Facility Architecture & Floor Specifications Guide

6-1. Functions, Equipment, and Floor Specifications in Logistics Facilities

1. Functions of Logistics Facilities and Main Equipment on the Building Side

A logistics facility functions not merely as a storage place for goods, but as a "hub that smoothly controls the flow of products." The necessary functions and the main building-side equipment supporting them are as follows.

1.1 Main Functions of Logistics Facilities

• Receiving and Inspection Function: Inspecting and accepting the quantity and condition of incoming products.
• Storage and Management Function: Managing inventory in the optimal state according to product characteristics (temperature zone, hazard level, size).
• Picking and Processing Function: Collecting specified products according to orders and performing distribution processing such as packing and labeling.
• Shipping and Transport Function: Sorting by delivery route or flight, consolidating, and loading onto trucks.

1.2 List of Necessary Equipment Required on the Building Side

Category	Equipment / Specifications	Function and Role
Carry-in/Carry-out Equipment	Truck Berth	Vehicle docking space. Designed with deep eaves to prevent getting wet during rain.
	Dock Leveler	Eliminates the gap and level difference between the berth and the truck bed, enabling direct entry of forklifts.
Vertical Movement	Freight Elevator	Vertically transports pallets and heavy loads between floors.
	Vertical Material Conveyor (VMC)	Automatically transports faster and with less space than elevators under the Building Standards Act.
Architecture / Floor Structure	High-Floor / Low-Floor Specs	Differentiated use for marine containers/large vehicles (High floor: approx. 1m) and collection/delivery vehicles (Low floor: flat).
	High Load-Bearing Floor	Load-bearing capacity of about 1.5t/㎡ and a dust-proof painted finish to prevent dust.
	Sufficient Effective Ceiling Height	Secures about 5.5m to 6.5m per floor to increase rack storage efficiency.
Environment / Disaster Prevention	Temperature Control (Refrigerated/Frozen)	Cold chain-compatible insulation structure, anti-condensation equipment, air conditioning units.
	Disaster Prevention / Security	Sprinklers, fire shutters, access control (gates, cameras).
Traffic Lines / Working Environment	Rampway	Slope structure allowing large trucks direct access to upper floors.
	Amenities	Employee break rooms, cafeterias, kiosks, driver shower rooms.

2. Details of Building-Side Carry-in/Carry-out Equipment (Berths, Dock Levelers, Shielding Equipment, etc.)

The carry-in/carry-out equipment in a logistics facility acts as the "front door of logistics," connecting outdoor transport/delivery trucks with indoor storage/work areas, and is an important group of equipment that dictates the operational efficiency and safety of the entire facility.

2.1 Truck Berth (Truck Docking Space)

A dedicated area for stopping trucks to perform unloading and loading.

• Shape Types:
  • Docking (Flat) Type: The standard shape where trucks dock perpendicularly to the building.
  • Saw-tooth Type: A shape that saves turning radius and space by having trucks park diagonally (e.g., 45 degrees) when the site depth is narrow.
• Main Incidental Equipment:
  • Eaves: Prevents damage to cargo and getting wet during rain. Securing a depth of 5m to 8m or more so that large vehicles can be completely hidden is the mainstream in advanced facilities.
  • Wheel Chocks / Guide Rails: Safe guidance of trucks and prevention of collisions with the wall surface when docking.

2.2 Comparison of Floor Height Structures (High-Floor / Low-Floor)

Structure	Floor Height	Features / Main Uses
High-Floor Type	GL+1.0m to 1.1m	A structure that levels the height of the truck bed and the warehouse floor. ・Uses: Hubs centered on pallet transport, wing trucks, and large trucks. ・Merits: Forklifts can drive directly onto the truck bed.
Low-Floor Type	GL±0m (Flat)	A structure with no level difference between the building floor and the outdoor road surface. ・Uses: Courier collection centers, manual loading/unloading, heavy use of small trucks and light vans. ・Merits: Can accommodate vehicles regardless of type, easy to roll and move roll box pallets (cage carts).
Hybrid Type	High Floor + Low Floor	Equipped with both high-floor and low-floor areas within the same facility to handle multi-purpose uses.

2.3 Other Carry-in/Carry-out Related Equipment

• Dock Leveler: Raises/lowers and extends a plate (lip) hydraulically or via airbag to eliminate gaps and level differences between high-floor berths and truck beds. Enables forklifts and hand lifts to drive directly into the truck bed, shortening unloading time.
• Dock Shelter / Dock Seal: Seals the gap when a truck docks using cushioning materials or rubber shelters. Maintains temperature control in refrigerated, frozen, and constant-temperature warehouses, and thoroughly ensures dust, insect, and rain proofing in food and pharmaceutical warehouses.
• Overhead Door / High-Speed Sheet Shutter: Motorized overhead doors with excellent thermal insulation, or high-speed sheet shutters that open and close several meters per second linked to approach sensors to prevent outside air intrusion.
• Dock Lock (Truck Restraint Device): Safety equipment that automatically reinforces and secures the rear wheels or rear bumper with metal hooks to prevent accidental departure of trucks during work.

3. Cost Comparison of High-Floor and Low-Floor Specifications

Differences in construction and equipment costs between high-floor (GL+1.0m to 1.1m) and low-floor (GL±0m) types arise depending on the "volume of earthworks (embankment/retaining walls)," "enhancement of structural strength of framework/floors," and the presence of "incidental equipment such as dock levelers." Generally, high-floor types are about 10% to 20% more expensive in initial construction costs compared to low-floor types.

3.1 High-Floor vs. Low-Floor Cost Comparison Summary

Comparison Item	High-Floor Type (High-Floor Berth)	Low-Floor Type (Flat Berth)	Factor of Cost Difference
Structural / Foundation Work	High	Standard	Requires embankments/retaining walls (retaining wall work) and embankment retaining structures to raise the berth section.
Floor / Slab Structure	Slightly High	Standard	Requires impact resistance and high load-bearing design because forklifts drive directly from trucks.
Carry-in/Carry-out Equipment	High	Very Cheap	Dock levelers (1.5 million to 3 million yen per unit) and dock shelters are mandatory.
Total Construction Cost	Base (1.1 - 1.2)	Base (1.0)	Unit price per tsubo/square meter increases for high-floor specifications.
Maintenance Cost	Slightly High	Low	Incurs periodic inspection and repair costs for dock levelers and hydraulic equipment.

3.2 Breakdown of Main Additional Costs in High-Floor Types

1. Civil Engineering / Foundation Work Costs (Embankment/Pit Work): Costs for large-scale embankment or hollow slab (pit structure) work to raise the entire floor surface by about 1m, and installation of high-strength retaining walls.
2. Dock Leveler Equipment Costs: 1.5 million to 3 million yen per vehicle space (main unit + installation cost). A direct additional cost of 15 million to 30 million yen for 10 vehicle spaces.
3. Slope / Exterior Costs for Slope: Construction costs for "vehicle slopes" and stairs for forklifts and people to enter the high-floor warehouse from the site.

3.3 Selection Criteria Based on Cost

[Cases where High-Floor Type should be chosen]
・Centered on the use of large trucks (10t trucks, trailers, marine containers) and wing trucks.
・Frequent bulk unloading of pallets, making direct entry of forklifts into the truck bed mandatory.
・Want to emphasize preventing cargo from getting wet during rain and measures against floor flooding (water damage).

[Cases where Low-Floor Type should be chosen]
・Want to minimize initial construction costs as much as possible.
・Centered on rolling loads of cage carts and manual loading/unloading (EC logistics, courier collection centers, etc.).
・Various vehicle types dock, such as van-type small trucks, light vans, and one-box cars.

*In recent years, rental multi-tenant warehouses adopting a "hybrid design with a high floor on the front side and a low floor on the back side" are increasing to meet diverse tenant demands while accepting cost increases.

4. Floor Specifications of Logistics Facilities (Load-Bearing Capacity, Floor Coating, Flatness, Repair)

The floor of a logistics facility is the most critical fundamental infrastructure for supporting the massive loads from forklifts, automated equipment (AGV/AMR), and high-rise racks, and for enduring daily wear and tear.

4.1 Three Basic Performances Required for Floors

1. Load-Bearing Capacity (Floor Slab Strength):
   • Standard General Warehouse: 1.5 t/㎡ (1.5 tons per square meter)
   • Heavy Goods/Heavy Machinery Compatible Warehouse: 2.0 t to 3.0 t/㎡ or more
   • Requires a strength design that can withstand concentrated loads from the legs of high-rise racks and large forklifts.
2. Flatness (Super Flat Floor Standard): High smoothness is required when operating high-place work forklifts (VNA trucks), AGV/AMRs, and automated 3D racks to prevent tipping and reading errors caused by millimeter-level tilts.
3. Wear Resistance / Dust Proofing: Prevents the generation of concrete dust (wear powder) due to wheel travel, avoiding product contamination and precision equipment failure.

4.2 Representative Floor Finishing/Coating Methods (Floor Coating)

Type of Floor Finish	Features and Merits	Main Uses / Suitable Areas
Surface Hardener Finish (Ferrocon, Concrete troweling)	Hardens the concrete surface layer, obtaining high wear resistance and dust proofing at low cost. Most standard.	General dry warehouses, driving paths, shipping berths
Epoxy Resin Floor Coating	Excellent oil and chemical resistance, hard coating film that is easy to clean. Also suitable for color line execution.	Precision equipment warehouses, distribution processing areas, walking zones
Water-based Polyurethane Floor Coating	Excellent heat, cold, and impact resistance, enduring -30°C environments and hot water washing.	Frozen and refrigerated warehouses, food processing areas
Anti-static Floor Coating	Suppresses the generation of static electricity, preventing destruction of electronic components and fires due to discharge.	Semiconductor/electronic component warehouses, hazardous materials warehouses

4.3 Special Structures and Maintenance Points

• "Underfloor Frost Heave Prevention" structure unique to frozen warehouses (-25°C): By laying moisture-proof sheets and insulation materials under the concrete slab and running electric heaters or ventilation pipes through the ground, freezing and heaving (frost heave) of the ground is prevented.
• Treatment of Joints (Concrete Expansion Joints): To prevent chipping due to impact when forklifts pass, joints are filled and smoothed with a high load-bearing repair material such as epoxy resin.
• Repairing Age-related Cracks: Because even microscopic cracks can lead to AGV driving sensor anomalies and wheel damage, early repair via resin injection is performed.