Views: 391 Author: HOWCOOL Publish Time: 2024-12-09 Origin: Site
In practical work, it is common to encounter situations where a client's existing factory warehouse is of a standard design, not originally intended to function as a cold storage facility. Later, due to development needs, the client wants to transform the original factory structures and regular warehouses into cold storage facilities that meet refrigeration and freezing requirements. For this type of project, an explanation will be provided here, based on actual retrofit cases.
1- Original Warehouse Condition
2- Renovation Process and Plan
3- Specific Practical Methods for Implementation
4- Cost-Effective and Economical Renovation Methods
Many of the original warehouses did not have floor insulation or wall insulation functions; they were just regular warehouses, as shown in the images below.
These are all typical regular warehouses. For warehouses that were not designed with insulation, if they need to be converted into cold storage, the first step is to determine the type and layout of the cold storage required. The renovation should be carried out according to the new functional requirements.
Currently, the most commonly used cold storage facilities are those that include a loading dock function, and the cold storage should ideally be raised 1.2 meters above ground level to facilitate the loading and unloading of refrigerated trucks. Therefore, cold storage with a platform height of 1.2 to 1.4 meters is the most suitable.
1- Renovation Method for the Cold Storage Foundation Insulation Layer
If the foundation of the conventional cold storage has not been treated for insulation and frost heave prevention, it is necessary to carry out frost heave and insulation treatment on the ground when converting it into a large low-temperature cold storage (-15 to -25°C). However, if the area is small (under a few hundred square meters), in order to reduce investment costs, a thicker insulation layer can be used instead. For larger areas, it is essential to perform frost heave prevention treatment.
Common methods for frost heave prevention include embedding cement ventilation pipes in the backfill soil, using heat transfer fluids such as water heated above 0°C, or employing electric heating cables to prevent frost. For areas where the foundation cannot be raised excessively, the use of gravel or large particle stone blocks, compacted to provide ventilation and drainage, can also be effective.
If there was a foundation platform originally, the existing platform floor can be excavated and gravel laid. If there was no platform in the original warehouse, backfill soil can be added, followed by the laying of gravel and insulation layers. In summary, frost heave prevention and insulation treatment of the foundation are key considerations when retrofitting a cold storage facility.
What happens if frost heave prevention is not implemented?
The rising warm air from the soil will meet the cold air descending from inside the cold storage, causing condensation of the warm air into ice. The transition from gas to solid can result in cracks in the foundation and cause the surrounding ground to swell and heave. This leads to irreparable foundation issues.
2- The original steel structure's top load-bearing structure
After converting into a cold storage, it is necessary to add insulation materials such as insulation boards on the top, and refrigeration equipment (such as air coolers, aluminum fin coils, and piping) inside the warehouse. The specifications and load capacity of the top steel structure and purlins must be considered. In northern regions, special attention should be paid to wind and snow loads, otherwise, the added weight on the original roof could cause structural collapse under extreme conditions. For every square meter of cold storage with aluminum fin coils, the weight of the aluminum coils, frost, refrigerant, and panel, along with the piping, is approximately 60-80 kg per square meter. Therefore, the load-bearing capacity of the original structure is also an important issue to address when retrofitting the warehouse.
3- Changes to the Fire Protection System
The original fire protection system of a standard warehouse cannot use sprinkler heads inside a cold storage or low-temperature warehouse after it is converted. For this reason, the fire resistance requirements for insulation materials used in the retrofitted cold storage become even more critical. Currently, the insulation materials available on the market mainly include B2 and B1 grade materials. We believe that B1 grade fire-resistant insulation boards are the preferred material for cold storage construction. It is important not to prioritize cheap prices and choose inferior or poorly fire-resistant insulation materials. Due to the large fire in Beijing last year, the government now requires the use of Class A insulation boards for cold storage. However, currently, no manufacturers produce Class A insulation boards for cold storage applications. Many manufacturers claim to produce Class A boards, but in reality, they are using products like rock wool or glass wool in sandwich panels, which do not meet the needs of the cold storage industry. Therefore, there is a gap between the Class A insulation boards available on the market and what is actually needed in the cold storage sector.
4- Electrical Power
The original standard warehouse did not account for the electrical power required by refrigeration equipment. Therefore, when converting to a cold storage, it is necessary to increase the electrical power capacity for the refrigeration equipment and make necessary modifications to the electrical system.
5- Other Considerations for Converting a Standard Warehouse into a Cold Storage:
For specific functional needs, different detailed plans should be adopted when converting a regular warehouse into a cold storage. The project team and the owner should discuss and determine the functional areas and usability requirements to ensure the conversion meets practical needs. This approach ensures that the cold storage conversion project is completed efficiently and in compliance with regulations.
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