This warehouse project formed part of a state-of-the-art Automated Robotics Sortation facility in Craigieburn, Victoria. Developed by ESR Australia, the facility is a key component of the company’s expanding national logistics network, integrating advanced automation and robotics technology to support efficient, high-volume distribution operations.
MAJOR Automated Robotics Warehouse STEELWORKS
The Project
Project: Major Warehouse Construction
Location: Craigieburn VIC
Builder: Roberts Co / Multiplex
Contract Type: Structural Steel (Supply & Install), Plant Platforms (Design & Construct)
Scope Value: Approx. $35M
This warehouse project related to a state-of-the-art Automated Robotics Sortation facility located in Craigieburn, Victoria. Developed by ESR Australia, the facility forms a key component of a company’s growing national logistics network, incorporating advanced automation and robotics technology to support high-volume distribution operations.
The Scope
APS was engaged to fabricate, supply and install over 2,800 tonnes of structural steel together with a complex package of rooftop plant platforms, screening systems and associated metalworks. The works spanned the main warehouse, bump out structures, awnings, stair cores and rooftop mechanical services infrastructure.
Warehouse Structural Steel
APS delivered the primary structural steel package across the warehouse and associated buildings, including façade support steel, VRC shaft structures, precast support steel, roof lid steel and canopy elements.
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Fabrication and installation of primary and secondary structural steelwork across multiple building zone
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Temporary works engineering including erection bracing and perimeter handrail systems
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Coordination of multi-stage installation sequencing across concurrent construction activities
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Fabrication and quality assurance to AS5131 Construction Categories CC2 and CC3
Awning Structure
APS fabricated and installed the project’s significant western awning structure measuring approximately 100 metres long by 20 metres wide.
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Development and execution of specialist dual-crane lift methodologies
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Complex installation planning to accommodate large structural assemblies
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Coordination with façade and architectural trades to ensure seamless integration
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Precision alignment and connection detailing to achieve both structural and architectural requirements
Rooftop Plant Platforms
APS undertook the design and construction of 30 rooftop mechanical plant platforms incorporating structural steel, aluminium decking and architectural screening systems. This included the re-design of the plant platforms into a modular format to suit installation.
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Design, fabrication and install of galvanised structural steel platform systems with composite aluminium decking, access stairs, gates and access systems
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Modular off-site assembly of platform sections to maximise installation efficiency
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Heavy-radius installation utilising 400-tonne mobile crane operations with 60m fly
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Custom fabricated cranked beams designed to accommodate complex mechanical services
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Design and fabrication of bespoke powder-coated aluminium screening systems and acoustic enclosures
Metalworks Package
APS delivered a substantial internal and external metalworks package supporting both operational and safety requirements across the facility.
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Installation of a 450-metre-long acoustic curtain system
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Delivery of internal security cages
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External fencing, safety barriers and handrail systems
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Delivery of multiple work fronts within critical programme milestones and early handover requirements
The Outcomes & Delivery
APS successfully delivered one of Australia’s largest industrial structural steel and rooftop plant platform packages, coordinating multiple stakeholders, suppliers and subcontractors across a complex and fast-paced construction programme. Through detailed planning, innovative installation methodologies and rigorous quality management, APS achieved the project’s safety, quality and programme objectives.
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Large-scale industrial delivery – Over 2,800 tonnes of structural steel installed across warehouse, awning and rooftop infrastructure packages
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Complex multi-phase execution – Coordinated delivery across multiple work fronts while maintaining programme alignment with principal contractor requirements
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Quality assurance to CC2 & CC3 – Comprehensive fabrication controls, NDT inspections and full manufacturer data record documentation
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Innovative plant platform solutions – Bespoke steel and aluminium platform systems designed to accommodate complex mechanical services and operational requirements whilst also creating efficiency in the installation with offsite assembly.
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Programme certainty – Critical steelwork and plant infrastructure delivered in accordance with construction sequencing, enabling timely commissioning of the facility’s automated logistics systems
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Safety-focused delivery – Detailed temporary works engineering, lift planning and installation methodologies executed without compromising safety or productivity
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