6 regrets people have after building an industrial building

A new industrial building of premises is often the largest single investment a business owner has made to date. Consequently, you can have a lot of concerns about getting the design right the first time. You really don't want to get to the end of the project and really wish they had done a bunch of things differently.

Not knowing enough about the design process and all the compliance and consultants required can make things difficult and confusing. 

This can be a classic case of  "you don't know, what you don't know". Most business owners have not built many buildings over their careers and are not exposed to the world of engineers, architects, builders, and councils. We have created an outline of the consultants you may require which you can read here.

There is no one process that fits all when it comes to commercial construction. A basic "shed" or storage building would likely only require a structural engineer, draftsperson, fire engineer, and a base-level Geotech investigation. However, a much more complex full commercial building with offices will likely require a structural engineer, fire engineer, civil/Geotech engineer, architect/draftsperson, accessibility designer, and interior designer. 

The key areas that can catch you out here are:

1. Not knowing the key aspects that will dictate the design

Often there are one or two key areas that will dictate the design. For example, if you are on a tight site and close to a lot of boundaries it is likely going to be the fire report that will have the most impact on the design. If other areas are developed too far ahead of the fire report this can result in re-work to integrate the extra firewalls or exit routes. Similarly, if you are on bad ground a geotech report will likely impact all areas of the design. If the structural design proceeds too far without the geotech report then again this can result in re-work and delays. 

2. Engaging consultants too late

This comes down to knowing who is going to be required for the project. Often an interior fit-out designer is engaged late in the project, which can result in a lot of rework in the architectural side as walls, windows etc need to be moved to accommodate the fit-out. Another example is: 

3. Having consultants work in ‘silos’

We hear a lot from clients, builders, and engineers in the industry that consultants are tending to work more and more in isolation rather than consultatively. 

With all complex projects, all of the factors are interlinked. For example, the interior fit-out is often considered ‘non-structural’ and more about dressing up the interior. However, the fit-out will often decide the ceiling height, wall materials, and hallway design which all impacts the fire report. Another example that the fit-out impacts is accessibility, and if the wrong handrails, toilets, basins, and hallway widths are specified the design will not be compliant and the accessibility report will need to be redone. 

Another example is architectural and structural plans. Often the engineer and architectural designer do not work closely which can result in clashes between the designs (i.e.beams and columns clashing with walls) or ‘gaps’ in the design. I.e. design or connection details that were not thought of by either party.

The best way to mitigate the above is for each consultant to have clarity on their role, and also have a one-party responsible for bringing all aspects of the design together and following up with each consultant. 

4. Exterior dimensions do not = interior space

This one seems simple but can be missed. The interior space is not equal to the overall dimensions. Typically when asked the size of a building, the size of the building is quoted. This is typically the outside of the framing OR the outside of the concrete slab. Likewise, the height of the building is typically taken from slab height to the underside of the roof. 

However, that is not the same as the interior space of the building, the size of the structure needs to be deducted from those measurements. The below images illustrate the point: 

Industrial building with trusses

5. Focus is too much on initial cost rather than lifetime cost/return on investment

We are all after a good deal and the best bang for our buck and you don't want to over-invest in your building. However, it is important not to be too singular on cost-cutting as it can become a false economy and cost you more in later years.

For example:

  • Andrew is currently leasing a 1800m² building and wants to expand his warehouse and own his own premises. He has set funds aside over the years and decides he wants to build using his funds and not loan any money. He obtains quite a large piece of land and builds a 2500m² warehouse which is the limit on his funds. The extra space allows him to hold more stock and grow more rapidly - and in 3 years he has outgrown the space and is renting more warehouse space.  He decides to add on an additional 1000- and gets a couple of build prices to do so. He finds that due to the inefficiencies of adding on and the increase in building materials that the cost per has increased by 50%.

Budgeting for a commercial building

The above calculation also does not take into account the fact that Andrew had the opportunity to rent out part of his warehouse while he didn't use it. This is a great way to help finance that extra m² of the project until you need it.

Another example is the quality of the materials are cut to meet a budget - but this is really a false economy as the cost is deferred to a later date. Some examples are: 

  • Light-weight door studs and columns rather than heavier structural members: This can be a saving in a building but a false economy in a heavy industry environment as they are very prone to forklift damage. So it pays to look at the heavy traffic areas and ensure that the structure is robust. 

  • Roller doors: There are a huge number of roller door options on the market, and they all vary in quality of the curtain, tracks, and componentry. If you have had door problems in the past you will know that the inconvenience and downtime make it worthwhile spending a bit more to get a high-quality door. 

  • Center columns are placed in the building: The center column can certainly save money and in some circumstances will save quite a lot. However, they do restrict your interior space and if you are having to make significant compromises. 

  • GIB Firewalls VS Tilt panel: Gib is a cost-effective way to fire protect a wall. However, it is prone to impact damage and chipping - which results in regular re-stopping to meet compliance (plus looks messy!). If you need a firewall in an area that is high traffic and likely to suffer damage then pre-cast concrete tilt panel may be cheaper in the long run. The other option is to line over the GIB firewall with Plywood or similar which provides a more durable surface. 

6. Planning time was sacrificed to meet a tight timeframe 

Business owners are all busy people and it is hard to juggle the whirlwind of every day and plan ahead. Oftentimes businesses can have a tight timeframe between when they need to move out of a current building and into the new one. 

But a common denominator to the regrets people have after the building was that the planning time was sacrificed to meet a tight deadline.’

For example:

  • Layouts not thought through: To save time it can be tempting to just make a quick decision on the layout of the building office/warehouse which can be regretted later. This can result in expensive onsite changes to make it work OR reduce the efficiencies of your operation. 

  • Limited options for builders/subcontractors: If timing is of all importance it often narrows down the pool of potential builders and contractors quite significantly. This means you may need to pay a premium OR have to go with a builder/subcontractor that is not as good a quality as another. 

When it comes to planning it really is best to ‘slow down to speed up’ i.e. spend the time to make the decisions in the early phases rather than rush them and risk re-work and delays later on.