Case Study: Extending storage space quickly with Pop-up Warehousing

Bird Stainless contacted us looking for a storage solution to enhance its operation. Company expansion, coupled with the necessity to store a large proportion of its highly valuable stock in a building not designed for the purpose, hampered the day-to-day handling and management of raw materials.

Following a site survey and management consultation, we began a two-phase installation by designing and specifying two new, purpose-built Pop-up Warehouses to accommodate bar diameters, weights and lengths, while also aligning the structure to the Combilift truck specifications. Constructed around an integral heavy duty cantilever racking system, the buildings would house the material stock in a more ordered and accessible fashion; allowing order-picking via a guided forklift system and making stocktaking a hugely simplified task.

No foundations required

Suitable sites had already been identified as locations for the new purpose built storage facilities as part of the planning phase. Following site clearance and access construction, the existing concrete base in one area was cleaned up and made good, and a second base was laid to provide suitable platforms for principal construction to begin. The new facilities were constructed consecutively, the smaller of the two buildings being the first to be commissioned. In each case, the racks and heavy duty forklift truck guide rail systems were installed first.

Once the racking was installed, the apex beams, purlins and side rails were then affixed and the cladding began, utilising durable Nor-Clad weather resistant lapped sheets on both the roof and walls to complete the Pop-up Warehousing structure.

Installation of rainwater goods ensured that both buildings were weatherproof and adequate drainage was provided. Once fully clad, safety exit doors were installed at the rear of each building and the cladding sheets were trimmed and flashed. High quality sheets were trimmed and flashed. High quality powered roller shutter doors finished off each build, providing security for the stock.

We used our standard range of heavy duty, bolted adjustable cantilever systems for the racking in both buildings. Constructed from hot-rolled steel beams and channels, each system provides a storage capacity of base + 8 x arm levels at 1000kg per arm giving a total of 8000kg per column side. Taken as a whole, the new buildings have a total storage capacity of 1500-1750 tonnes of stainless steel bar.

We co-ordinated the build with the planning authorities, building control and independent MIStructE sign off. Both the finished buildings are now in full use and have significantly contributed to the improved running of the whole Bird Stainless stock operation.

How does Pop-up Warehousing work?

The structure of Pop-up Warehousing is created by the steel uprights of a cantilever racking system, which is then enclosed by adding a canopy to the top and cladding to the outside.  No costly foundations are required because the load is taken by the cantilever racking system.  The structure just needs a suitable concrete base for installation, meaning construction is measured in days not months.

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