INNOVATIVE, FEATURE RICH STORAGE & CRANE BUILDINGS
WWW.BAN-AIR.COM
CONTENTS Introduction 03 Integrated Storage Soltutions
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Key Features & Benefits
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Construction of the OutStore速 08 Modular Options 10 Custom Built Solutions 12 Design & Engineering 14 Project Planning 18
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INTRODUCTION BAN-AIR STORAGE SYSTEMS速 Ban-Air Storage Systems is a leading manufacturer and turnkey supplier of high quality, durable storage and handling solutions. With extensive experience since the mid-1990s and hundreds of installations completed worldwide, Ban-Air has developed a unique product offering to provide highly versatile and effective solutions to address any storage problem. OUTSTORE速 STORAGE & CRANE BUILDINGS The Ban-Air OutStore provides an innovative solution for increasing storage capabilities outside of current building limitations. Utilizing existing hard-stand or yard space, the OutStore provides a permanent and durable structure that is quick to construct. More versatile and longer lasting than a canvas clad tent the OutStore delivers a building and advanced rack system for a similar, and often lower, cost than constructing a more traditional building. This cost effective solution can be designed to your unique specification, built and installed ready for immediate utilization in as little as 12 weeks. With a range of modular options ranging from lifting and handling devices, to renewable energy sources, the OutStore provides a complete solution for your growing storage needs.
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INSTANTLY ADJUSTABLE RACK SYSTEMTM (IARS) The Ban-Air Instantly Adjustable Rack System (IARS) provides the strong and durable supporting structure on which to build the OutStore, whilst delivering versatile and efficient storage capabilities. Unlike standard fixed-height storage racks, the IARS incorporates completely removable steel pallets that allow for variable shelving configurations. Pallets can be instantly adjusted at 6 inch (150mm) increments with the use of any standard forklift to provide custom fit storage across all available warehouse space. A wide range of accessories are also available to customize fully any system to meet your needs. The bolted sectional construction of the IARS is designed to provide the most flexible configuration for your storage needs, with the ability to incorporate different bay widths within the same aisle or create personnel walk-thru areas. VIEW FULL DETAILS ONLINE AT WWW.BAN-AIR.COM/IARS
WALKLIFT速 HANDLING SOLUTION A WalkLift system can bring further ease and efficiency to operations within your OutStore. The optional self-contained lifting and handling device consists of a Mast and Bridge assembly with lifting forks, enabling a single operator to handle loads weighing up to 5,000 lbs (2,275kgs) without the need for a forklift or certified operator. Narrow aisle width requirements result in extremely high density storage and with a variety of flexible configurations, the WalkLift can provide quick and efficient handling and retrieval across your entire OutStore structure. Used in conjunction with the IARS, the WalkLift can make a dramatic difference to your operations with the loading of pallets made safer, easier and more efficient.
VIEW FULL DETAILS ONLINE AT WWW.BAN-AIR.COM/WALKLIFT
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OUTSTORE速: THE COMPLETE SOLUTION
The OutStore is a fully steel-clad warehouse built around the IARS. It combines a cost effective building treatment, an advanced rack system, and the option of an integrated lifting and handling system, with the benefits of fast and efficient installation.
The design of the OutStore starts with the rack as the supporting structure, so there are no issues or obstacles to work around. This approach ensures the most efficient storage building possible, with wall-to-wall and floor-toceiling storage capabilities.
The modular design provides the flexibility to reconfigure storage facilities and even enables the structure to be disassembled, relocated and reassembled when circumstances change.
A wide range of modular options are available to further customize your OutStore - from cargo and personnel doors to fully secure the structure, to open spaces for creating office areas, to translucent cladding and skylights for maximum natural light.
As most storage systems are retro-fitted to the inside of a building once construction is completed, they often have to accommodate support columns, pipes and other obstacles. VIEW FULL DETAILS ONLINE AT WWW.BAN-AIR.COM/OUTSTORE 5
ADD A NEW DIMENSION TO STORAGE EFFICIENCY WITH WALL-TO-WALL AND FLOOR-TO-CEILING RACKING
USE EXISTING SPACE
COST EFFECTIVE BUILD
QUICK IMPLEMENTATION
INTEGRAL RACK BUILDING
EXISTING SPACE CAN BE USED FOR YOUR OUTSTORE, SUCH AS AN UNUSED CAR PARK
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KEY FEATURES & BENEFITS MAXIMIZE STORAGE RESOURCES on existing property and relocate external or temporary storage back into your existing site COST EFFECTIVE SOLUTION with integral rack building providing excellent value when compared to a traditional storage building outfitted with rack PERMANENT, DURABLE AND QUICK, designed, built and installed to your specifications in as little as three months for immediate utilization UTILIZE EXISTING YARD SPACE with design features to accommodate a wide range of existing floor conditions, often without the need for separate foundations AVOID LENGTHY PLANNING CONSIDERATIONS applications that can slow down building projects
and
SECTIONAL DESIGN allows structure to be easily disassembled and reassembled for relocation IMPROVE ENVIRONMENTAL PERFORMANCE with advanced insulation, renewable lighting, sustainable power sources and rainwater collection amongst many other options WIDE FLEXIBILITY with a variety of system sizes to meet almost any storage requirement
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CONSTRUCTION OF THE OUTSTORE速
3. ROOF ASSEMBLY ON THE RACKS
1. HARD STAND PREPARATION
2. RACK ERECTION ON HARD STAND 8
1. HARD STAND PREPARATION The OutStore is designed to accommodate a range of existing floor conditions without the need for separate foundations. Utilize existing hard-stand, yard space or car park areas, or lay a new concrete pad on unprepared ground to open up huge storage possibilities. 2. RACK ERECTION ON HARD STAND The rack system is erected to form the support structure of the OutStore. By spreading the storage, wind and snow loads over a large number of racking frames (compared to regular buildings) pressure is reduced allowing the OutStore to work on most existing surfaces. 3. ROOF ASSEMBLY ON THE RACKS Steel roofing trusses are bolted to the top section of the rack frame. Purlins tie the trusses together to create a super-rigid structure with significantly more support ties and cross members than a regular building.
4. SIDE WALL RAILING INSTALLATION The supporting structure for the side panel walls and building insulation are installed. 5. STEEL CLADDING INSTALLED TO ROOF A combination of steel and translucent cladding panels are installed to the roof to optimize the use of natural light within the OutStore and to provide protection from the elements. 6. CLADDING TO COMPLETE SIDES In the final stages of installation, cladding panels, building insulation and optional personnel and cargo doors complete the OutStore build, making the structure secure and weather proof.
5. STEEL CLADDING INSTALLED TO ROOF
4. SIDE WALL RAILING INSTALLATION
6. CLADDING TO COMPLETE SIDES 9
MODULAR OPTIONS TO ENHANCE YOUR OUTSTORE速
TRANSLUCENT CLADDING AND SKYLIGHTS Allow maximum natural light transmission, whilst retaining a semi-opaque finish for privacy and security.
BUILDING INSULATION Incorporate additional insulation for your OutStore with a variety of insulating materials of cladding options.
PERSONNEL & CARGO DOOR SYSTEMS Secure your OutStore with a variety of door options including roller shutter, personnel doors, electric, hydraulic and hanger systems.
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INTEGRATED SOLAR PHOTOVOLTAIC PANELS Generate low-cost, green electricity for lighting and battery charging – even on a cloudy day.
OPEN SPACES Incorporate open areas within your OutStore to accommodate for modular office systems, staging or picking areas for example.
WALKLIFT ®
Integrated captive handling solution for safer, easier and more efficient loading of pallets.
EXCEEDING DESIGN STANDARDS In addition to these modular options, the Ban-Air OutStore can help you work towards key performance areas for green building design, construction, operations and maintenance solutions to address Water Efficiency
Indoor Environmental Quality
Environmental Materials & Resources
Sustainable Use of Open Space
Energy & Atmosphere
Quality & Innovation in Design
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OUTSTORE® SPECIAL PROJECTS
SPECIAL PROJECTS
CUSTOM BUILT SOLUTIONS
BEAM RACK OUTSTORE Solution engineering using beam rack systems from leading global manufacturers. OutStore distribution centre solutions have been developed for 30,000+ pallet locations on greenfield sites worldwide
Established in close proximity to science and technology parks and with cooperation agreements with educational institutions and high-tech research centres, the Ban-Air Engineering Department is focused on pursuing a strategy of continuous development in the Instantly Adjustable Rack System (IARS) and OutStore product lines, providing complete engineering support for storage projects around the globe, often in locations with severe environments and extreme climatic conditions. The combination of the latest engineering software, hardware and techniques, together with our engineers’ background in structural and mechanics fields, make this happen. Whatever the rack system used as support structure – conventional beam rack, cantilever rack, drive-in racking or a Ban-Air IARS system – we can design an optimal solution to achieve a fully steel-clad warehouse, self-supported, of virtually any size and any configuration, even including elevated mezzanine structures, ready for immediate utilization through fast production and short installation time.
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OUTSTOREÂŽ SOLUTIONS OutStore solutions can be engineered from a range of different storage rack structures, depending on your storage requirements.
DESIGNED TO MEET THE TOUGHEST INTERNATIONAL INDUSTRY STANDARDS Ban-Air’s design process and structural analysis of OutStore buildings takes into account the latest and strictest international norms applying to racking systems and civil constructions. These include the standards and codes published by the: Rack Manufacturers Institute American Society of Civil Engineers International Code Council European Committee for Standardization
The above images show an OutStore engineered around cantilever racking, for the storage of long or very bulky items. For full details contact our sales team.
In addition to these standards, specific sites require a higher level of complexity due to their soil characteristics and climatic conditions. Earthquake prone regions located nearby two colliding tectonic plates or fault lines, hurricane and typhoon coastal areas or snowy and icy environments, require the use of extensive and rigorous standards published in the United States by the Federal Emergency Management Agency (FEMA), and the American Military Standards from the Department of Defence (DoD), as well as the latest available data and resources from the US Geological Survey. In other countries, local, national, as well as international, standards are applied. Ban-Air engineers make use of these codes in their day-to-day practice to warrant the highest standard of safety for OutStore buildings. Fire protection engineering practices are a must for storage of specific hazardous materials. For projects in the USA, the Ban-Air Engineering Team follows recommendations from the DoD and the National Fire Protection Association for storage planning and to mitigate possible disaster consequences. 13
DESIGN & ENGINEERING All engineering and design software is maintained to provide latest versions and the state of the art structural design and analysis techniques: Designs based on the 3D mechanical CAD (ComputerAided Design) software SolidWorks速, a parasolid-based solid modeller, utilizing a parametric feature-based approach to creating models and assemblies Prediction of physical behaviour of practically any part, assembly or structure under any loading condition, simulating real-world operating conditions through CAE (ComputerAided Engineering) Analysis and computer simulations based on the FEA (Finite Element Analysis) software SolidWorks Simulation Professional速
TOP Strength analysis showing the concentrated force on an upright section ABOVE Compression testing in our research and development facility RIGHT Rigorous quality control checks at every stage of manufacture FAR RIGHT Cold rolling, laser profiling, and robotic welding technology
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Structural analysis and design based on the FEA software StaadPro速, an advanced tool capable of analyzing any structure or building exposed to static loading or dynamic r e s p o n s e , including soil-structure interaction, wind, earthquake and moving loads, with built-in US, European and international design codes
STRUCTURAL ANALYSIS Powerful embedded structural analysis capabilities allow practically any type of behaviour simulation during real life of any OutStore structure: Linear static analysis (stress, strain and displacement) Buckling, frequency & vibration analysis P-Delta and geometric second order non-linear analysis Thermal heat transfer and thermal stress Fatigue analysis for cyclic loading Response spectrum simulation)
and
pushover
analysis
(seismic
Time history analysis Design optimization to meet pre-specified design criteria
COMPUTER-AIDED ENGINEERING Real world hi-tech modelling of structure loadings allows for rapid design and engineering processes, delivering optimized solutions fast
The Ban-Air Engineering Team established a liaison and works in close co-operation with several international civil and geotechnical engineering organizations and firms, to handle the submittal of plans to the applicable city or county building and fire departments for permit approval around the world, or for studies of soil subsurface conditions and foundations or slabs engineering. In North America, Ban-Air utilizes an engineering consultancy which is licensed in each of the 50 States and Canadian provinces, and can provide services in the Structural Engineering and Building fields, such as construction design, project sealing, seismic retrofit and sustainable design, among others.
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SUSTAINABILITY AND ENERGY ECONOMY Custom-made, feature-rich OutStore projects can achieve the next level of energy efficiency and sustainable design, whether as part of the LEED® Green Building Certification Scheme, the European Green Building Programme, or with the general target of minimizing the energy requirements in isolated remote regions, and of optimizing the customer operations carbon footprint. Ban-Air implements practical and measurable green building design practices, with clear energy saving effects on construction, operations and maintenance procedures. Our engineers use real-time software-embedded tools to improve environmental impact of every new design, including calculation of carbon footprint and instant feedback of energy consumption as well as the effects of air and water, considering raw material, manufacturing location and processes. Our design team focuses on 100% energy recovery systems and implementation of renewable energy, through features such as: Cladding embedded photovoltaic cells or independent highefficiency panels and micro-wind turbines for store lighting, water pumping, WalkLift® or crane powering, among others Solar water heating technologies
USE OF LIGHT Maximization of natural light throughout the facility reducing energy consumption . Solar panels can be used for water heating and power generation
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Natural lighting exploitation and natural heating/cooling through solar radiation Building energy insulation and space conditioning, ventilation and air conditioning Energy Storage techniques Structure design and materials efficiency
SEISMIC PERFORMANCE The Ban-Air Engineering Department can perform a full range of seismic analysis to mitigate seismic effects on structures, implementing strategies to: Lower the natural frequency of the building Increase damping and energy dissipation Strengthen the global capacity Selectively upgrade local capacity of individual structural components The ongoing efforts and developments of Anti-Seismic Systems led to reach high strength and ductile racking systems, achieving an increased rate of resistance against ground motion during earthquakes.
4.8 3.2 1.6 0.8 0.4
LOW
0.2 0
STRENGTH AND STABILITY Ban-Air Instantly Adjustable Rack System achieves increased resistance against ground motion providing a sound structure for the OutStore
MODERATE
2.4
HIGH
4.0
VERY HIGH
5.0
In the United States for example, Ban-Air engineers use the latest USGS Seismic Hazard Maps providing spectral response acceleration values for ground motions with only a strict 2% probability of exceedance in 50 years (2,500-year return period). As a consequence, the Ban-Air OutStore is built using a tough and durable structure, suitable for regions with high seismic activity.
GLOBAL SEISMIC ZONES
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CONSIDER THE PROJECT: PLANNING AHEAD Designing the right OutStore for your application starts with a process of Considerations, taking into account the site available, or the planned use for the new storage structure. To achieve the optimum solution, there are many design elements which can be employed for an OutStore to bring together the features required.
CONSIDER: THE SITE You might be limited to an existing pad of hardstand, or have the ability to pour a new concrete pad to meet the OutStore requirements – either way, a number of solutions exist to address the site circumstances. When outline planning your new OutStore, please consider the suitability of your existing site:
FLOOR TYPE & CONDITION
PAD SIZE & LOCATION
GEOGRAPHICAL INFO
The OutStore can accommodate a wide range of flooring conditions, but is typically installed on concrete capable of supporting compressive storage and building loads spread evenly across the pad surface.
What is the overall maximum site area available, and what is the proposed or desired OutStore footprint?
Consider the prevailing wind, snow, temperature range and seismic conditions when building your requirements list.
Consider the degree and direction of any slope on the site, and how this may influence the building or rack orientation and surface drainage.
Is the new structure to be a standalone facility, or a ‘lean-to’ adjacent to an existing building? Will services (e.g. power) be run to the OutStore and if so, from where?
The OutStore can be built to accommodate the most extreme climactic environments, but an efficient site design may reduce solution cost.
CONSIDER: THE PURPOSE The proposed usage of the OutStore greatly influences the final efficient design, so consider how you would like the structure configured:
USE OF SPACE
SECURITY & ACCESS ISSUES
OutStore overall footprint can focus on maximizing storage, with aisles as narrow as possible to minimize storage cost per pallet position and achieve the greatest impact on your capacity.
What physical security is needed for the enclosure? Are access doors required? Will the public have access?
The OutStore may also need additional space for Receiving or Dispatch activities, modular office space, or work-in-progress areas, so consider the space required along with desired and alternative positions. 18
Please describe the daily operation of the OutStore so that our Engineering Team can consider not only the security and access implications, but also the structure ergonomics as part of the design process.
APPLICABLE BUILDING OR DESIGN CODES OutStore structures are designed as standard to applicable National, and International or even Military design norms. However the proposed site may additionally have local or company-based design requirements which need to be incorporated. Consider additionally any local permitting required for such a structure.
Finally, to move towards a completed proposal, we need to consider the project implementation phase, and any special timeframes or site specific issues which need addressing. The following guide is a non-exhaustive list of Considerations to address when building the OutStore you need.
CONSIDER: THE DESIGN Now the site and purpose have been identified, there is a comprehensive design menu of options and configuration choices to address your requirements:
STORAGE ENVELOPE & OPEN AREAS What is the desired rack layout and/ or cubic size limits (L x W x H)? Is there a preference on aisle spacing (wide v. narrow v. WalkLift?) and what products or commodities will be stored? Are there any custom storage considerations? What space (if any) is needed for offices, small parts storage, receiving, packing or other working processes.
ENCLOSURE & LIGHTING Depending on the interior environment desired, should the building be singleskin metal clad, or fully insulated (double-skin with cavity insulation)? Consider what doors are needed (cargo, personnel, roller-shutter) and whether any power is required for operation. Consider interior lighting conditions and how much translucent cladding (if any) to be included on the walls and roofing, along with any skylights, or lighting (traditional/solar).
ENVIRONMENTAL UPGRADES Various options can be integrated in the design, from solar photovoltaic panels to power internal systems, to simple rain-water collection guttering. Many options are available to address your environmental concern, so please consider what (if any) special features should be built into the design required.
CONSIDER: THE PROJECT OutStore solutions can be designed, delivered and installed in as little as 12 weeks to individual specifications. To ensure smooth OutStore project management, there are a number of considerations that Ban-Air needs to address:
TIMEFRAME & PLANNING What is the desired lead-time, and also the timeframe for planning, budgeting and implementation? Consider the plan of action for site visit and evaluation, along with design consultation and confirmation.
INSTALLATION CONSIDERATIONS What are the working hours on site, and are there any special working conditions or other factors (e.g. union/ non-union/prevailing-wage labor). Is there equipment available to be used by Ban-Air, such as forklifts or cranes, or is a turn-key solution required?
LOGISTICS Consider the site preparation that may be required, in particular any flooring treatment and services provision. The materials for the construction may need staging prior to and during the installation, so consider what space is available for this purpose.
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UNITED STATES (TOLL-FREE) Tel: 1 866 890 1864 Fax: 1 866 890 1865 For DSN dialing: 1. Dial 809 463 3376 2. Wait for a second dialling tone 3. Then dial 1 866 890 1864 UNITED KINGDOM Tel: +44 (0)1922 640 800 Fax: +44 (0)1922 616 617 GERMANY (TOLL-FREE) Tel: 0800 664 84 44 ITALY (TOLL-FREE) Tel: 800 897 670
CALL US TODAY FOR A DISCUSSION ON HOW OUTSTORE COULD BENEFIT YOUR OPERATION
Email: sales@ban-air.com
www.ban-air.com