A M King, Charlotte, N.C., completed the expansion of an existing food distribution facility for ALDI, Inc. in Frederick, Md. The new cold storage distribution center will boost the Batavia, Ill.-based discount grocer’s existing perishables space.

A M King renovated the existing 100,000-square-foot refrigerated and freezer perishable space, including conversion to new temperature zones, and added a new 48,000-square-foot, 32-foot clear, fully-racked freezer. Additional improvements include expansion of the ammonia refrigeration system; a new perishable break room and locker rooms; updates to millwork cabinetry/appliances in employee welfare areas; conversion to interior and exterior LED lighting; and energy-saving modifications on new and existing equipment. The employee parking, which now accommodates 236 cars, is double the original size, and the expanded truck apron allows for more parking and improved site/trucking logistics.

This facility has a unique building design to accommodate coordination with the local airport authority and to protect forested conservation areas located to the South of the property.

A unique challenge presented by the project was engineering a massive and complicated retaining wall that would support a majority of the expansion area and meet FAA regulations for the area. The result is a wall built of large-format, concrete blocks that stretches nearly 40 feet high and 275 feet long, covering 10,000 square feet and supporting more than 95,000 cubic yards of soil.

“We also faced an accelerated schedule, limited available work space and the challenges of maintaining company operations during construction,” says Carl Morse, senior project manager for A M King. “But, in the end we presented ALDI with another exceptional project, on time and within budget.”