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

Innovative Warehouse Design

Council of Supply Chain Management Professionals Global Conference

Warehousing InnovationsTrack 20

Session E-1

Doug Pope


1

http://cscmp.org/default.asp

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


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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)


1. Sustainable Sites 26 points2. Water Efficiency 10 points3. Energy and Atmosphere 35 points4. Materials and Resources 14 points5. Indoor Air Quality 15 points6. Innovation and Design Process 6 points7. Regional Priority Credits 4 points

110 points


• Sustainable Design & the LEED Score Card

0-40

40-49

50-59

60-79

80-110

Certified

Silver

Gold

Platinum

Not Certified

Points

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


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Site Considerations• 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


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Landscaping• Using natural vegetation

– Limiting the use of grass to eliminate mowing and irrigation

• Collecting rainwater in cisterns for irrigation and toilets


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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

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


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http://en.wikipedia.org/wiki/File:Santarem_carfree.JPG

Landscaping

• Reducing the amount of disturbed area through the use of underground parking or parking decks

• Waste diversion– Trees to mulch


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Landscaping• Light trespass

– No light off the site– Down lighting so you

don’t illuminate the night

• Night sky compliant fixtures


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http://en.wikipedia.org/wiki/File:Earthlights_dmsp.jpg

http://en.wikipedia.org/wiki/File:Flat_earth_night.png

Landscaping


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• Vertical Axis Wind Turbines• Helix wind turbine testing

– Smaller footprint than typical wind turbines– Generates enough electricity to power a battery room


Building Envelope

• Roofs– Single ply white PVC roof

• Mechanically installed• Heat welded seams

– R-12 insulation in roof


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Building Envelope• Roofs

– The Tesco photovoltaic roof


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Building Envelope• Roofs

– Grass roofs


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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


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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


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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


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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


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Lighting• Daylighting

– Decreasing energy use by installing skylights in combination withsmoke vents


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LightingInterior Electrical Lighting

– Fluorescent Lighting except in freezers

• T-5 or T-8


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http://www.ultraluxlight.com/t5_high_bay_235_prd1.htm

Lighting

• Lighting Controls– Computer controlled timers for all areas– Motion sensors


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HVAC Equipment and Systems

• Cooling Equipment Efficiencies– Night flush air vents for summer


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HVAC Systems


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Thermal Mass Temps.

0

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Hours

Tem

per

atu

re (

C)

Ambient

Air Temp

Mass Temp

start of night flushend of night flushheat release from mass

heat gain by mass


HVAC Equipment and Systems• Heating Equipment

Efficiencies– Radiant heat system

with ceiling mounted radiant panels


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HVAC Equipment and Systems

• Supply Fans


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http://www.bigassfans.com/images/gallery/photos/originals/Graybar_install1.jpg

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


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Refrigeration

• Ammonia vs. Freon– 300 tons is the current limit– 404 and 410 are the main remaining Freon types


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Refrigeration

• Variable Frequency Drives– Based on sensor feedback– Potential for hot spots– Inexpensive to install

• Compressors• Evaporators• Drives


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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


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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


32


Plumbing• Low Flow Toilets• Waterless fixtures• Gray water treatment


33


Fire Protection• Upright sprinkler heads

– Supplied from a wet system in a heated space

– Eliminates the need for in-rack sprinklers in temperature controlled areas


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http://news.thomasnet.com/images/large/816/816828.jpg

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


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• Column spacing and flexibility


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38




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• Application of automation– Look for where it fits

• Avoiding future expense through design


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Other Considerations


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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



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BIM (Building Information Modeling)



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Charge in place systems



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Recycling waste through anaerobic digestion

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


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Overall Cost Premiums- Certified 1%- Silver 2%- Gold 4%- Platinum 7%

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


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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


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Thank YouDoug Pope

Kennesaw Advisory [email protected]

770-330-4172


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Documents

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