Rack Supported Cooler and Freezer – A Case Study

Solution at a Glance:

• Services Provided: Design, Project Management, Permitting Support, Installation 
• Products Provided: Pallet Flow Rack, Selective Rack 
• Location: Temecula, CA 

Concern: Tight Timeline for New Distribution Center

A vaccine distributor was relocating to a new distribution center and required a storage system for their cooler and freezer.

The company initially issued separate RFQs for the insulated enclosures and the pallet rack systems. This traditional construction approach would require the cooler and freezer structures to be built first, followed by installation of the storage systems inside.

The sequential installations along with having to manage multiple vendors created a timeline that was not ideal for the company to resume operations.

Solution: Rack Supported Cooler and Freezer 

REB Storage Systems was selected to project manage the rack system and evaluate alternatives to accelerate the project timeline. After reviewing the facility requirements, REB recommended a rack supported building approach for both the cooler and freezer.

A rack supported design uses the pallet rack structure as the primary support system for the walls and roofs, eliminating the need for separate building frameworks. By integrating the storage system with the insulated enclosure construction could occur simultaneously.

This approach provided several key advantages:

• Reduced overall construction time through parallel installation
• Decreased project cost by eliminating redundant structural elements
• Increased storage capacity due to the removal of building columns
• Simplified coordination with a single point of contact for the project

REB managed all aspects of the project, including material procurement, freight coordination, structural and seismic engineering, permitting, and installation.

To complete the temperature-controlled environments, REB partnered with a specialized cooler and freezer manufacturer that supplied insulated wall and ceiling panels, as well as refrigeration components. Both teams worked in tandem to erect the rack structure and enclosure simultaneously.

Rack Supported Cooler Construction 

The cooler utilizes selective pallet rack. Rack frames are extended to the full height of the enclosure to support the walls and ceiling.

Because the cooler operates at higher temperatures than the freezer, roll-formed rack was used as a cost-effective solution without compromising structural integrity. Additional structural components included:

• Ceiling support beams and bracing above storage areas
• Cross-channel beams to support evaporators and refrigeration equipment

Rack Supported Freezer Construction 

The freezer incorporated pallet flow rack to support high density storage and first-in, first-out (FIFO) product rotation. Due to the extremely low operating temperatures, structural steel rack was used to maintain strength and durability.

Like the cooler, rack frames extended to the full height of the structure to support the enclosure. Additional components included:

• Structural mono-posts for enhanced load capacity
• Cross-channel bracing for structural stability
• Integrated support for refrigeration evaporators

Outcomes: Accelerated Timeline, Reduced Costs, and Increased Storage Density

Combining the storage systems and cooler and freezer frameworks provided several benefits for the company, including:

Faster project completion: Rack supported construction enabled simultaneous installation of the rack system and insulated enclosure. This significantly reduced the project timeline compared to traditional consecutive construction.

Lower total project cost: Eliminating the need for a separate building structure reduced material and labor costs associated with columns, structural steel, and redundant construction phases.

Maximized storage capacity: The absence of building columns increases usable storage space, allowing for a higher number of pallet positions and full use of the cube within both the cooler and freezer.

Streamlined project management: A single point of contact through REB simplified coordination and minimized risk across design, engineering, procurement, and installation.

Improved operational readiness: The accelerated build schedule allowed the company to transition into the new facility sooner.

Contact REB for Your Rack Supported Building Requirement 

At REB Storage Systems International, we look at each project as unique. While many have similarities for which we can leverage our experience and knowledge, each client has unique needs that must be met. 

REB has the flexibility to integrate products from multiple manufacturers based on the requirements of your rack system including pricing and lead time. This combined with in-house design, project management, and permitting support allows us to provide you with your unique storage solution. 

To receive storage solutions that optimize your unique requirements, fill in the contact form or call (800) 252-5955.