Coldstore construction experts ISD Solutions have finished work on their largest ever project, helping build what is believed to be the UK’s tallest high bay freezer warehouse.
The facility, constructed for Magnavale in Easton, near Grantham in Lincolnshire, is a giant, 101,000 pallet coldstore standing at 47.5m high.
The technologically advanced Automated Storage and Retrieval System (ASRS) warehouse is designed with an energy efficient external envelope and will operate entirely on renewable energy.
Gloucester-based ISD Solutions was the first UK company to build a high-bay clad rack warehouse – so-called because the internal racking supports the cladding envelope – in 2009, and has also pioneered ‘single envelope’ construction since installing the first of its type in the UK, over 20 years ago.
Now it has designed and installed all the exterior cladding on the brand new £130m development for Magnavale, including the high and low bay warehouses, adjacent office block and plant room.
Following successful projects in Warrington and Chesterfield, the new development brings ISD’s portfolio of work with Magnavale to just under £20 million in the past three years.
The new building is due to be fully operational later this year, after the construction phase is fully complete and with a month needed to gradually bring the interior down to freezing temperature.
Once finished, it will be the latest addition to the UK’s warehousing stock – addressing a shortage issue brought into stark focus following Brexit and during the Covid pandemic.
“We are extremely proud to be involved with such a landmark project and to be one of the trusted ‘client direct’ contractors for the scheme,” said Jason Denning, Director of Industrial and Commercial Projects at ISD Solutions.
“We believe that the finished building, with its energy efficient design, physical proportions and unique aesthetic features, sets it apart from all previous similar facilities and will raise the bar for future temperature controlled ASRS buildings.”
Standing at over 150 metres long and 100 metres wide, construction of the Easton facility required ISD Solutions to install almost 60,000m2 of composite Kingspan Cold Store quadcore panel and 18,500m2 of floor insulation, incorporating high density thermal blocks to support the building structures.
ISD’s special projects team also designed the facility’s low-bay freezer envelope, split over three mezzanine levels and standing at 24m high. The completed project includes 28 conveyor airlocks, each with two rapid roll airtight doors to minimise hypoxic air loss, with a further 28 fire rated shutters for fire compartmentalisation.
Meanwhile 20 loading dock pods each feature inner dock freezer rapid action doors, with strict humidity controlled via a bespoke dehumidification system.
All elements had to be delivered and constructed within a footprint restricted on all sides presenting logistical and storage challenges
“Safely installing the freezer envelopes at up to 47m height, within 3.5m of adjacent working buildings, whilst avoiding disruption to their operation, took a great deal of careful and highly co-ordinated logistical planning between all of the main trades,” said Mr Denning.
“However we’ve been doing this for a long time. So our team, most of whom were involved with the development of the UK’s very first single envelope and high bay clad rack buildings, drew on all their experiences to overcome the logistical challenges of the site.
“We’re pleased to have managed the scale of the buildings to successfully complete the installation to exceptional standards and with minimal disruption to the site.
“We know that the UK is severely lacking in frozen warehousing space, and we also know that high-bay automated warehouses are what is needed to make up this shortfall. So we’re looking forward to continuing our relationship with Magnavale to help meet that demand.”
Adrian Smith managing director at ISD Solutions, paid tribute to the site workforce provided by S Tysoe Installations: “This project was a test for the resilience of our site resource teams and ISD is extremely proud to have a skilled in-house workforce with the necessary drive and determination to deliver a first-class facility.”
Jonathan Gagg, director at Magnavale’s parent company Sadel Group, said: “Once in operation, in late 2024, we expect that the Easton development will transform frozen storage and value-added capabilities across the UK, allowing our partners to cut unnecessary cost, risk and complexity within their cold chain. We thank the team from ISD Solutions for their exceptional work on this project and we look forward to working with them again in the future.”
ISD Solutions is part of Gloucester-based The P & M Group, which includes PLG Insulations, a division in Australia and Midlands-based installations specialists S Tysoe Installations. Together the companies employ more than 190 staff, with a combined turnover of around £70m.
