Structural Challenges of an Automated Warehouse System and a BIM-Based Solution

New steel columns 

We designed HEB 220 steel columns made of S235-grade steel connection to the inner faces of the existing reinforced concrete columns. These columns do not simply function as new supports but form a supplementary system that works in conjunction with the existing reinforced concrete columns. 

When designing the columns, special attention was required to ensure: 

• minimizing the load on the existing structure,  

• ensuring a secure connection to the existing reinforced concrete columns, and  

• and managing the stresses resulting from the building’s movements.  

The upper four connections of the steel columns were designed with vertical slotted holes to prevent lateral displacement, while the lower connection transfers the vertical loads to the reinforced concrete column through a non-slotted hole.

Structural Analyses and Structural Assessments 

A detailed analysis was conducted during the design process to assess: 

• the additional load on the existing reinforced concrete columns,  

• the load-bearing capacity of the foundations,  

• the internal forces and stresses on the new steel structure,  

• the deflection limits, 

• the load-bearing capacity of the joints,  

• the effects of building movements.  

BIM-Based Design: Coordinated Interdisciplinary Collaboration in a Complex Industrial Conversion 

The entire design process was carried out using Autodesk Revit in a closed BIM environment. The structural, architectural, mechanical, process engineering, and fire protection disciplines were all represented in the shared model, allowing design decisions to be made continuously and in coordination with one another. 

The BIM workflow proved particularly valuable for a project that required integrating a new steel structure into an existing reinforced concrete hall system. Using the three-dimensional model, it became possible to examine geometric relationships, structural connections, and coordination with existing mechanical and process engineering elements as early as the design phase. 

Construction Considerations 

One of the greatest challenges during construction was that the structure had to be built in an operational industrial environment. The installation method had to be planned to minimize disruption to the operational processes. 

The dimensions of the prefabricated truss girders were determined by transportation constraints and the dimensions of the galvanizing bath. Accordingly, each main girder was delivered to the site in three sections, which were assembled on site using bolted connections, enabling quick and safe installation. 

When planning the installation sequence, special attention was paid to the temporary condition of the structure, the hoisting of the components, and the protection of existing mechanical systems. 

This project serves as a good example of how adapting existing industrial buildings to modern technologies can present a complex engineering challenge. The implementation of the automated high-bay warehouse system involved not only a technological  conversionbut also the adaptation of an existing reinforced concrete hall structure to new operational, structural, and fire safety requirements. 

One of the keys to the success of such interventions is a precise understanding of the existing structural conditions, as well as the coordinated management of various engineering considerations. The design of the independent steel structural system, detailed structural analyses, and the BIM-based design and coordination process collectively enabled the new function to be safely implemented while maintaining the operation of the existing building. 

For our company, the application of advanced design methods is not a standalone technological element, but an integral part of our reliable engineering services. In a closed BIM environment, interdisciplinary collaboration based on a shared digital model supports more accurate decision-making, more efficient coordination, and the reduction of construction risks, thereby contributing to the successful implementation of complex industrial projects.