Kloosterboer Delta Terminal 3, Rotterdam | Cold as ice

During the successful realization of an automated high-rise warehouse in Lelystad, Kloosterboer, specializing in cold and freezer storage and transport of food products, approached B-Built again. This time for the realization of a new freezer warehouse (KDT-3) on the Maasvlakte in Rotterdam, a project built according to the recipe of BREEAM 'Outstanding' (five stars). An interview with Martijn Baartmans of B-Built.

The new freezer storage on the Maasvlakte is a nice second collaboration between B-Built and Kloosterboer, begins Baartmans. "The initial design dates back to January 2018, and in June of last year we started implementation on site.  Completion was scheduled for mid-February this year. For us, therefore, a 'fast track' project for good reason due to the tight lead time. We were responsible for the architectural part of the project, but also fulfilled the role of coordinator for the client for all other stakeholders within the project. Think of the E- and W-installer, the cooling installation, the fire alarm system and the storage system for pallets, the mobile racks, ...."

23,000 pallets
The floor plan of the new freezer storage facility measures 11,000 m² and is equipped with an integrated mobile shelving system. "A detailed coordination between the racking system and the building envelope led to fitting as many pallets per compartment as possible," says Baartmans. "We also optimized the freezer storage according to regulations, with maximum permissible dimensions per building compartment of 2,500 m² each. Incidentally, the total capacity of the new freezer storage is 23,000 pallets." The mobile shelving system is similar to an automated library where entire sections shift on rails and 'new' aisles are constantly being created for the benefit of the reach trucks, Baartmans explains. "In the freezer storage area there is a constant temperature of minus 22 degrees Celsius. This also applies, incidentally, to the area in front of it, which acts as a buffer zone for loading and unloading. Freezer trucks can connect to the shipping area via one of the nine docks. An air cushion seal is then inflated to ensure an optimal seal between the freezer truck and the dock, and use is made of the so-called DOBO system (dock on before opening) in which the truck doors are not opened until the air cushion seal is inflated. Also provided is an additional dock for automatic unloading (and loading in the future)."

KDT-3 was designed according to BREEAM "Outstanding," on which a design certificate has already been issued. "This means that the construction process and the building meet the highest sustainability requirements," Baartmans says. "For example, Kingspan Quadcore roof and wall panels were deliberately chosen in a combination of 200 and 220 millimeters in thickness. Thanks to the white color setting, the radiation of temperature into the insulation core is kept as low as possible." In addition to the storage cells and shipping area, KDT-3 also includes a small office area, an engineering area serving compressors and switch boxes, among others, as well as a battery charging area for the electric reach trucks.