Post-Tension Works for NewCold Melbourne II – Dispatch Extension

Pioneering Netherlands-based cold chain logistics company NewCold has strengthened its presence in Victoria with an additional $160 million investment in its state-of-the-art facility. This brings the company’s total investment in Victoria to an impressive $460 million, reinforcing its commitment to innovation and efficiency in cold storage solutions.

Expanding Cutting-Edge Cold Storage Capabilities

The NewCold Melbourne II facility is among the world’s largest automated high-bay cold storage facilities. Designed to offer a fully integrated one-stop solution, it accommodates ambient, chilled, and frozen storage and sets new service standards in the industry. The facility, standing at an impressive 43 meters (141 ft) in height, spans a footprint of 132 x 141 meters (433 ft x 462.5 ft).

With the latest extension, the facility’s storage capacity has expanded significantly from 110,000 pallet positions to 225,000—a remarkable increase of 115,000 pallets. The extension incorporates:

• 31,680 pallet positions for ambient/chilled products
• 86,640 pallet positions for frozen goods
• First Expired, First Out (FEFO) handling, capable of processing over 7,500 pallets per day in and out
• A shipment buffer zone, minimizing truck waiting times before loading
• Enhanced facilities for container loading and unloading

Interspan’s post-tensioning 

Symal engaged Interspan, with Hutchison as the main builder, to design and construct 4,500m² of post-tensioning for the dispatch extension zone.

The Interspan design team utilized Ram Concept and RAPT software to optimize the project’s structural integrity. The post-tensioning approach used a 15.2mm strand throughout, effectively reducing material costs relative to the strand weight required.

Due to limited spacing between edge stressing, a double stack edge stress detail was adopted. The storage floor’s live loads were considerably high, requiring a detailed pattern load analysis. Additionally, pans were restricted from use to maintain a smooth finished floor.