Warehouses Projects in Structure Services in Pakistan

E-commerce is booming. Retail supply chains are expanding. Pakistan’s logistics sector is growing at 8-10% annually. Consequently, the demand for modern warehouses has never been higher. But here is the problem: a warehouse is not just a big shed. It must support heavy floor loadings from pallet racks and forklifts. It must provide clear spans for efficient storage. It must withstand seismic forces while protecting inventory worth crores of rupees. At Ahmed Construction Company (ACCO), we provide specialized warehouses projects in structure services in Pakistan that optimize storage capacity while ensuring structural safety. For over 25 years, we have designed and built structural frameworks for Gerry DNATA (logistics hubs), Savour Foods (cold storage), Bata (distribution centers), and warehouses across Lahore, Karachi, and Faisalabad. From heavy-duty floor slabs to long-span steel frames, our PEC-certified engineers deliver warehouses that perform.

What Are Warehouse Structural Services?

Warehouse structural services encompass the engineering, design, and construction of load-bearing frameworks for storage and distribution facilities: general merchandise warehouses, cold storage, e-commerce fulfillment centers, logistics hubs, and distribution centers. Unlike other industrial buildings, warehouses face unique challenges: heavy floor loadings (5-15 kN/sqm from pallet racks), forklift traffic (point loads from wheels), large clear spans (30-60 meters for unobstructed storage), high bay racking (20-40 feet tall), and specialized floor flatness requirements (for high-rack automated systems).

In Pakistan, the Pakistan Engineering Council (PEC) and private developers require compliant structural designs. Furthermore, international logistics companies often require compliance with US or European warehouse standards. Therefore, ACCO’s warehouses projects in structure services in Pakistan meet both local regulations and international best practices. We serve 3PL providers, e-commerce companies, retailers, manufacturers, and cold storage operators.

Who We Are: ACCO – 25+ Years of Warehouse Structural Excellence

For over two and a half decades, Ahmed Construction Company (ACCO) has been the trusted structural partner for Pakistan’s logistics and warehousing sector. From our head office at Office 2, 3rd Floor, Bigcity Plaza, Gulberg-III, Lahore, and our operational hub in Karachi, we have delivered structural solutions for Gerry DNATA (air cargo logistics), Savour Foods (cold storage and dry warehousing), Bata (distribution centers), and textile warehouses in Faisalabad.

What sets us apart is our understanding of warehouse operations. We know that floor flatness affects forklift efficiency. We know that column spacing affects racking layout. We know that roof design affects HVAC loads for temperature-controlled storage. Consequently, when you choose ACCO for warehouses projects in structure services in Pakistan, you get a team that designs for operational performance—not just structural compliance. Learn more about our Architectural Engineering capabilities.

Our Warehouse Structural Services – Detailed Breakdown

We provide complete structural solutions for all types of warehouse projects across Pakistan and internationally.

1. Heavy-Duty Floor Slabs for Pallet Racking & Forklifts

Warehouse floors are the most critical structural element. We design jointed reinforced slabs, post-tensioned slabs, and steel fiber reinforced slabs for heavy loadings. Our designs include: sub-base preparation (compacted granular fill), reinforcement detailing (for shrinkage and temperature cracking), joint layout (to control cracking and allow movement), load transfer devices (dowels at joints), and floor flatness specifications (FF/FL numbers for high-rack warehouses). For Gerry DNATA, we designed a floor slab for 15-ton forklifts and 35-foot high racking.

2. Long-Span Steel Framework for Clear Storage

Warehouses need large clear spans—30 to 60 meters—to maximize storage density. We design pre-engineered steel buildings (PEB) with tapered sections, rigid frames, and optimized bracing. Our designs include: main frames (columns and rafters), mezzanine floors (for offices or light storage), crane girders (if needed), purlins and girts, and all connection details. Furthermore, we provide Tekla models and NC files for fabrication. For a 50,000 sq ft distribution center in Karachi, we designed a 40-meter clear span warehouse with 30-foot eave height.

3. High-Bay Racking Support Structures

Modern warehouses use high-bay racking (20-40 feet tall) for dense storage. These racks impose concentrated loads and require stable floors. We design: rack anchor locations (embedded plates or post-installed anchors), floor slab thickening under rack legs (to prevent punching shear), and rack bracing integration (where racks provide lateral stability to the building).

4. Loading Dock & Ramp Structural Design

Warehouses require loading docks (truck-height platforms) and ramps (forklift access). We design: dock leveler pits (reinforced concrete pits with edge angles), dock shelters (structural supports), ramp slabs (with proper slope, surface finish, and guardrails), and heavy-duty edge beams (to withstand truck impact).

5. Cold Storage Structural Design

Cold storage facilities have unique structural requirements: insulation integration (structural supports for insulated panels), vapor barriers (to prevent condensation), heavy floor insulation (load-bearing insulation below slab), and thermal break details (to prevent heat transfer through structural elements). We have designed cold storage structures for Savour Foods with -20°C freezers.

6. Seismic Design for Inventory Safety

Warehouses contain valuable inventory. Therefore, our seismic designs include: importance factor of 1.25 (higher than residential), ductile detailing for steel and concrete, non-structural component anchorage (racking to floor, lighting to roof), and collapse prevention (so racks remain standing during earthquakes).

7. BIM Modeling & 3D Visualization for Warehouses

We provide 3D architectural walkthrough and BIM Modeling to coordinate structural, architectural, and MEP systems. For warehouses, this includes: clash detection between steel framing and conveyor systems, coordination of sprinkler piping with roof purlins, and visualization of racking layouts. See our Architectural 3D Modeling and Modular BIM Modeling pages.

Comparison: ACCO vs. Typical Warehouse Builders

Many contractors claim to build warehouses but lack specialized expertise. Here is why ACCO is different:

Our Step-by-Step Warehouse Structural Process

We follow a rigorous, quality-controlled process tailored to warehouse requirements.

1. Step 1: Initial Consultation & Storage Needs Assessment – You call +92 322 800 0190 or email info@acco.com.pk. We discuss: storage type (pallet, bulk, cold), racking system (selective, drive-in, high-bay), forklift types, and throughput requirements.
2. Step 2: Site Investigation & Geotechnical Study – Our team visits your site. We conduct or arrange a geotechnical investigation (critical for heavy floor slabs). We analyze soil bearing capacity, settlement potential, and water table depth.
3. Step 3: Structural Design & Analysis – Our engineers model your warehouse in ETABS (concrete) or Tekla (steel). We calculate: dead loads, live loads (rack loads: 5-15 kN/sqm), forklift point loads, seismic loads, and wind loads.
4. Step 4: Floor Slab Design & Flatness Specifications – We design the floor slab for your specific racking and forklift loads. We specify concrete mix, reinforcement, joint layout, and flatness (FF/FL numbers). For high-rack warehouses, we specify FF 50 / FL 35 (very flat).
5. Step 5: Drawing Production & PEC Stamping – We produce detailed structural drawings: steel framing plans, floor slab reinforcement, foundation layouts, loading dock details, and rack anchor locations. PEC-registered engineers stamp every drawing.
6. Step 6: BIM Coordination & Clash Detection – We integrate structural, architectural, and MEP models (sprinklers, lighting, conveyors). We run clash detection and resolve conflicts virtually. We also provide 3D architectural walkthrough for warehouse visualization.
7. Step 7: Construction Supervision & Quality Assurance – During construction, our engineers visit the site at critical stages: floor slab pouring (monitoring flatness), steel erection, and rack anchor installation. A 2-year structural warranty is provided upon completion.

Why Warehouse Clients Nationwide Choose ACCO

Pakistan’s logistics sector is modernizing. Third-party logistics (3PL) providers, e-commerce companies, and retailers are demanding better warehouses. First, floor slabs must remain flat and crack-free under heavy forklift traffic. Second, clear spans must maximize storage density. Third, cold storage must maintain temperature without structural thermal bridges.

ACCO has provided warehouses projects in structure services in Pakistan for clients including Gerry DNATA (air cargo warehouse with 24/7 operations), Savour Foods (cold storage and dry warehouse), Bata (distribution center), and multiple 3PL providers. Our structural designs have been approved by PEC and international logistics companies.

Furthermore, we serve warehouse clients across all major industrial zones: Lahore (Sundar, Kot Lakhpat, Quaid-e-Azam Industrial Estate), Karachi (Port Qasim, SITE, Korangi), Faisalabad (M3 Industrial City), Multan, Sialkot, and Gujranwala. We also support international logistics companies building in Pakistan with headquarters in the UAE, UK, Saudi Arabia, Canada, and the USA.

Our integrated approach means we also provide architectural drafting and building design for warehouse offices and employee facilities. Explore our Architectural Engineering page for more.

By The Numbers: ACCO’s Warehouse Structural Track Record

• 50+ Warehouse projects structurally designed and supervised.
• 2 million+ Square feet of warehouse floor slab designed.
• Zero Floor slab failures (cracking, settlement) across our warehouses.
• 100% PEC compliance rate for all warehouse submissions.
• 25+ Years of continuous warehouse structural practice in Pakistan.
• 40 meters Maximum clear span designed (steel PEB).
• 2 Offices (Lahore & Karachi) covering all industrial zones.
• 10+ PEC-registered structural engineers on our warehouse team.

Frequently Asked Questions (FAQs) – Warehouse Structural Services

1. What is the difference between warehouse and industrial factory structural design?

Warehouse structural design focuses on: heavy floor loadings from racking and forklifts, large clear spans for storage, floor flatness for high-bay racks, and loading dock integration. Factory structural design focuses on: machinery foundations, crane runways, process piping integration, and vibration control. Both are industrial, but the priorities differ. ACCO specializes in both.

2. How do I get a floor plan designed for a warehouse?

For warehouse projects, we recommend starting with our Architectural Engineering team. We will develop a functional building design and architectural drafting that optimizes storage density, receiving/shipping flow, and office space. Then our structural engineers provide the heavy-duty framework. Call +92 322 800 0190 to discuss.

3. What is architectural engineering, and why is it important for warehouses?

Architectural engineering integrates structural, MEP, and operational systems. For warehouses, this is critical: floor slabs must accommodate rack anchors, roof structures must support sprinkler systems, and column spacing must align with racking layouts. Learn more on our Architectural Engineering page.

4. Do you provide 3D walkthroughs for warehouse projects?

Yes. We provide 3D architectural walkthrough of your warehouse structure. This helps stakeholders visualize racking layouts, forklift paths, and loading dock operations before construction. See our Architectural 3D Modeling page for examples from recent warehouse projects.

5. Can ACCO design cold storage warehouses with freezer floors?

Absolutely. We have designed cold storage structures for Savour Foods with -20°C freezers. Our designs include: heated reinforced floor slabs (to prevent frost heave), structural supports for insulated panels, vapor barriers, and thermal break details at column bases. Call us for references.

6. Do you offer a warranty on warehouse structural work?

Yes. We provide a 2-year workmanship warranty on all warehouse structural construction services (vs. 1-year for residential). This covers structural defects, floor slab cracking, and settlement. For high-rack warehouses, we provide additional floor flatness performance warranties (FF/FL numbers).

7. How long does warehouse structural design take?

A typical warehouse (20,000-100,000 sq ft) takes 3-6 weeks for structural design and PEC-stamped drawings. A complex cold storage or high-bay facility may take 6-8 weeks. Construction supervision continues throughout the project (typically 4-8 months depending on size).

8. What is floor flatness (FF/FL) and why does it matter?

Floor flatness (FF) measures bumps and dips (smoothness for forklifts). Floor levelness (FL) measures tilt (flatness for racking). For high-bay warehouses (racking above 30 feet), we specify FF 50 / FL 35 or higher. Poor flatness causes forklift damage, rack misalignment, and safety hazards. ACCO designs and supervises to achieve these specifications.

Build Warehouses That Maximize Storage – Choose ACCO

Every square foot of your warehouse represents storage capacity and revenue. A poorly designed structure wastes space through unnecessary columns. A cracked floor slab damages forklifts and racks. A thermally bridged cold storage leaks energy and spoils product. Therefore, investing in proper warehouse structural engineering is an investment in operational efficiency.

ACCO has been providing warehouses projects in structure services in Pakistan for over 25 years. We are trusted by Gerry DNATA, Savour Foods, Bata, and logistics providers across Pakistan. Our PEC-registered engineers use advanced software (ETABS, Tekla, STAAD.Pro), follow international codes (ACI, AISC, AWS), and deliver designs that maximize your storage capacity while ensuring safety.

We cover all major warehouse zones nationwide: Lahore (Sundar, Kot Lakhpat), Karachi (Port Qasim, SITE, Korangi), Faisalabad (M3 Industrial City), Multan, Sialkot, Gujranwala, and Islamabad/Rawalpindi. We also support international logistics companies building in Pakistan with headquarters in the UAE, UK, Saudi Arabia, Canada, and the USA.

Ready to build a warehouse that performs? Contact ACCO today. Structural integrity means storage efficiency.

ACCO – Engineering Storage Capacity. Since 1998.

Explore related services: Learn about our Architectural Engineering integration or view our Our Projects gallery to see our warehouse structural work in action.