There’s a lot more steel on this job site than the racking and ASRS conveyor components --we’re pretty sure that there’s some steel in the veins of the crane operators as they maneuver the unit-load ASRS components from outside the warehouse precisely into place between rack rows on the inside of the rack-supported building --did we mention it was a windy day! Watch as dual cranes and this expert team seamlessly position the ASRS mast into place.
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Read project excerpt below:

Precision Takes on a Whole New Meaning with ASRS Crane Installation

It’s been a few months since our last update on this exciting midwestern rack supported building ASRS crane installation project. This summer, we passed a few milestones worth showing off… so here we are!

That’s a Lot of Steel
There’s a lot more steel on this job site than the racking and ASRS conveyor components --we’re pretty sure that there’s some steel in the veins of the crane operators as they maneuver the unit-load ASRS components from outside the warehouse precisely into place between rack rows on the inside of the rack-supported building --did we mention it was a windy day!

Watch as dual cranes and this expert team seamlessly position the ASRS mast into place.

Some Gusty Challenges -
We experienced some significant headwinds early in the day… literally. The wind gusts were a significant challenge and required constant, clear communication between the entire team. First, the two crane operators lifted, turned, and vertically positioned the mast. Next, the team released the 2nd crane in order to lift the mast up and over the roof. A man on the roof communicated with the team outside and inside to guide the mast into place in aisle 3, where the mast would connect the chassis (already in place).

The goal was to align 16 galvanized bolts with the mast and the chassis. Despite the mast swaying due to wind, the connection was perfect --barely making a sound as the mast and chassis locked into place.

ASRS Project Overview
A quick refresh on the project specs includes the following:
The installation is a plant expansion project to accommodate four new product lines.
The total warehouse space will be 180,000 sq ft.
Ambient space: 14,000 sq ft x ~40' high, with 2,360 pallet positions (5H x 2D Push-Back) and 3 VNA turret aisles.
Cooler space: 12,800 sq ft x ~80' high, with 3,040 pallet positions (8H x 2D) and 2 crane aisles.
Freezer space: 18,800 sq ft x ~80' high, with 4,560 pallet positions (8H x 2D) and 3 crane aisles.

Pallet Loading & Unloading in a Rack-Supported ASRS-Equipped Building

A few highlights of the nearly fully-automated facility include:
After completing the rack-supported building, only the dock and ambient section will require operators for forklifts or lift vehicles. The cooler and freezers will utilize automated cranes, while AMRs will load pallets into the load-handling unit. The load-handling unit interfaces with the rack location and pushes into place. Once in place, the load handling unit extracts. Activity is reversed for pallet selection. Careful slotting ensures that every pallet has a designated location.

The project's logistics are complex due to accommodating three pallet styles through the warehouse automation system - wood, plastic & metal; however, high-tech pallet sensors will determine if the load is “putaway ready,” i.e., it scans for pallet condition to confirm stability and integrity as well as confirms the proper size and weight. The system identifies and flags pallets that require pallet supports and redesignates them to locations with pallet supports.

What’s Next for the ASRS Rack-Supported Building Installation? Stay Tuned for Updates!
Next Steps -
Conveyor installation now
Extensive electrical work
ETA - Early 2024

At the project's conclusion, three freezers and two coolers with 100% automated order fulfillment systems require only a small crew on deck for any minor technical or maintenance concerns.

If you’re interested in exploring a complex rack-supported fully-automated warehouse project or a less intense but not less significant warehouse application, the Apex team is here to help! We are a full-service warehouse facilitator with personnel and offices throughout the U.S. Call today to schedule a free consultation with an Apex team member.