI and motor control panels for communication. Servers are usually located in Main Distribution Frame (MDF) rooms in larger DCs and sometimes Intermediary Distribution Frames (IDF) cabinets are required throughout the DC to help organize and manage the data feeds from the MDF rooms to the equipment.
Taking the time to define the building criteria will minimize change orders and maintain schedule.
Let Sedlak assist you in your DC design. With over 65 years of experience advising industry-leading organizations, Sedlak will help address the challenges of today and prepare you for an ever-evolving future.
Contact Dave Gealy, Director of Client Services at Sedlak Management Consultant Inc., at dgealy@jasedlak.com for more information.
Also register for our upcoming Virtual event, Construction & Facility Design Considerations for New and Existing Facilities – A Sedlak Virtual Lunch & Learn with FCL. On May 20th, FCL and Sedlak will showcase Under Armour’s recently completed 1.3 MSF E-Commerce facility in Baltimore to cover a variety of developer and supplier topics including sizing determinations, a comparison of pricing structures (Design-Build vs Design, Bid, Build), how the Design-Build process helps developers mitigate risks with schedule and costs, Brownfield vs. Greenfield expansion, and the potential impact of the tariffs on project schedules and costs this year and beyond.
