Food Distribution Center Steel Warehouse Facility – Pre Fabricated (55,000 SQUARE FEET)

Challenge

Delivering a 55,000 sq.ft. food distribution hub required engineering a large clear-span facility capable of handling continuous high-volume logistics operations while maintaining strict food-grade compliance and thermal performance standards.

Site Development & Ground Engineering

The project began with detailed geotechnical soil investigations to determine safe bearing capacity and settlement limits. Based on this analysis, foundation systems were engineered to support portal frame column reactions under full operational loading.

Groundworks included:

• Site clearing and bulk excavation
• Controlled backfilling and compaction
• Sub-base preparation for slab construction
• Formation leveling and grading
• Underground stormwater drainage pipe installation

Foundation & Substructure

The foundation system comprised reinforced concrete pad and pedestal foundations designed for heavy structural loads.

Works included:

• Precision anchor bolt cage installation
• Reinforced concrete pad foundations
• Pedestal column construction
• Structural concrete curing and strength verification
• Integration with slab reinforcement system

Industrial Flooring System

The industrial floor slab was engineered to accommodate pallet racking, heavy forklift traffic, and continuous logistics movement.

The flooring package included:

• Heavy-duty reinforced concrete slab
• Double reinforcement mesh system
• Saw-cut expansion and control joints
• Surface hardener treatment
• Food-grade epoxy coating system
• Dock leveller pit construction
• Loading apron integration

Structural Steel Superstructure

The building was constructed using a long clear-span Pre-Engineered Steel Portal Frame system eliminating internal columns.

The structural system incorporated:

• Built-up tapered steel columns ( H – Iron Nut and Bolt System )
• Fabricated steel rafters
• Z-section roof purlins
• C-section wall girts
• Sag rods for purlin restraint
• Cross bracing and knee bracing systems
• High-tensile bolted structural connections
• Expansion-ready end-wall design

Roofing & Thermal Performance

The roofing assembly was engineered for tropical heat and heavy rainfall exposure.

The roof build-up included:

• Zinc-Aluminium (Alu-Zinc) roofing sheets
• MCFOIL radiant barrier insulation system
• Z-purlin support grid
• Ridge caps with sealed weatherproof joints
• Industrial flashings at roof transitions
• Fabricated box gutters
• Eave gutters
• Downpipe rainwater discharge network

Cladding & Envelope Completion

The full enclosure system included:

• Zinc-Aluminium wall cladding sheets
• C-girt framing
• Corner & trim flashings
• Ridge ventilators
• Ventilation louvers
• Industrial roller shutter door systems

This project demonstrates complete end-to-end execution from ground preparation to finished industrial facility.