Basics of Warehouse Construction: Explanation of Features, Merits, and Demerits of Each of the Four Types of Warehouse Construction, as well as Construction Examples

When planning a logistics network, “optimal use of warehouse architecture” plays an important role in improving operational efficiency and optimizing logistics. However, selecting a warehouse that meets your objectives is difficult. Understand the characteristics of warehouses and select the most suitable warehouse.

This article describes the four main types of warehouse construction: conventional, tent warehouse, prefabricated warehouse, and system warehouse, for those who are planning to build a warehouse.

Types of Warehouses" you need to know about in warehouse construction.

In building a warehouse, it is important to understand that warehouse construction can be categorized into the following four types

• traditional construction
• Tent Warehouse
• Prefab warehouse
• System Warehouse

Be sure to properly understand the advantages and disadvantages of each and use them in selecting the type of warehouse.

Attractive "tent warehouse" with short construction period and low cost

Tent warehouses are constructed by building a framework and covering it with a sheet.

The use of light-transmitting fabrics provides the following four characteristics, in addition to the feature of a brighter interior.

• Advantages: Short construction period and immediate availability
• Advantage: Low construction costs
• Disadvantages: Tent fabric easily deteriorates.
• Disadvantage: Requires periodic reupholstering.

Advantages: Short construction period and immediate availability

The greatest advantage of tent warehouses is their short construction period and immediate availability. These warehouses are constructed by covering a metal framework with a lightweight, high-strength membrane material, and their simple structure allows for short construction periods.

The design and construction period is short, and depending on the scale and local conditions, construction can be completed in as little as two months from the start of construction.

Advantage: Low construction costs

Another advantage is the low cost of construction due to its simple structure.

There are three reasons for the low cost of construction

• Low design cost because of systematization
• Fewer materials used and lower material and labor costs
• Lightweight and requires no ground improvement even on weak ground

Related article: Detailed explanation of warehouse construction costs｜From market prices by type and structure to how to keep costs down.

Disadvantages: Tent fabric easily deteriorates.

On the other hand, the tendency of tent fabrics to deteriorate is a disadvantage. Fabrics used in tent warehouses are more susceptible to deterioration than the exteriors used in prefabricated or system warehouses, and the estimated durability is about 10 years. In addition to the fabric, attention should also be paid to the deterioration and loosening of the ropes that hold the fabric in place.

Disadvantage: Requires periodic reupholstering.

Although the low cost of construction is mentioned as an advantage, periodic reupholstering is required, and in the long run, the cost may be the same as for other warehouses. It should also be noted that repair costs will also be incurred if flying debris strikes the building during a typhoon or if the building is torn down for intrusion purposes.

Free design is attractive "conventional construction method warehouse"

A “conventional construction method warehouse” is built with columns and beams, similar in structure to an ordinary house. Conventional construction method warehouses, which are made to order, have the following features

• Advantage: Freedom to design for any purpose
• Advantage: Can be used for a long period of time
• Disadvantages: Construction costs can be high.
• Demerit: Longer design and construction period

Advantage: Freedom to design for any purpose

The greatest advantage of conventional construction method warehouses is that they can be freely designed to suit any purpose. The position of columns and beams can be changed to suit the cargo to be stored, and spans can be skipped in some areas, giving the warehouse a degree of freedom not found in other warehouses.

Advantage: Can be used for a long period of time

Another advantage is that depending on the specifications, the building can be used for a long period of time. Since the structural materials used and the exterior and interior walls can be freely selected, depending on the design and construction details, the use of highly durable materials may ensure durability in excess of 30 years.

Disadvantages: Construction costs can be high.

While it can be designed freely and has the potential to be used for a long period of time, its high construction cost is a disadvantage. The total cost of construction tends to be high because of the need to use thicker steel in many areas to ensure strength and the need to design from a blank sheet of paper.

Demerit: Longer design and construction period

Another disadvantage is that the design and construction period is prolonged. Conventional construction methods often require different contractors for each section, such as design, material production, and construction, which tends to increase labor costs. If components are custom-made, the construction cost will be even higher.

Prefabricated warehouse" for easy expansion and remodeling

A “prefabricated warehouse” is a warehouse built from factory-produced components that are assembled on site. The characteristics of a prefabricated warehouse with a fixed standard are as follows

• Advantage: Easy to expand and remodel
• Advantage: Quick turnaround time for construction
• Advantage: Can be used as a store or office.
• Disadvantages: expensive if fire protection measures are required.
• Disadvantage: Low flexibility in size and design

Advantage: Easy to expand and remodel

The greatest advantage of prefabricated warehouses, which are assembled from standardized components, is that they can be easily expanded or remodeled. The scale of the warehouse can be easily changed to accommodate business expansion or contraction, and when the warehouse is finished being used, it can be easily dismantled and removed.

Advantage: Quick turnaround time for construction

Another major advantage is the short turnaround time from commissioning to completion. Although it depends on the scale of the project, it can be constructed in one to three months, about the same speed as a tent warehouse. Another advantage is that the construction cost is relatively inexpensive due to the short delivery time and lack of special materials.

Advantage: Can be used as a store or office.

Prefabricated warehouses use standardized products manufactured in factories, making it easy to ensure high earthquake resistance, and depending on the specifications of the exterior wall materials, long-term durability can also be expected.

In some cases, insulation is available as an option to achieve a high living environment. The above features also make it possible to use a portion of the warehouse as a store or office while keeping costs low.

Disadvantages: expensive if fire protection measures are required.

Prefabricated warehouses are relatively inexpensive, but as with other warehouses, fire prevention measures are required if there are other buildings within 3m or 6m (depending on the number of floors) of the property line.

Depending on the fire protection measures required, the cost may jump, so the need for fire protection measures should be confirmed at the estimating stage.

*Source: Article 2, Paragraph 6 of the Building Standards Law

Disadvantage: Low flexibility in size and design

The use of standardized products means that the dimensions of the components are fixed, and this is a disadvantage, as it reduces the degree of freedom in exterior design. In addition, since it is necessary to insert posts and beams at regular intervals, the types of items that can be stored in a warehouse may be limited.

Attractive "system warehouse" with high durability and longevity

The “system warehouse” offers a high degree of design flexibility while utilizing standardized components. The features of a system warehouse that standardizes design and construction are as follows

• Advantages: Allows for a high degree of freedom in design
• Advantage: High strength, resistant to earthquakes, typhoons, etc.
• Demerit: Exterior design tends to be simple
• Demerit: Cost and construction period are higher than other construction methods.

Advantages: Allows for a high degree of freedom in design

System warehouses can be customized to meet your needs within the standardized design and construction details, allowing you to build warehouses with a high degree of freedom. As with prefabricated warehouses, depending on the specifications, they can also be used as offices or stores, making them a highly versatile construction method.

Advantage: High strength, resistant to earthquakes, typhoons, etc.

Another advantage is that the construction can be done with constant quality and high strength can be expected because of the use of established standards. Since the strength of the warehouse can be calculated, it can be expected to withstand earthquakes and typhoons as expected. Depending on the specifications, a service life of more than 30 years can be expected, and is recommended for warehouses that will be used for a long period of time.

Demerit: Exterior design tends to be simple

Since it uses materials manufactured to a certain standard, it can be expected to be functional and durable, while the exterior design is simple. For offices and stores that also pay attention to design, there is a possibility that they may not meet expectations.

Demerit: Cost and construction period are higher than other construction methods.

Although less expensive than conventional construction methods, the disadvantage is that construction costs are higher than for tent warehouses or prefabricated warehouses. On the other hand, the high durability of these warehouses makes them cost-effective when used for long periods of time.

Basic knowledge you need to know when building a warehouse

Next, we will introduce some basic knowledge that you should know when building a warehouse. Warehouses are divided into two categories: “commercial warehouses,” which are registered with the Minister of Land, Infrastructure, Transport and Tourism to operate as a warehousing business, and “private warehouses,” which are used by warehouse users to store their own cargo.

This article describes one type of commercial warehouse, the “ordinary warehouse,” and explains the types of warehouses and laws and regulations.

A "warehouse type" to be set up for different purposes

Ordinary warehouses are classified into eight categories: Class 1 warehouses, Class 2 warehouses, Class 3 warehouses, storage tank warehouses, dangerous goods warehouses, refrigerated warehouses, open storage warehouses, and surface water warehouses. (*”Field warehouses and surface warehouses” are methods of storing goods outdoors and are omitted from this article.)

*Source: Article 3 of the Ordinance for Enforcement of the Warehousing Business Law

Class 1 warehouse: high grade warehouse

Category 1 warehouses have the highest required facilities and structural standards among regular warehouses. It can store a variety of goods, except for Class 7 goods that fall under the category of hazardous materials and Class 8 goods that must be stored at temperatures below 10 degrees Celsius.

Category 2 warehouses: Warehouses that do not require fireproof performance

Compared to Class 1 warehouses, Class 2 warehouses have less stringent equipment and structural standards. Fire prevention and fire resistance are no longer required, and the types of goods that can be stored in a Category 2 warehouse are reduced compared to those in a Category 1 warehouse.

Category 3 warehouses: Warehouses that do not require moisture-proof performance

Category 3 warehouses do not require moisture-proof performance in addition to fire and fireproof performance. Products that are resistant to changes in humidity and temperature, such as glassware and ceramics, fall under this category.

Storage tank warehouse: for bulk liquid

A storage tank warehouse is an enclosed warehouse, such as a tank or silo. These warehouses contain liquid or bulk grain and are characterized by the required strength of the sides of the warehouse.

Dangerous Goods Warehouse: Warehouse for hazardous materials and high-pressure gas

Hazardous Goods Warehouses are warehouses for storing category 7 goods, which are hazardous materials and high-pressure gases as designated by the Fire Service Law. Depending on the goods to be stored, the warehouse must meet the standards required by various laws such as the Fire Service Law, the High Pressure Gas Safety Law, and the Law for Securing and Proper Trade of Liquefied Petroleum Gas.

Refrigerated warehouse: Warehouse for low-temperature storage

Refrigerated warehouses are for goods such as meat, marine products, and frozen foods that must be stored at temperatures below 10 degrees Celsius. They are classified into seven grades, from F4 to C3, according to the goods to be stored and the temperature classification suitable for storage.

Laws and Regulations" related to warehouses

Knowledge of the law is necessary when building a warehouse. Warehouses are considered special buildings under the Building Standards Law because of the possibility of fire, and an application for building permit must be submitted prior to construction. The Fire Service Law and the Urban Planning Law, which must be met at the same time, are also explained.

Building Standard Law, Article 6, Paragraph 1: Application for building permit not required

When building a warehouse, it is important to confirm whether or not an application for building permit is required under Article 6, Paragraph 1 of the Building Standards Law.

(1) Total floor area: 200m2 or more (2) For wooden buildings: 3 stories or more, total floor area: 500m2 or more, height: 13m or more, eave height: over 9m (3) For buildings other than wooden buildings: 2 stories or more, total floor area: 200m2 or more (4) For buildings other than those in (1) through (3), city planning district, quasi-city planning district, quasi-landscape district, or governor-designated district area, quasi-city planning area, quasi-landscape district, or governor-designated area, except for buildings in (1) through (3) above.

If any of the above apply, an application for building permit is required.

*Source: Building Standards Law, Article 6, Paragraph 1

Fire Service Act, Article 17, Paragraph 1: Installation of fire-fighting equipment

Article 17, Paragraph 1 of the Fire Service Act describes the installation of fire extinguishing equipment, and confirms the preparedness in case of a fire. For example, if the total floor area exceeds 500 m2, an automatic fire alarm system must be installed, etc. The required fire extinguishing equipment varies depending on the size and type of warehouse.

*Source: Building and Fire Prevention Law, Article 17

City Planning Law Article 29: Permission to build warehouses on land restrictions

Article 29 of the City Planning Law stipulates permission for development activities. Some land may not allow the construction of warehouses, so you need to confirm this in advance. Warehouses for business use can be built on land zoned for the following six types of uses.

• semi-residential district
• neighborhood commercial district
• commercial district
• semi-industrial zone
• industrial zone
• exclusive industrial zone

*Source: Building City Planning Law, Article 29

What kind of warehouse can you build?" Example of Warehouse Construction

System warehouses have become mainstream in warehouse construction in recent years due to their high durability, longevity, and flexible design. The following are examples of system warehouses to illustrate what kind of warehouses can be cited as examples.

System architecture: long and wide spaces without columns and beams

The “Noguchi Unyu Bando Warehouse” is a warehouse with as few pillars and beams as possible that would interfere with various operations. The opening utilizes a W5.0m x H5.5m heavy electric shutter and two W5.0m x H4.5m light electric shutters.

The main features of the facility are as follows

• Span length (m): 20.8
• Length of girder (m): 31.4
• Construction floor area (m²): 706
• Eave height (m): 8.4

System architecture: efficient warehouses suitable for distribution centers

The warehouse constructed by Marukyo Unyu Co., Ltd. in Shimono-shi, Tochigi Prefecture, is a highly open warehouse with support columns aligned in the center of the warehouse. The sides of the warehouse have long eaves with attached lighting to allow warehouse operations to be carried out even in stormy weather without loss of efficiency.

Part of the warehouse is also an interior space that functions as an office. Insulation functions were also added, resulting in an office with a comfortable environment while reducing air conditioning costs.

The main features of the facility are as follows

• Span length (m): unknown
• Length of girder way (m): Unknown
• Construction floor area (m²): 10,844
• Eave height (m): unknown

System architecture: Disaster-resistant and reliable warehouse

The warehouse and office built in Matsue City is a warehouse that is highly resistant to earthquakes and other disasters, thanks to the use of a special earthquake-resistant joining method and a fire-resistant structure. The shutter doors for loading and unloading goods provide ample space around them, and the overhanging eaves allow the warehouse to be used in a variety of situations.

The main features of the facility are as follows

• Span length (m): 25.00
• Length of girder (m): 57.20
• Construction floor area (m²): 2,003
• Eave height (m): 8.50

System architecture: a vast warehouse created by land development.

Toda Warehouse Logistics Co., Ltd. warehouse was built on a site that was originally a large valley. There are no pillars or beams inside the warehouse, and high workability can be expected. A large portion of the roof overhangs to form an eave, providing a sense of security even in strong winds.

The main features of the facility are as follows

• Span length (m): 34
• Length of the girder (m): 133
• Construction floor area (m²): 5,453
• Eave height (m): 7.15

summary

This section describes the types of warehouses, basic knowledge, and examples of warehouse construction that you should know when building a warehouse.

Tent warehouses are constructed with a simple framework and sheeting, making them attractive because of their low cost and short construction period, which is a hurdle to overcome when introducing them. Although the low durability and weather resistance of tents are sometimes pointed out, with appropriate maintenance, they have the durability to continue to be used for more than 10 years.

In addition, the light-permeating nature of the sheeting allows a level of brightness that eliminates the need for lighting during the daytime, making this method of construction highly workable. With these advantages, tent warehouses have been adopted by many advanced manufacturers and logistics companies, and their introduction can be expected to lead to more efficient warehouse operations.

If you are at all interested in tent warehouses, please visit the website of Taiyo Kogyo Corporation, which is celebrating its 100th anniversary and has the largest market share in Japan.