Load-bearing sprinkler structure as a smart solution for fire safety in a tall distribution center

In a modern distribution center, everything revolves around efficiency, flexibility, and safety. But what if the building’s height itself poses a fire safety issue? This was precisely the challenge facing one of Almacon’s clients. The distance between the roof and the stored goods was too great to comply with applicable sprinkler standards. This called for a smart, innovative, custom solution that complied with all laws and regulations.

The project

The request came from a specialist in warehouse racking and automated storage systems. The end customer had built a distribution center that is flexibly leased to various users, each with their own type of storage.

With a building height of approximately twelve meters, a problem arose: a sprinkler system on the roof was too far from the goods. As a result, the building did not meet fire safety requirements. At the same time, sufficient floor space had to remain available for the storage of loose pallets and logistics operations.

The question was clear: how do you bring the sprinklers closer to the storage area without sacrificing flexibility and storage space?

Solution: a smart load-bearing sprinkler structure

The solution lay in a specially designed, lowered structure: a load-bearing sprinkler structure. This is a lightweight, non-walkable custom-built support structure to which the sprinkler system is attached.

By placing this structure between the roof and the storage area, the sprinklers are positioned at the correct height. This ensures compliance with applicable fire safety requirements, while the entire space beneath the structure remains available for storage and logistics operations.

The structure consists of:

columns and a beam structure
a corrugated steel sheet on top
sprinkler pipes, attached to the underside of the floor

The design was based on a number of key principles:

a lightweight construction
large spans for maximum use of space
an unscored version
preserving as much floor space as possible

Thanks to the large spans and the unsupported design, the space beneath the structure remains fully available for storage and logistics operations. This solution thus makes it possible to utilize the full height of the distribution center for storage without compromising fire safety.

Laws and regulations as a starting point

Legislation and regulations play a key role in successfully implementing this solution. Fire safety requirements depend on regional regulations, the building’s use, and its total volume. A crucial factor here is the maximum distance between the sprinkler and the goods.

It is precisely on this point that the load-bearing sprinkler structure offers a solution: because the sprinklers are installed lower in the building, standards are still met, while high-rise storage remains possible. At the same time, the presence of a sprinkler system often allows for lower fire resistance requirements to be imposed on the main load-bearing structure. This provides additional design flexibility.

Projectdetails

The project included multiple units within a single distribution center:

9 separate units
total area of 45,000 m²
a dedicated sprinkler floor structure per unit

The spans ranged from:

8 x 8 meter
8 x 12 meter

The design took the following into account:

sufficient clearance beneath the structure
the location of expansion joints (joints in a concrete floor that accommodate expansion and contraction)
an unedited version

The following factors were taken into account when calculating the sprinkler floor:

the weight of sprinkler pipes
cable trays and lighting

Extra clearance has been intentionally provided to ensure that future installations can be accommodated without any issues.

The Power of Almacon

This project required more than just a structural solution. It demanded an understanding of laws and regulations, flexibility in design, and speed of execution. By developing a custom solution within the framework of laws and regulations, we created the flexibility needed to make optimal use of the building. It is precisely in these types of challenges that Almacon makes a difference—by combining technical expertise, practical insight, and safety into a single design.

What are your options?

Do you operate a high-bay distribution center and are you facing fire safety requirements? If so, a sprinkler structure may be the solution you’re looking for. Please contact one of our engineers so we can discuss your specific situation.

📞 Call 079-3610663
📧 Mail info@almacon.nl