18 B ULK D ISTRIBUTOR
Warehousing
Bulking up the
distribution network
July/August 2019
Paul Gouland, marketing
director at Clugston Group,
discusses the complex
challenges and opportunities
surrounding the construction
of large-scale warehouses and
distribution centres
H
andling and storing bulk materials can present a myriad of
challenges, from ever more stringent regulatory
requirements to health and safety risks, blast proofing and
even security.
Most dry bulk commodities are prone to spillage and dust pollution,
contamination and even combustion if not stored correctly.
Warehouses which handle bulk materials, from fuel to flour and
grain, steel, cement or more, therefore, present unique design
challenges for bulk logistics providers and construction companies
alike. The manufacturers, carriers and logistics providers who store
and transport these products must adhere to a complex array of
regulations, from specialised COMAH Regulations to ATEX, DSEAR
and the Health and Safety at Work Act 1974 (HASAWA), each aimed
at minimising the risk to both employees and the wider public.
Due to the varied nature of products stored in such facilities, and the
regulatory constraints placed on them, the potential implications of
improper storage and handling must be carefully considered at all
stages of the design, build and post-build care of facilities.
Add to this advancements in sophisticated warehouse automation
to deliver improvements in efficiency, speed, reliability, accuracy and
(in the long-term) cost savings, and the challenge of constructing such
facilities becomes even more apparent.
With a new wave of automated technology from storage and
retrieval appliances to state-of-the-art conveying systems now in
operation in many warehouses, the required process capacity, site
constraints and local planning can all impact the layout and building
design, meaning no two facilities are the same.
A bigger, better future
One of the most noticeable impacts this has had is an increase in the
number of large-scale warehouses and distribution centres being
built to meet the demands of the sector. Facilities are not only
becoming bigger, taller and wider, but also smarter, and more flexible
than ever before.
To meet this challenge, leading construction companies are now
using building information modelling (BIM) – an intelligent 3D
model-based process – to model sophisticated warehouse designs
before on-site work begins. This ensures businesses get the space
they require for equipment, products and employee movements.
To accommodate both the storage systems, machinery and
handling equipment, facility layouts need to be completed to an
incredibly high level of accuracy as even a minor degree of inaccuracy
can cause major problems.
The utilisation of innovative BIM technology allows building data to
drive efficiency, boost sustainability and minimise waste during the
construction process. Prototyping structures virtually guarantees
facilities not only meet the requirements of the end-user, but also
maximise efficiency for day-to-day activities taking place at the
facility.
Robustness should be central to the design and construction of any
bulk or semi-bulk storage and handling facility – particular in
instances where blast proofing may be required – and therefore
should form part of the underlying design requirements.
Evolutions in construction methods are enabling warehouses and
distribution centres to be built to withstand larger blast loads than
ever before, but careful consideration should be given to both the
construction procedures and materials utilised during the build. The
glass, bricks and cladding of a facility, for instance, can be
constructed to high blast proof overpressure specifications, while
innovative construction methods such as including additional brick
ties throughout the structure can bolster the strength of the building.
Clugston has expertise in construction, property, facilities management and logistics
Operational efficiency
Efficiently stockpiling large amounts of bulk powders in any given
space is fundamental to ensuring operation efficiency, as well as
reducing risk to employees.
Bulk products are more complex and difficult to store and, indeed
transport, meaning storage facilities not only require a greater level of
attention when it comes to safety, as well as extensive training for
handlers and more careful planning, but it also often requires
specialised storage systems to accommodate the potentially sensitive
goods.
Large and complex storage systems, such as steel bulk silos, hoppers
and IBC containers, are often required to store all types of powdered
products. The way that such systems are installed and arranged can
make a huge amount of difference to the number of products that a
building can accommodate. When it comes to storing sensitive goods,
special attention should be given to making sure that storage systems
installed are correctly designed and constructed to ensure stability at
all times. However, perhaps more importantly, spacing and positioning
of such storage solutions should also be a key consideration during
the design of a warehouse.
Warehouses are dynamic environments, in which employees,
vehicles and machinery are continuously on the move. It is essential
that the layout of each warehouse is carefully planned and custom-
built for the specific requirements of the facility.
Typically the storage area will be determined by the most
hazardous property of the bulk powder and the potential risks it
could pose should an incident occur in the facility. For instance, if a
material is flammable it would be appropriate to store with other
flammables. Electronics and electrical wiring may also need to be
guarded and protected more, due to the risks of sparks that could
lead to combustion. Such ignition sources can be avoided with
clever workspace planning and diligent construction processes, with
careful planning from the outset.
Redhouse Interchange is a joint venture between Clugston Estates and Cromwell. The 200 acre
distribution, office and leisure park is located near Doncaster, South Yorkshire
It is essential that the layout of each warehouse is carefully planned and custom-built for the
specific requirements of the facility
To avoid dangerous situations and to spare the environment
sometimes storage tank protection is needed. This often means
tanks must be fitted with adequate means of operational and
emergency venting, and explosion protection devices for use in
potentially combustible atmospheres. This will ensure systems
comply with industry standards such as ATEX & ISO 16852 (Flame
Arresters) and API2000/ISO28300 & NFPA30 (Venting & Storage of
Combustible Vapours & Liquids).
Value added logistics
The completion of a bulk material warehouse project, complex and
involved from the early consulting and planning stages, through
design, build and final handover, is not the end of the story. Indeed,
it is just the beginning of another chapter in the lifetime of a facility.
A well-organised bulk storage warehouse ensures that fulfilment is
as streamlined as possible, and having an effective distribution
network in place can not only ensure the capacity to transport a
multitude of different products, but also provide valuable flexibility,
short lead times and enhanced customer service for dry and
granulated products across a diverse variety of sectors.
Despite the critical role it plays, however, less than a fifth (18
percent) of UK companies are happy with their third-party logistics
suppliers (3PLs), according to the latest research from supply chain
and logistics consultancy SCALA.
Streamlining the transition process from completion of the build to
day-to-day operations can provide a competitive advantage for
supply chain professionals in the bulk and semi-bulk sector. Working
collaboratively with one organisation, such as Clugston, which has
expertise in construction, property, facilities management and,
perhaps most crucially, logistics, which already has in-depth
knowledge of a site, ensures a fluid handover.
www.clugston.co.uk