General Interest

What’s so different about cold store floors?

What’s so different about cold store floors?

Normal warehouse floors are designed to carry the loads that will be imposed on them, including forklifts, pallet racking systems or bulk product. These concrete floors are reinforced both to carry load and to stop unwanted cracking both during the curing process and thereafter for the life of the store. Storing new products should be done with care. I once visited a good friend whose office was on the third floor of an old CMT (cut, make and trim) building. All of a sudden his office door wouldn’t close. It didn’t take much investigation to reveal the cause. 12 pallets of sugar weighed rather more than fabric and were forcing the concrete floor downwards. All concrete floors will crack. However this process can be managed by way of fibre, reinforcing, anti-crack mesh, expansion/contraction joints and saw cut joints. If rails are installed in the concrete floor either for cranes or mobile racking, then increased reinforcing is likely both to assist in carrying and spreading the increased rail point loads and to prevent the concrete floor from cracking around the rails. This can happen as embedded rails are crack inducers. The actual design of normal concrete warehouse floors depends on the supporting ground beneath. If it is of a variable nature or not weight supporting, and the imposed loads will be relatively large, then piling may be needed. Freezer store concrete floors or wearing slabs must incorporate all the requirements of normal warehouse floors with a few extras for freezing. If the temperature of the subfloor approaches freezing, usually plus 4 degrees C is taken as the danger point, then any water moisture in the subfloor will freeze. When water becomes ice, it expands in volume and has to be accommodated. This normally leads to the concrete floor rising and cracking as the rise is variable over the floor area. Ice will lift just about any weight which is particularly important when pallet racking is present. As well as underfloor insulation, all freezer floors should have added protection from frost heave. In South Africa the current standard is the electric heater mat which is normally laid in three circuits in case there is a circuit malfunction. The mat only uses energy if the subfloor temperatures reaches 4 degrees or less. Some larger freezer stores are now using a warm piped glycol/water mixture which absorbs the waste heat given off by the condensers. These run continuously. The Australians favor underfloor 200mm diameter pipes through which warm air should be blown via a fan system. The pipes are laid at a slight angle to prevent moisture from lying in them as this might freeze, gradually closing the pipe. I was in one freezer where frost heave had raised portions of the floor by over 800mms. The store had a good underfloor air ventilation system but the openings had been blocked with checker plate to stop rats from entering. Mobile racking is especially affected by “frost heave” as the drive systems are designed to only operate on reasonably level floors. Freezer floors also experience a secondary contraction when cooled to below zero temperatures and it’s not unusual to see a 10 to 15mm gap between the concrete floor and the insulated wall panels. It is not a good idea to ‘cool’ a new freezer store quickly as it’s more likely to crack – especially around the door, a high traffic area. In freezer stores there can be either contraction or construction joints. I have seen freezer stores up to 1600m2 without contraction joints where the reinforcing is designed to make the floor shrink inwards. In this situation one would expect to have about 120 to 130 kgs of reinforcing per m3 of poured concrete. Contraction joints should be designed so that both sides of the joint can move, but that the same level is maintained. These should be armored when in high use areas like gangways. We try and design mobile layouts s that any contraction joints are under fixed racks. In such instances where a double fixed rack spans a joint, the one side should only be bolted down once the floor has stabilized at its sub- zero temperature. Although tempting in a mobile store, construction joints should not be placed at rails as this encourages cracking and voids. Cold store floors are the most important part of a freezer store and should be seen not just as a wearing surface but also as a foundation for the racking system. It is therefore worth taking time to get the floor right as subsequent repairs on a large scale at subzero temperatures are extremely difficult. For those who do have the occasional floor problem, Barpro stocks Spalpro 2000 and Febset 45. Read more: Issues to consider when building a new cold or freezer store Read more: New innovations at Novo Fruit Packers Read more: Would you like to reduce energy usage in your freezer store?

What’s so different about cold store floors? Read More »

Barpro Storage Celebrating 21 Years in mobile racking and shelving

Celebrating 21 years

This article was originally published in the August 2017 Edition of the Supply Chain Today Magazine When Barpro Storage opened for business in Cape Town on 26th September 1996, South Africa was still very much “in transition”. Cold storage’s, as of 2017, still continuing super cycle would not start for another four years. Export markets were still depressed by South Africa’s prior pariah status. The Rand/Pound exchange rate continued to slide the wrong way for imported goods, even then down to over 20 to 1 as world opinion betted against a bright future. Sitting in the first-floor offices at the corner of Section and Shropshire streets in Paarden Eiland, with only a store-man for company, I missed my previous cold store manager’s job and spacious office at Auckland Cold Store just down the street.   With 34 Storax systems  installed, mainly in Cape Town, my biggest fear was that the mobile racking market was already saturated. As the phone wasn’t exactly ringing itself off the hook, the future looked somewhat bleak and I suspected there might be more money in selling dried milk powder, a product inherited from Storax UK’s previous  agent.   Fast forward to twenty-one years later. Barpro now occupies a 1200 square meter factory in Montague Gardens and has 30 employees including a branch office in Johannesburg. There are over 250 Storax systems in Southern Africa as well as a few on Mauritius and one in Melbourne, Australia.   While Barpro Storage hasn’t exactly blown the lights out, it has more than survived, which gives me a measure of wary confidence amidst the current uncertainties. There are many who deserve our appreciation. From Gert Wolfson, WW2 Mosquito pilot and Storax agent who originally saw the potential for Storax mobiles, to Peter Spears, with the exactitude of the UK automotive industry behind him, who had a hard time  transforming  me from a cold store to a business manager. As well as sympathetic bank managers, before they all seemed to disappear, there are the learning opportunities afforded by customers, ever helpful suppliers and competitors who will never, I trust, allow complacency to creep in.   Our business model is simple. We like to help. That means we not only enjoy designing Storax systems, but also like to look after them long after they have been installed. While most are for palletized products, we have one to store motorcars and others for wood, steels and other metal extrusions. So far, our oldest system operated for 23 years until the freezer store closed. Though it may sound corny, we see a contract as the start of an ongoing relationship, which may have its ups and downs, rather than a one night stand.       Initially our workshop was there to make spares. Accidents happen, but warehouses cannot afford to stop for six weeks until a new mobile wheel unit arrives from Europe. In emergencies no mechanical spare must take more than 48 hours to dispatch. Generally, we do better than this. Trouble was, although we needed the facility, there weren’t enough break downs to make it profitable, so we decided to make smaller Storax systems under license from our principal, Storax, which is based in the UK.   Barpro is now training CPUT technical students who are working on sites and wiring control panels. Mike Vermeulen, Barpro’s Technical Director, has, with his team, designed a new safety PE (photo electric) safety trip bar which has been approved by Storax and is assembled on the premises. Practical training is a critical requirement for South Africa. Barpro believes that anything made in Europe can, with the correct training, be made to the same standard here.         Globalization is all very well, but we cannot afford to be fundamental about it when unemployment rates are heading north of 40%. Industry has got to supply not just jobs but challenges which give confidence to South Africa’s youth.   I just wish that our Government would stop dictating how we must do business through endless BEE requirements. Far more would be achieved if they tended the playing field and let us get on with playing the game. My other gripe concerns some of South Africa’s larger conglomerates. Barpro lost a project  even though we are, within all the constraints, employing and training local staff. It was made clear that the customer had no interest in such “philanthropy.” “Your European competitor was cheaper and that’s all that matters.” This is ironic as most of our staff frequent their stores.  Yet there has been no interest on their part in seeing for themselves what Barpro has accomplished. This sort of attitude has got to change if South Africa wants to employ the youth it is spending so much to train and who, after all, are the future of this country.     Barpro Storage SA (Pty) Ltd was established in 1996 to market, install and maintain Storax mobile racking. Mobile racking can almost double the useable storage capacity of a warehouse or cold store while maintaining immediate access to every storage location.   Mobile racking consists of special rails which are laid into the cold store floor. The Storax mobile bases run on these rails and support the racking superstructure. These bases, which when loaded, can weigh over 300 tons, are electrically driven by energy efficient geared motors.   Barpro Storage now markets the Storax Ranger, the new and improved Shuttle system as well as other complimentary products to de-ice and repair freezer room floors. Barpro Storage is the African agent for the UK based Delf range of Freezer Wear.   For more details contact us on 021 552 9190 or 011 450 1075 [gravityform id=”10″ title=”true” description=”true”]   Read more: Why Barpro Storage? – Its simple! These 5 points explain… Read more: Changing Load Parameters in Mobile Pallet Racking Read more: Barpro has been manufacturing mobile bases for over 5 years!

Celebrating 21 years Read More »

2 door nesting Rolltainers

Rolltainers and Roll Cages

This article was published on behalf of Cape Gate Fence & Wire Works (021 937 7133) If you run a freezer store and need Rolltainers or Roll Cages why not contact Cape Gate Fence & Wire Works in Cape Town? Their new range has freezer friendly wheels, is well priced and creates local jobs. For more information contact their sales department on ctsales@capegate.co.za or call 021 937 7133

Rolltainers and Roll Cages Read More »