Issue link: https://www.e-digitaleditions.com/i/825042
May/June 2017 25 continued on page 32 The VC5G gas convection oven features removable, dishwasher-safe doors for easy cleaning. Plus, cutout grab-and-go oven racks, simple controls and the durability and performance you expect from Vulcan. Now there's no excuse for dirty doors. To learn more, visit vulcanequipment.com © 2016 Vulcan VC5G most important attributes of real estate— location, location and location. Unfortunately, tearing the building down would open up the property to current zoning and code restrictions that would preclude rebuilding at anywhere near the same size. The question was, "What can we do without breaking the bank?" This is where Footlik & Associates became part of a team effort. The fi rst step was to create a master plan for ultimate usage of the overall facility. This necessitated measuring the existing structure and noting signifi cant structural features, along with potential areas for improvement. With knowledge came insight. For example, although many walls were required to support the structure, a ribbon of windows just under the roof indicated that there was a lintel above the glass. Signifi cant parts of the walls could be removed with- out compromising structural integrity. A layout was designed to embrace this opportunity with minimal cost for con- struction, and enormous labor savings for the operation. In a branch with a high inventory turn rate and overnight replenishment from a master distribution center, ceiling height for overstock storage is far less important than fl oor reachable "fronts" where prod- ucts can be easily picked. Therefore, the layout emphasized "picking fronts" for the widest variety of products. Shelving aisles were held to 3 feet and pallet rack aisles to 8 feet so that two pallets could pass. Cross aisles for adequate material fl ow was designed to do double duty for night-time staging without compromis- ing early morning operation. The EPA Provides an Opportunity Indoor loading docks, a highly desir- able feature, at fi rst appeared to be a problem due to the low ceiling and topography of the site. With some adroit engineering and luck, however, a perfect solution was found. An environmentally knowledgeable attorney drafted a contract that forced the seller to clean up the property and provide a "No Further Remediation" (NFR) letter. This involved removing some of the dirt in the parking lot and paving over the area. Turning this to our advantage, the loading docks were moved and redesigned to include both indoor and outdoor positions. By pitch- ing the paved area toward the rear, at the seller's expense, rainwater runoff could be properly directed and a depressed dock to accommodate a full 53-foot trail- er became economically and technically feasible. Examining the roof structure revealed wood beams that could be easily cut over the loading dock area. Rebuilding the roof 4 feet higher and lowering the paved approach, provided suffi cient height for an overhead door to accom- modate the longest trailers. Bringing the vehicle indoors, shortened the turning area outdoors, providing adequate space for truck maneuvering. The overall cost was relatively low and the building mod- ifi cations were easily accomplished with a chain saw. Similarly, channeling rain toward the available drainage necessitated pav- ing a yard storage area included in the master plan. By specifying the materials and design for this area, no addition- al expense was incurred by the buyer. Paving for storage was completely com- patible with the requirements of the EPA and local codes. Staying on Track As the planning progressed, changes were made by the architect. In some cases, these were justifi ed by interpre- tations of the local building inspectors and implemented. In other areas, a plan review by the materials handling consul- tant and the team resulted in signifi cant improvements without additional cost. Replacing the roof with tar and gravel, without new insulation, was the least expensive option in terms of fi rst cost. But, adding 2 inches of insulation under the same roofi ng material had a four- year payback. Switching to a "membrane roof" with 4-inch insulation resulted in a three-year payback in heating expenses and a signifi cantly cooler building in the summer. Lighting over every aisle was specifi ed. The initial contractor proposal called for standard fl uorescent strip fi xtures. Instead, we proposed using high output