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Yingcai Mini-Class | Specialized Implementation Procedure for Automated Storage and Retrieval System Foundations
2026-09-20
Foundation for automated high‑bay warehouses: Key requirements include bearing capacity, settlement control, surface flatness, and resistance to differential settlement. High‑bay racking systems are highly sensitive to foundation settlement; therefore, both total settlement and differential settlement must be strictly controlled. Design shall follow the drawings provided by the design institute. The following is a general construction process flow.
01 In-depth preliminary research and finalization of the project plan
A comprehensive, in-depth project study was conducted, with both parties jointly holding multiple rounds of discussions on key aspects such as automated storage‑and‑retrieval system (AS/RS) requirements, site conditions, equipment operating standards, load parameters, and anticipated usage frequency. Taking into account the actual on-site working conditions, the operational requirements of automated equipment, and relevant industry codes, a preliminary overall foundation construction plan, foundation structural configuration, and embedded‑part installation procedures were established, providing a solid basis for subsequent detailed design and pile foundation construction.
02 Foundation Drawing Design and Pile Foundation Verification & Approval
Party B shall take the lead in preparing the preliminary foundation design for the automated storage and retrieval system, clearly defining key technical parameters such as foundation load‑bearing locations, load magnitudes, dimensions and specifications of embedded components, and construction‑process standards. At the same time, the design documents shall be submitted to a specialized design institute, which, based on the project’s geological investigation report, will verify critical parameters including the site’s soil stratification, bedrock depth, and foundation bearing capacity, and conduct a rigorous structural analysis of the foundation load‑transfer system. The institute will ultimately approve the preferred pile‑foundation construction method—whether driven piles or drilled piles—and finalize the complete set of detailed construction drawings for the foundation, pile foundations, and embedded components, ensuring that the design fully meets the operational requirements and long-term load‑bearing demands of high‑rise automated storage equipment.
03 Construction of the Pile Foundations and Main Foundation Structure for the Automated Storage System
Based on the design institute‑approved plan, core foundation construction is carried out, with pile foundation work prioritized. Pile driving and bored pile techniques are employed, with pile lengths determined according to site geological conditions. At critical locations, piles must penetrate into solid bedrock to ensure the overall stability of the foundation from the outset. Throughout the construction process, precise calculations are performed to assess both the overall ground‑bearing capacity and localized point‑load capacities, enabling rigorous selection of appropriate pile‑foundation construction methods. Simultaneously, operations such as laying ground reinforcement mesh, erecting load‑bearing structures, and installing embedded components are executed to comprehensively optimize the ground’s load‑bearing system, evenly distributing the loads from racking, goods, and automated equipment. Construction quality is strictly controlled to prevent potential issues such as uneven settlement or deformation of the foundation.
04 Stress‑bearing structural installation and precise adjustment and fixation of embedded parts
Lay the floor reinforcement mesh or load-bearing steel beams in accordance with the construction drawings and relevant specifications, thereby establishing a complete load‑bearing framework for the floor. Precisely position, secure, and reinforce all embedded components, and throughout the process use levels and total stations to verify elevation and alignment, ensuring that the embedded parts and the steel structural framework meet required flatness and accuracy standards, thus laying a precise structural foundation for subsequent equipment installation and secondary concrete placement.
05 Grouting Works and Embedded Part Cleaning
After completing the alignment and securing of the load-bearing structure and embedded components, proceed with grouting of the base concrete, rigorously controlling grout density, surface flatness, and curing quality to ensure the overall strength of the base structure. Following grouting, promptly clean and grind the exposed portions of the embedded components to remove laitance and debris, ensuring that the working surfaces of the embedded parts are smooth and free of contamination, thereby meeting the requirements for subsequent welding and equipment installation.
06 Specialized Installation and Construction of Core Embedded Components
Adopt Embedded steel plate + secondary concrete pouring With a mature construction process, the foundation is cast in two stages, thereby mitigating precision deviations and settlement‑induced deformation that can arise from single‑pour operations, and ensuring reliable, high‑frequency, stable performance for high‑rise automated storage systems.
1. First pour construction: The foundation base is poured up to -0.070 m elevation , simultaneously completing the installation of embedded steel plates. Specifically, the embedded steel plates for high‑bay rack load‑bearing applications and those for the stacker crane’s floor rails are all coordinated to achieve a common top‑surface elevation of -0.070m . Strictly control installation accuracy: the deviation of all embedded components from their theoretical installation positions shall be ≤ ±5 mm, and the elevation deviation of the top surface of the embedded steel plates shall be ≤ ±5 mm.
2. Secondary Concrete Pouring: Weld anchor bolts to the top surface of the embedded steel plates. After all racking and stacker‑crane equipment has been installed and accurately commissioned, proceed with a second concrete pour to bring the foundation up to the design elevation of ±0.00 m, thereby achieving a rigid and stable connection between the equipment and the foundation.
3. Note: Some applications may use embedded chemical anchors; however, for automated storage systems that operate at high frequency, it is recommended to avoid chemical anchors and to completely refrain from using expansion anchors.
07 Auxiliary chemical anchor installation (selected as needed)
For non‑core load‑bearing locations and auxiliary fixing points, chemical anchors may be used as needed for installation and fixation, provided that design and code requirements are met. The use of chemical anchors is strictly prohibited at core load‑bearing locations. A clear distinction must be maintained between primary and secondary structural construction methods to mitigate the risk of equipment loosening or displacement in the future.
08 Division of Construction Responsibilities Among All Parties
01
Party A’s Responsibilities
Responsible for the final approval of the project’s overall plan; coordinates and manages all facility‑related support services, including compliance approvals for the plant, on‑site lighting, fire‑safety system acceptance, connection to power and network infrastructure, and other essential prerequisites, to ensure the smooth progression of the entire construction process.
02
Party B’s Responsibilities
Responsible for designing the overall foundation load‑bearing scheme for the automated storage and retrieval system, accurately calculating the load values at all equipment load‑bearing points, and specifying the dimensions and installation standards for the complete set of embedded components. Throughout the entire construction process, meticulous oversight is maintained, with each embedded component’s position, levelness, and elevation accuracy rigorously verified prior to equipment installation to ensure compliance with installation requirements.
03
Responsibilities of the Design Institute
Based on the site’s geological conditions, the overall bearing capacity of the foundation is verified, the pile‑foundation construction method and design parameters are approved, and a complete set of specialized drawings for the foundation, pile foundations, and embedded components is prepared, thereby ensuring structural safety and construction compliance at the design stage.
04
Responsibilities of the Civil Engineering Contractor
Strictly adhere to the construction drawings provided by the design institute and the technical standards agreed upon by both Parties A and B, ensuring that all civil engineering processes—including pile foundation work, subgrade concrete placement, rebar installation, embedded component installation, and secondary grouting—are executed in full compliance with applicable codes and specifications, while effectively implementing quality control and on-site execution.
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