Isolare, responsible for project supervision and insulation at new cooling and freezing terminal in Moerdijk: 'Successful construction is a team effort'

In the port of Moerdijk, a new cold and freezer terminal with a floor area of 21,000 m2 is being built for Frigo Warehousing. The company, which specializes in total logistics solutions, chose this location because it is a multimodal hub of goods and all transport options are nearby. We talk about the construction of this project and its special approach with representatives of the various disciplines. Because this project proves once again that successful construction is a team effort!

Reinier van Elderen, founder of Frigo and also client of this project: "The new building will be realized at a unique location. On a plot of approximately 6 hectares and with a good connection to the road network, a rail access in front of the door and our own quay, we can optimize logistical operations. The Port of Moerdijk is truly a hub where goods arrive from overseas for distribution within Europe or re-export with short-sea connections. This allows us to keep the cost of the logistics operation for customers as low as possible, as well as the environmental impact." Frigo will also establish a "Border Inspection Point" there. "This will allow us to be the only one in the whole of the Netherlands to inspect goods for distribution within Europe via a direct water connection. That too is a big advantage for our customers."

Principal as prime contractor

"Normally you realize such a project with a general contractor, but given the construction of several cold stores we have already realized this way, we like to be the general contractor ourselves. For the various disciplines within the construction, we sought suitable subcontractors who have the right knowledge and expertise, understand each other and focus on the common goals and ambitions." Transparency, trust and a structured approach are key to this, Van Elderen knows from experience. "A contractor can make money and save the client money if everyone is focused on smooth cooperation and proper execution of the job."   

Constant coordination

For a project of such size and involving so many disciplines to succeed, it takes a good project manager to provide constant coordination between all parties involved. And that important task lies in the hands of Marco Crum, project manager at Isolare. "This is really construction team work," Crum says, "with outstanding work being delivered by each party." Communication between them is crucial, and this is extremely pleasant and effective, he believes. Crum also emphasizes the importance of good preparation: "The architect for this project, Dinus de Rooij of BUREAU-R in Sprang-Capelle, had an enormous amount of experience in building cold stores. Together with him we made important choices. Unfortunately, he passed away suddenly in November 2021. A great loss, which made us work together even more closely if possible."

Calculate and draw

The new cold store will have a storage capacity for approximately 47,000 pallet spaces in this Phase I and will be equipped with mobile racking. Six freezer cells with associated expeditions, a cold store, a machine room and an office will be built. To take care of the drawings and calculations regarding the supporting structure, Bobby Goedhart of Raadgevend Ingenieursburo Van Nunen has been appointed chief structural engineer. Goedhart says: "In Moerdijk we are dealing with a highly variable ground pattern, which meant that a diverse and sound pile plan had to be drawn up. 1,877 piles were used with pile lengths ranging from 26.1 to 38.1 meters." The main load-bearing structure of the freezer cells and office is a steel frame. The expedition is combined with (precast) concrete. "The most special - and thus also a hefty challenge - is the mezzanine floor in the expedition, which spans 16 meters freely and can be loaded with a useful load of 3,500 kg/m2. With the designed construction and the desired freedom of layout, you have to calculate this well," says Goedhart. "The intermediate floor consists of N-beams specially produced by Haitsma for this purpose."

Building smart, fast and efficient with steel and concrete

Whereas Van Nunen set up the model for the purpose of construction, the delivery and execution of the steel structure are in the hands of Eric Vullings of Koppes Group. Niek Augustinus of Aannemersbedrijf Augustinus is responsible for the concrete. Goedhart: "We know Koppes Group from previous projects. You speak each other's language and can switch quickly." Vullings: "Thanks to, and in good consultation with constructor Goedhart, we were able to purchase the steel on time, especially because decisions were made quickly and professionally, early in the process. It is nice that you can rely on what has been discussed beforehand and that issues have been tackled beforehand, because all details have been professionally gone through." 

According to Vullings, Goedhart also played a crucial role in the interplay of steel supplier and concrete supplier. Augustinus: "For us, this is a big project. Not necessarily difficult, but a lot of square meters. And the concrete floors are often large, with cell floors of 2,500 m2, where there were high demands for flatness. In the case of the floor in the shipping department, we didn't have to set up columns to support the weight: I don't know of any other distribution center where that's the case." According to Augustine, it is clear that the client sought specialized parties who can work well together as a team. "The superintendent, who is quite relaxed about it and gives each discipline time to do its thing, contributes to good cooperation and to the fact that the quality is of an excellent level." Van Elderen agrees that outstanding work has been and is being done by each party: "I have really watched with admiration how quickly Koppes' assembly crew works. He himself indicates that it is also because the sizing and dimensions are prepared so accurately on site. That way you can build smartly, quickly and efficiently."

Best system for insulation and roof

Thanks to previous experience in building several cold stores, the client knew exactly which systems he wanted to apply for the insulation and the roof. Crum: "So the thickest sandwich panels on the market (200 mm) were used to save energy. Insulation was also used in the floors and near part of the doors of the freezer cells, plus an extra insulation shell near the dockboards because there are often insulation leaks there. The insulation values and fire resistance played a decisive role in choosing these panels from Isolare." Van Elderen adds: "Moreover, they have perfect vapor tightness (virtually 100%), especially on the roof. That used to be a challenge, but is so important in a cold store!" Berry Snel of Dakteam BV: "We were involved in this project thanks to a previously successful collaboration. Even for the roof, the client immediately knew what he wanted to go for: the best system in this area. No amount of convincing was needed for that." Snel explains that a high-quality loose-laid system with a two-layer bitumen roof covering was chosen. 

"Given the volume that has to be delivered each time, and the challenge of obtaining materials in this day and age, making good agreements and sticking to them is very important. To guarantee a good lead time and ensure watertightness, so that other parties can do their work, tight planning is crucial. And here too, Crum has acted as the oil in this well-run machine."

Refrigeration system and associated electrics

Also with regard to the selection and installation of the refrigeration systems, Pim Nettinga of Koudeservice Nederland BV notices that the mutual consultation between all parties is excellent. "Short lines, effective consultation moments and people with expertise. That really makes a difference." Among other things, he refers to the close and pleasant cooperation with the electrical installer. In this project, Pieter Paardekoper of Grimbergen Elektra is responsible for the power supply for the cooling installations, among other things. "The details of the cooling installations were supplied by Nettinga and we apply them in the electrical plan," he says. All other electrical installations were designed by Grimbergen Elektra itself, based on the input provided by the suppliers of the electrical doors, elevators, etc., combined with the knowledge and expertise of the installer to arrive at a good overall installation. "Thinking ahead within the chain also contributes to optimal cooperation and efficient working," says Paardekoper. "For example, we first connected the lighting in the cells so that the people of the concrete pour and the scaffold builders have light while performing their work. Incidentally, the entire installation was laid out with future expansion in mind."

Scaffolder

Frank Bunders of Dexion Netherlands is responsible for the layout of the cold store. Bunders: "To get the best filling and save on space - and thus energy - you want to use every cubic centimeter optimally. That is why mobile pallet racks were chosen. To use this system optimally, there has to be good coordination with the party in charge of the floor construction. The right foundation, the right timing between reinforcement and concrete pour: all factors that are important to us."

The mobile systems are a great sustainable choice. Because of the compact way of pallet storage and the flexibility within the system, you have an optimal filling state of your cold store and therefore less energy consumption. Moreover, it is arranged in such a way that one cell is made up of three parts, which gives you an operational advantage that every pallet space that is released can also be used again immediately for new goods. "In the mobile racking, every pallet space is directly accessible an sich," Bunders says. "The full height of the building is utilized. We set off the tallest pallet at just over 12 meters: this saves ground area and energy costs. Quite unique with mobile racking. Software-wise, we had to come up with the necessary solutions for this." Van Elderen adds: "We very deliberately chose a party - that is, Dexion - that could realize all this."

"You find that when you work with several expert parties, all of whom have a focus on optimizing their performance while taking each other into account, but also when this is well coordinated, you can build a high-quality building of a size like this without a general contractor. A true team effort that I am proud of," Van Elderen says in conclusion.