Steel structure serves as backbone of cold room, which supports refrigeration systems and maintains optimal temperature conditions.
In this article, we will explore how to select the ideal steel structure for your cold room, from material strength to insulation performance, to help you make an informed decision.
What is Cold Room Steel Structure?
Cold room steel structure is a critical component of cold room, primarily used to construct the framework, support, and load-bearing systems of the cold room. These structures must meet the specific requirements of cold room, included high insulation performance, strong load-bearing capacity, and good corrosion resistance, to ensure stable operation in low-temperature environments over a long period.
Cold Room Steel Structures Classification
Frame Structure
I. Features
Frame structure is the most basic and widely used form of cold room steel structure. Its features are mainly reflected in the following aspects:
1. Main Components
Frame structures consist of steel columns, steel beams, and foundation connectors, forming a spatial framework. The steel columns bear vertical loads, while the steel beams support horizontal loads.
2. Connection Method
The components are connected by high-strength bolts or welding. Bolt connections are convenient for assembly and disassembly, while welded connections are more stronger.
3. Flexibility
Frame structures have high design flexibility, allowing for adjustments to the spacing of columns and beam spans to suit different building areas and internal layouts.
4. Simple Construction
The construction process for frame structures is straightforward, with a mature process and fast construction speed, making it ideal for small and medium-sized cold room projects.
5. Seismic Performance
Due to its reasonable force design, frame structure has good seismic resistance within certain limits, which is suitable for areas with low seismic risks.
6. Low Material Cost
Frame structures use small amount of steel, reducing material costs. When paired with lightweight insulation materials, such as polyurethane boards, it can further save on overall costs.
II. Disadvantages
1. Limited Span
The load-bearing capacity of frame structures is limited, suitable for medium-to-small span cold room (such as those within 20~30 meters). For large-span cold room, needed additional intermediate support columns, which could impact internal space utilization.
2. Limited Wind Resistance
In regions with high wind resistance requirements (such as coastal areas), additional strengthening components are necessary, which would increase costs.
3. Insulation Layer Limitation
Must add an external insulation layer to the frame structures, but due to the numerous joints, it may be difficult to fully cover every corner with insulation material, leading to heat loss or cold bridge.
4. Weaker Corrosion Resistance
If the frame structure is exposed to damp environments for extended periods (e.g., in sea freight cold room or tropical regions), the steel may rust, requires frequent corrosion protection and adds to operational costs.
III. Applications
Frame structures, due to their cost-effectiveness, ease of construction, and flexibility, are widely used in the following types of cold room:
1. Food Processing Cold Room
Suitable for small to medium-sized food processing companies to store semi-finished or finished products. The cold room area ranges 500~3000m2 (square meters), and the frame structure can meet spatial requirements while control construction costs.
2. Supermarket Cold Chain Room
Supermarkets and convenience stores need to build low-cost, small-scale refrigeration facilities to store short-term goods such as vegetables, fruits, dairy products, etc. The quick construction and cost-effectiveness of frame structures make them the preferred choice.
3. Pharmaceutical and Medical Cold Room
Pharmaceutical room requires strict temperature control but doesn’t need large cold room areas. The frame structure can flexibly design to meet storage requirements.
4. Community Cold Room
With the development of community group buying and fresh product delivery, the demand for small community cold room has increased. Frame structure can quickly build such facilities to meet local users’ cold chain storage needs.
5. Agricultural Products Cold Room
Frame structure cold room is ideal for farmer cooperatives or local agricultural product processing plants for short-term storage and preliminary refrigeration of fruits, vegetables, meats, and other agricultural products, help to improve supply chain efficiency.
Truss Structure
I. Features
Truss structure is made up of a series of rods (usually steel) arranged in triangular frames. It achieves strong load-bearing capacity through the coordination of these components and used in cold room with large spans and heavy loads.
1. Structural Form
Truss consists of multiple rods, connected by joints to form a stable triangular structure. Common types include plane trusses and space trusses, and the design can be adjusted by altering the angles and number of rods.
2. Load Characteristics
Truss structure distributes the load across the connection points. Each rod primarily bears tension or compression forces rather than bending forces, reducing material usage.
3. Large Span Design
Truss structure is especially suitable for large-span buildings, providing effective support over large distances and reducing internal space occupation. Normally used for spans ＞30 meters.
4. Lightweight
Since the load distributed across the rods, can use lighter materials in the design to achieve the same load-bearing capacity, making the overall structure lighter and helping reduce construction costs.
5. Strong Stability
The triangular form of the truss structure makes it very stable, and it can better distribute forces during earthquakes or strong winds, reducing the risk of deformation or damage.
6. High Space Utilization
Truss structures can support large spans, allowing for maximum use of internal space and reducing the number of internal support columns, increasing storage flexibility and wider aisles.
II. Disadvantages
1. High Construction Requirement
The design and construction of truss structures require advanced technical skills, precise calculations, and a professional construction team. Poor construction quality control can lead to structural instability.
2. Not Suitable for Small Cold Room
For smaller cold room projects, truss structures may not be ideal because of their higher design and production costs, making them less cost-effective compared to frame structures.
3. Complex Joint Design
The joints of a truss structure are complex and require precise calculation and fabrication. If welding or bolt connections are not done properly, will compromise stability of the overall structure.
4. Transportation Issue
Large truss components require special transport equipment and longer transit times. In areas with complex geography or poor transportation conditions, this could increase transportation costs.
III. Applications
Due to their superior large-span load-bearing capacity and efficient space utilization, truss structures are widely used in the following cold room and related industries:
1. Large Cold Chain Logistics Centers
Truss structures are ideal for large-scale cold chain logistics centers, sorting centers, and storage facilities. The large, unobstructed design facilitates efficient room and transportation of goods.
2. Agricultural Product Cold Room
Truss structures are well-suited for storing bulk agricultural products (such as fruits, vegetables, meats, etc.), particularly for high-end agricultural product storage, providing large storage spaces to meet high-volume storage needs.
3. Super Large Freezer Room
Super-large freezers, such as those used for storing frozen fish, meat, or other frozen products, which require large-span designs. Truss structures provide sufficient support and maximize space efficiency.
4. Cold Room Factory
In cold room factories where production and storage occur simultaneously, require large spans between refrigerated and processing areas. Truss structures are especially suitable in such scenarios as they can effectively support production equipment and shelving arrangements.
5. Custom High-End Cold Room Project
For high-end custom cold room, such as pharmaceutical storage or special product storage, that require spacious and stable interiors. Truss structures can meet these specific needs.
Grid Structure
I. Features
Grid structures are a spatial structural form that transfers loads through a network of interlaced rods, creating a stable force system. They commonly used in large-span buildings, including cold room, warehouses, exhibition halls,etc.
1. Spatial Structure
Grid structures consist of interwoven rods forming a network. These can be planar grids or three-dimensional grids. The spatial arrangement of rods provides uniform load distribution and enhanced stability.
2. Support System
Grid structures efficiently distribute their weight and loads, ensured overall stability. The load is primarily handled through tension and compression in the rods, rather than bending forces, leading to high structural efficiency and material utilization.
3. Large-Span Design
Ideal for large spans and long-distance spatial design, grid structures maintain stability and support without requiring multiple interior columns. This maximizes usable space.
4. Lightweight and High Strength
The combination of optimal geometric shapes and efficient load transfer mechanisms allows grid structures to use minimal materials while maintaining a high load-bearing capacity. This reduces construction costs and steel usage.
5. Flexible Construction
Grid structures can be partially or entirely prefabricated off-site, ensuring quick and efficient on-site assembly. The flexibility to adjust dimensions and connections further shortens construction timelines and enhances adaptability.
II. Disadvantages
1. Complex Design and Construction
Grid structures require precise calculations for the forces on each rod. Their connections are intricate and demand high-precision manufacturing. This complexity increases both design and construction costs.
2. Transportation Challenge
Prefabricated components are often large and require special transport equipment. This can escalate costs, especially in areas with challenging geographical or logistical conditions.
3. High Maintenance Cost
The connections in grid structures, typically welded or secured with specialized bolts, require meticulous maintenance. Repairs, especially for damaged nodes, can be time-consuming and costly.
4. Skilled Workforce Requirement
The construction of grid structures demands a team with advanced technical expertise. Inexperienced workers can cause errors during construction, leading to safety risks or compromised structural integrity.
III. Applications
Grid structures are widely used in cold room and related fields due to their large-span capability, lightweight design, and efficient space utilization.
1. Frozen Food Room Facilities
For high-capacity cold rooms storing frozen food products, grid structures provide the necessary support and space to accommodate efficient storage and logistics operations.
2. High-Standard Pharmaceutical Cold Room
In the pharmaceutical industry, cold room must meet strict temperature and humidity requirements. Grid structures provide the stability and space needed for such special applications, ensuring compliance with high standards.
Which Steel Structure is Best for Cold Room?
Consider factors such as insulation, load-bearing capacity, and cost, grid structures are the best choice for large-sized cold room due to their ability to support large spans without interior columns and maximize usable space. For medium to small-sized cold room, frame structures are more cost-effective and flexible.
To optimize thermal insulation performance, steel structures should be paired with high-efficiency insulating materials, such as polyurethane sandwich panels, spray-applied insulation layers, or vacuum insulation panels. These materials ensure energy efficiency and reduce operational costs in the long term.
Cold Room Steel Structures Installation
The installation of steel structures in cold room is a critical part of the entire construction process. It requires precise adherence to design specifications to ensure structural stability, safety, and efficient refrigeration performance. The following outlines the key steps and considerations in the installation of steel structures for cold room:
I. Preparation Before Installation
Before starting the steel structure installation, thorough preparation is necessary to ensure a smooth and successful process:
1. Material Inspection and Acceptance
–Prior to installation, all steel components must be thoroughly inspected and accepted. Ensure that all parts meet quality standards, dimensions align with design specifications, and materials are free from defects such as corrosion, deformation, or damage.
–Pay particular attention to the integrity of corrosion-resistant coatings on steel surfaces, as defects could impact the overall installation quality.
2. Site Cleaning and Preparation
–The installation site must be cleared and leveled to meet installation requirements. Uneven ground can cause instability or misalignment during assembly.
–Establish a safety perimeter with fencing and warning signs to prevent unauthorized access to hazardous areas during construction.
3. Personnel and Equipment Preparation
–Ensure that all installation personnel have the necessary qualifications and experience and are familiar with installation procedures.
–Workers should undergo safety training before commencing.
–All equipment, including cranes, hoists, and connection tools, should be checked in advance to ensure they are in good working condition.
II. Foundation and Anchor Bolt Installation
The foundation and anchor bolts are crucial for supporting the entire cold room steel structure. Therefore, the quality of the foundation directly affects the installation’s stability and long-term performance.
1. Foundation Construction
–The foundation should be excavated and concrete poured according to the design drawings. The depth, width, and shape of the foundation must meet the design specifications.
–Before foundation construction begins, must conduct a soil survey to confirm the soil’s bearing capacity and ensure the foundation design is appropriate for the site conditions.
2. Anchor Bolt Installation
–The anchor bolts must be positioned, sized, and aligned accurately. Typically, anchor bolts are embedded in concrete during the foundation pour.
–Prior to installation, should precisely calibrate anchor bolt positions using tools such as a level or laser measuring device.
–The anchor bolts must be securely fixed in place to prevent any movement during subsequent stages of installation.
III. Hoisting and Assembly of Steel Components
The primary components of the steel structure, including columns, beams, and frames, must be hoisted to their designated positions and then assembled and fixed together.
1. Pre-Hoisting Preparation
Each component should be marked to ensure it is installed in the correct sequence and position. Prior to hoisting, should inspect all components for defects or damage.
2. Hoisting Process
–During hoisting, should use tools such as steel wire ropes or lifting straps to raise the steel components into place, ensuring no overloads or lifting errors.
–Components must be hoisted carefully to avoid tilting or slipping.
–Once each steel component is in place, it should be temporarily secured to prevent movement. After securing, permanent connections can be made.
3. Assembly and Connection
–Steel columns and beams are connected using either bolts or welding. Bolt connections are more commonly used due to their ease of installation and flexibility, while welding provides stronger, more permanent joints and is used in areas that require higher strength.
–For welded sections, strict control over the welding process is essential to ensure high-quality welds. For bolted connections, the bolts should be properly tightened to ensure structural integrity and prevent loosening.
–After assembly, must inspect each connection point to confirm that it is secure and correctly positioned.
IV. Support and Reinforcement
During the installation of steel structures, it is crucial to implement support and reinforcement measures to ensure the stability and safety of the structure throughout the process.
1. Temporary Support
–Temporary support is especially important for large components and structures with long spans. It helps prevent components from tilting or deforming during installation.
–Temporary supports are made from materials such as steel pipes or angle steel. The stability and load-bearing capacity of the support must be ensured to prevent failure during installation.
2. Permanent Reinforcement
–After installation, require additional support members or reinforcement ribs in key areas of the steel structure to enhance overall stability, according to design specifications.
–These reinforcement measures must meet design standards and undergo strict acceptance testing.
V. Roof and Wall Installation
The roof and walls of the cold room are the outer layers of the steel structure. During installation, it is essential to ensure the insulation, sealing, and structural stability of these components.
1. Roof Installation
–Roof installation generally involves installing steel beams, roof panels, and insulation materials. Must take care to ensure the roof panels are properly sealed to avoid leaks.
–The connection between the roof panels and steel structure should use special fasteners, with each connection point checked for tightness.
–For areas requiring special corrosion protection, should apply appropriate anti-corrosion coatings as per requirements.
2. Wall Installation
–The walls of the cold room are made of insulation boards, such as polyurethane or rock wool panels.
–During installation, the panels should be measured and installed accurately according to design specifications. The panels must be securely connected, with minimal gaps between them to enhance the cold rooms’ thermal insulation performance.
VI. Electrical and Fire Protection Installation
Cold room construction involves not just assembling the steel structure but also the installation of electrical and fire safety systems to ensure the proper functioning and safety of the facility.
1. Electrical Installation
–Electrical installation includes setting up lighting, power systems, and temperature and humidity control systems. Installation must comply with electrical safety standards to ensure the circuit’s safety and reliability.
–Distribution boards, switches, and wiring conduits should be strategically placed to facilitate future maintenance and repairs.
2. Fire Protection Installation
–Cold room buildings must meet strict fire protection regulations. This includes the installation of smoke detectors, fire extinguishers, and sprinkler systems.
–During installation, fire protection system components, such as pipes and sprinkler heads, should be laid out according to design specifications to ensure wide coverage, allowing for prompt suppression of fire in the event of an emergency.
VII. Safety Measures and Acceptance
Safety is the top priority during steel structure installation, and it is essential to continuously monitor the construction site to ensure compliance with safety standards.
1. Safety Protection
–During installation, must use safety measures such as safety belts, guardrails, and safety nets to prevent workers from falling from heights.
–The installation work zone should be clearly defined to prevent unauthorized personnel from entering hazardous areas.
2. Acceptance and Quality Inspection
–After the steel structure is installed, must conduct a rigorous inspection to check the quality of the installation. This includes verifying the tightness of connections, stability of components, and alignment of structures.
–All components must be inspected and approved by the relevant authorities to ensure compliance with design specifications and relevant standards before the cold room is operational.
What is Most Economic and Time-Saving Installation Method?
1. Modular Prefabricated Steel Structure
In this method, all components are pre-fabricated in the factory and then transport to the construction site for assembly. This significantly reduces both construction time and labor costs.
2. Efficient Insulation Integrated Material
Use steel panels with pre-installed insulation layers simplifies the construction process, as it eliminates the need for separate insulation installation. This approach also reduces material costs and speeds up the overall installation.
Other Considerations During Installation
I. Design Review and Confirmation Before Installation
Before the installation, it is crucial to thoroughly review and confirm the design plans to ensure that all parameters and details meet actual needs and construction conditions.
1. Blueprint Review
–Prior to steel structure installation, the design blueprints must undergo a detailed review to ensure their feasibility. The blueprints should cover specifications such as steel component sizes, quantities, connections, and support systems. Any discrepancies between the design and actual conditions may result in installation issues.
–Ensure that all details in the blueprint are clearly defined, with the correct sizes, positions, and connection methods, in accordance with construction standards.
2. Structural Calculation Confirmation
Carefully calculate the load requirements, wind load, snow load, etc., to confirm the necessary steel specifications and structural strength.
Before installation, confirm that parameters related to load-bearing capacity, seismic performance, and wind load have been adequately considered to avoid potential issues during the installation process.
II. Adaptability of the Construction Environment and Weather Impact
The construction quality and safety can be significantly impacted by environmental and weather conditions during installation, making it essential to monitor these factors closely.
1. Weather Monitor
–Extreme weather conditions (such as strong winds, heavy rain, or snow) can affect the safety of steel structure installation. Therefore, it is important to closely monitor weather forecasts and avoid lifting or high-altitude work during adverse weather conditions.
–In the event of extreme weather, such as a storm, should immediately suspend the work to ensure the safety of workers.
2. Temperature Effects on Steel
Steel’s properties can be influenced by temperature. In cold weather, steel may become brittle, while high temperatures can cause deformation. During construction, should avoid welding or cutting in excessively low or high temperatures.
Pay more attention during winter or summer months to manage temperature conditions effectively, should take appropriate protective measures to ensure the quality of steel and prevent structural damage.
Conclusion
Cold room steel structures are a critical component of cold room construction, directly impacting the lifespan and operational efficiency of the cold room. Scientifically and rationally selecting the type of steel structure, optimizing the installation process, and paying attention to construction details can not only maximize the refrigeration performance but also save costs and time.
For professionals in the cold room industry, focusing on safety and quality is key to ensure the success of the project.
Any comments?
Welcome leave a message or repost.
