US Cold Storage

United Insulated Structures spearheaded the design, engineering, site development, and construction of a monumental 750,000 sf freezer distribution warehouse, executed in six distinct phases over 24 years. This state-of-the-art facility stands as one of United States Cold Storage’s largest and marks their second fully-automated warehouse, featuring a sophisticated 180,000 pallet Automated Storage and Retrieval System (ASRS) freezer.

Phase 6 of the project significantly expanded the facility’s capacity by adding 26,000 pallet positions to the existing 55,000. It also introduced advanced central ammonia refrigeration systems and a cutting-edge ASRS equipped with 13 high-efficiency cranes and a comprehensive inbound and outbound conveyor system. The ASRS boasts an impressive clear height of 100 feet, a multi-level automation system for both layer and case picking operations, and in-rack sprinklers, enhancing both operational efficiency and safety.

Innovative Structural Strategies for Cold Storage Automation
To support the complex ASRS system, we developed a creative seismic solution by installing 2’x2’x2’ concrete piers on top of the slab—eliminating the need to cut into the slab and protecting the glycol system beneath the freezer floor. A mezzanine built over the dock reversed the conventional warm-to-cold layout with an insulated metal panel (IMP) ceiling, while also being engineered to withstand heavy forklift traffic and support a gantry crane system. The mezzanine’s sawtooth slab edge required precise coordination with the ASRS contractor. Additionally, we implemented a custom snow load design to accommodate the elevation change between high and low roofs, ensuring structural integrity throughout the facility.