With speed to market as a driving force for all projects, owners are often anxious to begin construction quickly for a variety of great reasons. In an industry where retrofits and corrections can be prohibitively expensive, getting it right the first time isn't just an advantage—it's a necessity.  Including an experienced design/build general contractor in the design team prevents the owner from going over budget, adding time to the schedule for redesign, or building a cheap, low-performance building that is expensive to operate.

Design/build general contractors provide the unique opportunity to research and identify the best building solutions upfront, considering the functionality and durability of the facility as if it were their own. With a variety of key design factors at play to determine the project outcome, the early involvement of a knowledgeable, experienced partner can help optimize performance, minimize unforeseen costs, and address both present and future needs. After all, a well-designed cold storage facility is not just a structure—it’s an investment in operational efficiency, sustainability, and long-term success.

Designing and constructing controlled environment facilities requires a knowledge of many unique aspects across many different disciplines that determine the long-term success and efficiency of these complex, multi-purpose structures. General contractors who are actively involved in the construction of controlled environment buildings keep their finger on the pulse of the industry by maintaining relationships with subcontractors and constantly training their teams. This insight can effectively guide the A/E design team through refrigeration options, fire protection limits, structural decisions, wall types, concrete floors and several other variables to produce a streamlined, cost-efficient building that meets all the owner’s needs.

Optimizing Utilities for Facility Performance

The refrigeration system is the heart and soul of a controlled environment building and is often the first decision that owners make. There are many factors to consider when choosing, including performance, upfront costs, operational costs, maintenance and looming government regulations. Different refrigeration systems have different advantages depending on the climate of the region, the size and load of the building, the operator’s involvement in maintenance and the system's lifespan. Perhaps, the most important consideration should be understanding the utility needs of the refrigeration system.

The availability and cost of utilities, particularly electricity and water, will directly affect the long-term operational cost of the refrigeration system.

In regions where electricity is expensive, energy-efficient refrigeration systems may be more appealing, while areas with cost-efficient electricity might allow for different system options. Water quality and availability are especially critical for facilities using evaporative cooling systems, as the water quality must meet specific standards to prevent waste and inefficiency since the process requires a large amount of water. Poor water quality can force evaporative condensers to bypass the water supply, resulting in considerable water waste and increased costs.  Air-cooled and adiabatic systems use less water but typically require more electricity and a larger surface area.

Thoughtful utility planning goes beyond upfront refrigeration system cost implications, as it includes considerations for energy efficiency, reliability and adaptability to new technologies. By carefully analyzing power requirements, backup systems, and potential renewable energy integration during the preconstruction phase, owners can be confident that their new facility will not only meet current operational demands but also remain flexible for future advancements and evolving industry standards.

Assessing Regulatory Compliance Guidelines

Regulations create a multi-layered compliance landscape for cold storage facilities, spanning federal, state and local jurisdictions. One important example involves facilities using ammonia refrigerant. If a facility uses large amounts of ammonia refrigerant (over 10,000 pounds), it is subjected to stringent Project Safety Management (PSM) oversight, requiring specialized staffing, such as a full-time safety manager, and comprehensive reporting to agencies such as the Environmental Protection Agency (EPA), the Occupational Safety & Health Administration (OHSA) and Homeland Security.

Evolving environmental standards are also driving industry-wide shifts, such as the phase-out of some HFCs in favor of refrigerants with lower Global Warming Potential (GWP) values. The federal government currently has legislation in place that will limit the GWP to 150 for refrigerants in cold storage systems greater than or equal to 200 pounds that are installed after January 1, 2026.

Regulatory compliance is more than a legal obligation—it's a fundamental driver of facility design, staffing strategies, operational protocols and long-term financial planning. A knowledgeable preconstruction professional can help an owner better understand these requirements and identify strategic considerations that result in the development of innovative, efficient facilities.

Integrating Efficient Building Design

Building designs must be properly detailed for controlled environment facilities to achieve optimal performance. The thermal envelope of the building must account for exterior conditions and rooms of different temperatures, often necessitating either double-column lines or frost ribbon installation to prevent condensation issues. Insulated Metal Panels (IMP), roof and underfloor insulation thicknesses with the correct R-value must be selected to meet the performance of the room. A single air leak in the envelope can cause a huge operational disruption in the future. Even seemingly minor details like electrical conduit sealing are critical to preventing cold air travel and condensation problems.

Different refrigeration systems will create different challenges for both the facility's overall structure and operations. Rack-based refrigeration systems may eliminate the need for engine rooms, but their weight requires additional structural support. If not properly positioned, this can significantly increase construction costs. This cost can be reduced by placing these units on lower dock roofs instead. The structure must also accommodate substantial piping systems for both refrigeration and fire protection.

Fire protection systems can also significantly influence the building structure. Current overhead systems generally allow for a maximum of 50-foot clear heights for buildings. Exceeding this limit will cause a large added cost for in-rack sprinklers and put the owner at risk of a forklift operator hitting a sprinkler head in the rack. The water supply needed for these overhead systems is also immense, generally creating the need for an onsite water storage tank. To circumnavigate these issues, some controlled environment buildings are considering low-oxygen environment systems for their automated areas.

Automation in controlled environments has been steadily increasing in large or complex operations. Owners face many factors when considering if automation is a good solution for their project, as large upfront costs may take years for an operator to offset.  Low dependence on labor markets, increased safety, and operation speed are all attractive reasons to move into automation. Adding automation to a building design will radically change the building structure design and construction sequencing. Many automation systems have very specific floor requirements that must be considered when designing the concrete floor.

Concrete floor design can also be a major focus during the design phase.  There are many ways to structurally satisfy the constraints required for the building, including conventional design mixes, shrink-compensating mixes, space-age fibers, and hardened wear surfaces. Steel fibers may provide an opportunity to eliminate rebar and reduce section thicknesses, while shrink-compensating mixes and hardened wear surfaces may provide fewer joints, creating a more resilient floor for heavy traffic.

Incorporating Food Safety into Design

Successfully integrating food safety considerations into a controlled environment facility requires a holistic approach that balances design, technology and operational protocols. The design should identify potential contamination risks and incorporate preventative measures that are essential for maintaining product integrity and meeting increasingly strict industry regulations.

Standard measures should include floors, walls and ceilings that are non-porous, washable materials to prevent moisture buildup. Proper details are essential to prevent water and germs from accumulating in areas that are difficult to clean, as this can create a breeding ground for bacteria. Implementing air filtration and positive air pressure systems can help reduce airborne contaminants. Even the dock equipment should be selected carefully with food safety considerations.

The level of food safety measures required will depend entirely on the specific operation, as different processes demand different standards. This may include heating and ventilation for the room with hygienic units, as well as operational programs for cleaning and washdowns with harsh chemical cleaners that require specialized finishes.

Identifying Strategic Budget Opportunities

A trusted general contractor’s preconstruction team will consider your budget when it comes to determining all aspects of the build. Particularly, this knowledgeable advisor will recommend that you spend smart money effectively. For example, increasing the roof insulation is more effective than increasing the wall insulation. A shrink-compensating floor may be more expensive to install but may prevent costly maintenance in the future. Even if a design consideration increases the overall upfront project cost, the future operational returns will far outweigh the initial expense.

It is also important to consider plans for future expansions, paying close attention to critical components like engine rooms, which once placed, are extremely costly to relocate. Future expansions and operational change costs can be alleviated by proper planning. Installing insulation and floor heat under a cooler now that will be transitioned to a freezer in the future is a fraction of the cost if the owner were to wait. Designing the roof for solar panels in the future is more cost-effective when designed into the original structure compared to retrofitting joists later.

By collaborating closely and keeping an open line of communication with preconstruction professionals early in the planning process, these considerations can be addressed with a practical, strategic approach, keeping the owner’s best interest and the long-term building efficiency top-of-mind.