Automated Storage Retrieval Systems (ASRS) Rack-supported Construction
March 6, 2025
Safety
Rack-supported structures pose unique construction risks, requiring design and execution plans that take into account the fact they may be more than 100 feet tall. The risks associated with the height of the structure can be addressed by installing as many of the systems and equipment (e.g., piping, conduit, ductwork, MEP) as possible on the ground. Safety can also be improved by meticulously planning post-erection access for tie-ins, commissioning, and maintenance by considering catwalks, platforms, and use of the storage retrieval machine (SRM) for access. High-definition laser scanning drones also positively impact safety by removing the need for physical access to perform risky post-construction tasks such as rack plumbing, testing and balance, and other commissioning activities.
Collaboration
Project success is determined by the ability of all stakeholders to work together effectively. Key stakeholders such as mechanical, sheet metal, electrical, fire protection and rack erector trade contractors must begin sharing information during the bidding process to ensure the construction plan accommodates each firm’s scope of work. While some trades will move faster, others will need to move slower to allow for pre-installation of systems. Earlier communication will also enable the team to plan the sharing of critical equipment such as narrow-base high- access scissor lifts and develop a plan for out-of-aisle access that can be used by all trade contractors on the project. This approach will increase production and improve workflow by reducing equipment in the constrained space.
Quality Control
It is important to develop a project-specific quality program that addresses the elements most critical to your project’s success:
- Tolerances – Rack systems that support a SRM have exceedingly small tolerances (approximately 3/4” in aisle width and 1/4” plumbness) that are more stringent than American Institute of Steel Construction (AISC) tolerances found in traditional steel. How do you confirm the entire aisle meets these requirements? High-definition laser scanning each aisle from the ground enables you to pinpoint any member that is out of tolerance without requiring anyone to assume the risk of physically accessing each post.
- Elevation – Defining the slab’s high point to establish bottom plate elevation is a critical part of the project. Once again, laser scanning is an excellent solution. We can scan the slab and develop the topography using 1/8” topo lines. This approach quickly enables you to establish an elevation, determine isolated problems, and communicate variations to all parties, including the integrator and insulated metal panel (IMP) installer.
- Thermal Breaks and Vapor Emission – This is a major point of concern that requires engaging subject matter experts during the review of the shop drawings for the IMP and roof. The primary focus should be on penetrations and ensuring they are detailed specific to the penetration type. Due to their height, many ASRS facilities do not lend themselves to an effective spray test to check for intrusion. A blower door test can be conducted prior to system startups to identify areas of air leakage and thermal scans can be used afterward to determine air leaks through temperature variations of the building envelope. These processes and technology enable quality control tests to be performed safely from the ground with results that will more effectively pinpoint problems versus losing valuable time chasing leaks.
Schedule
Our unique construction approach provides a faster, safer project despite appearing slower at the onset. The traditional building method results in the rack being constructed quickly, with the IMP installed shortly thereafter. However, this leaves a significant amount of work remaining within the rack itself, creating a less safe and more congested environment.
Experience has shown us pipe, duct, fire protection and other components take longer to complete and are difficult and risky to install into the rack at heights. That is why our strategy phases the work to enable more scope to be completed concurrently. Using our approach, the facility is more than 80% complete for rough-in and fit-out at enclosure versus the 0% completion we typically see at that stage using conventional means. This reduces the duration from enclosure to project startup significantly. Those time savings shorten the entire project schedule.
Tom Hart, VP and Manufacturing Market Segment Leader
Vice President Tom Hart is a 28-year construction veteran who has been responsible for completing many of Messer’s most complex projects throughout the Midwest and Southeast. In his role as Manufacturing market segment leader, Tom has become well-versed in the construction of facilities featuring Automated Storage Retrieval Systems (ASRS) for material handling and rack-supported structures. Leveraging his experience delivering these buildings, Tom has identified best practices that address the most important challenges associated with this project type.
