As a business owner, developer, or landlord, you may have pondered what steps you can take to make your industrial building more environmentally friendly, and how this will impact your business. You may be looking for some ‘low hanging fruit’ or things you can do that isn't going to increase the cost of your project dramatically. Incorporating some sustainable practices isn't just about doing good for the planet; it's also about reaping tangible benefits like cost savings, attracting quality tenants, and enhancing your company's reputation. This guide outlines some effective ways to transform your industrial building into a greener, more efficient space. How can solar energy benefit my building? Solar energy is one of the most impactful ways to reduce your building's reliance on non-renewable energy sources. By installing solar panels, you can significantly cut down your electricity bills and even generate extra income by selling surplus power back to the grid. While the initial investment might seem high, government incentives and the long-term savings make this a smart choice. What’s the best way to enhance my buildings insulation? With our variable climate here in New Zealand, high-quality insulation can help keep your building warm in the winter and cool in the summer, reducing the need for excessive heating and cooling. Many companies in colder climates are looking to add insulation to warehouses/workshops to reduce heating requirements. There are also options of using wool insulation rather than less sustainable fibreglass products. The use of large, glazed areas can impact on both the heating and cooling of a building. Consider using higher grades of thermally broken or Low E gas filled windows, than what the NZ Building Code requires as minimum. Additionally adding large eaves or louvres to shade glazed areas can reduce the heat buildup and energy required to cool. Should I upgrade to energy-efficient lighting and HVAC systems? Switching to LED lighting and upgrading to energy-efficient HVAC systems are simple yet impactful ways to reduce energy consumption. LEDs use significantly less electricity than traditional bulbs and have a longer lifespan, which means fewer replacements and lower maintenance costs. Modern HVAC systems are designed to operate more efficiently, using less power and providing better climate control. Implementing smart thermostats and automated lighting controls can further enhance these systems' efficiency, adapting to occupancy and usage patterns. Consider integrating motion sensors and daylight sensors to optimise lighting use, ensuring that lights are only on when needed. Similarly, programmable thermostats can adjust heating and cooling schedules based on occupancy patterns, reducing energy waste during off-hours. For more information on how to make your building more energy efficient, read this article. Use smart technology for building management Incorporating smart technology like energy management systems (EMS) can revolutionise how you manage your building's energy use. These systems provide real-time data on energy consumption, allowing you to identify inefficiencies and optimise operations. Networked lighting controls can automatically adjust based on natural light levels or occupancy, while smart HVAC systems can maintain optimal temperatures without wasting energy. The data collected by these systems can be used to create detailed reports on energy usage, helping you set targets for improvement and track progress over time. Implement water-saving measures Water conservation is an essential aspect of sustainability, especially in regions prone to water shortages. Installing low flow plumbing fixtures, such as toilets and faucets, can drastically reduce your water usage. Consider implementing rainwater harvesting systems to collect and reuse rainwater for non-potable purposes like landscaping or industrial processes. In addition to hardware upgrades, encourage water-saving practices among staff and tenants, such as reporting leaks promptly and using water-efficient appliances. Implementing a regular maintenance schedule can help detect and fix leaks early, preventing water waste and ensuring the long-term efficiency of your water systems. Support sustainable transportation Encouraging sustainable transportation options can significantly reduce the carbon footprint associated with your building. Installing electric vehicle (EV) charging stations can promote the use of electric vehicles among employees and visitors. Providing secure bike storage and promoting public transport options can further reduce reliance on private vehicles. Incorporate green spaces Creating green spaces within and around your industrial building can provide numerous environmental and social benefits. Green walls not only enhance insulation but also improve air quality by filtering pollutants. Outdoor green spaces can serve as recreational areas for employees, promoting well-being and productivity. Integrating native plants and promoting biodiversity can support local ecosystems and create a more pleasant working environment. Opt for eco-friendly building materials Choosing sustainable and locally sourced building materials can significantly reduce the environmental impact of construction and renovation projects. Materials like recycled steel, bamboo, and sustainably harvested wood are excellent alternatives to traditional options. Additionally, using low-VOC (volatile organic compounds) paints and finishes can improve indoor air quality, creating a healthier environment for occupants. Prioritise materials that are durable and require minimal maintenance, reducing long-term costs and environmental impact. When renovating, consider recycling or repurposing materials where you can from the existing structure rather than sending them to landfill. This approach not only conserves resources but also reduces waste and disposal costs. Engage and educate stakeholders on sustainable practices Engaging your stakeholders—whether tenants, employees, or clients—in sustainability efforts is crucial for creating a green culture. Start by educating them on the importance of waste reduction and recycling. Provide easily accessible recycling bins and clear instructions on what can be recycled. Encourage digitalisation to reduce paper waste and promote eco-friendly practices like reusing materials. Offering incentives, such as recognition or discounts for sustainable behaviour, can motivate participation and foster a sense of community around your sustainability goals. Regularly communicate your building's sustainability initiatives and achievements and encourage people to share their own green ideas and practices. Making your industrial building more environmentally friendly is not only good for the planet but also beneficial for your business. By taking these steps, you can reduce operational costs, make your property more attractive to tenants, and contribute to a sustainable future. Whether you're just starting or looking to improve existing efforts, there are always ways to enhance your building's sustainability.

Are you a busy business leader curious about potential new insurance costs or puzzled by a recent surge in insurance premiums for a new build? Understanding these costs is crucial for keeping your budget on track and avoiding compliance issues. At XL Structural, we recognise the challenges of managing budget constraints and meeting regulatory requirements to ensure your buildings are both compliant and cost-effective. In this article, we’ll explore the key factors influencing the cost of insurance for commercial and industrial buildings. We'll address common concerns and provide valuable insights to help you make informed decisions and effectively manage your insurance expenses. Building Location The location of your building plays a significant role in determining your insurance costs. Insurers evaluate the risk associated with the geographical area where the building is situated. Factors such as crime rates, natural disaster risks (like earthquakes, floods, and storms), and proximity to fire stations and hydrants are considered. Buildings in high-risk areas tend to have higher insurance premiums. Conversely, buildings in areas with lower risk profiles may benefit from reduced premiums. For example, Christchurch's earthquake-prone regions typically see higher premiums due to increased risk, whereas buildings in Auckland might have lower premiums due to a relatively lower seismic risk. Climate Change Impact It is impossible to ignore the impact of climate change on insurance costs. The frequency and severity of severe weather events are increasing globally, leading to higher premiums as insurers seek sustainable pricing models. In New Zealand, flooding has been the most common weather event, accounting for over 90% of losses from natural disaster claims since January 2021. The New Zealand Government's National Adaption Plan, published in April 2022, outlines actions to address climate-related risks, reflecting the growing need for buildings to be resilient against such events. Building Construction and Materials The construction type and materials used in your building can greatly influence your insurance costs. Buildings constructed with fire-resistant materials, such as concrete or steel, generally attract lower insurance premiums compared to those made with wood or other combustible materials. Fire-resistant buildings are less likely to suffer extensive damage in a fire. Additionally, modern construction techniques and materials that enhance structural integrity and resilience to natural disasters can also result in lower premiums. In high seismic risk areas, the use of materials such as Expanded Polystyrene Panel (EPS) and Aluminium Composite Panel (ACP) requires robust risk management procedures, and insurers may limit coverage or increase premiums based on these factors. Building Size and Usage The size of your building and its intended use are also crucial factors. Larger buildings typically have higher insurance costs because they represent a greater risk to insurers in terms of potential loss. Similarly, the usage of the building impacts insurance premiums. For example, a warehouse storing flammable materials will have higher insurance costs compared to one storing non-flammable material. It's essential to accurately communicate the purpose of your building to your insurer to ensure appropriate coverage and cost estimation. Safety and Security Measures Investing in safety and security measures can significantly reduce your insurance premiums. Insurers favour buildings equipped with robust security systems, fire alarms, sprinkler systems, and other safety features. These measures lower the risk of damage and loss, making your building a safer bet for insurers. Installing surveillance cameras, security lighting, and access control systems can further enhance security and potentially lower insurance costs. In New Zealand, adhering to the Building Code’s safety requirements, which were updated in 2023 to include more stringent fire safety measures, can also be beneficial. Building Age and Condition Older buildings often have higher insurance costs due to their increased risk of structural issues, outdated electrical systems, and plumbing problems. Insurers may require a thorough inspection of older buildings to assess their condition before providing coverage. If the building is well-maintained and has undergone recent renovations or upgrades, it can help in securing lower premiums. Regular maintenance and timely repairs are crucial in keeping insurance costs in check for older buildings. For instance, buildings in Christchurch that have been retrofitted to meet earthquake safety standards often benefit from lower insurance premiums. Claims History Your claims history as a business owner can impact the cost of insurance for your commercial or industrial building. If you have a history of frequent claims, insurers may view you as a higher risk, leading to higher premiums. On the other hand, a clean claims history can work in your favour, potentially resulting in lower insurance costs. It's advisable to implement risk management practices to minimize incidents and claims, thereby supporting a favourable claims history. This is especially relevant in New Zealand where the Earthquake Commission (EQC) plays a significant role in claims related to natural disasters. Coverage and Policy Type The type and amount of coverage you choose for your building will directly affect your insurance costs. Comprehensive policies that offer extensive coverage, including protection against a wide range of risks, will naturally be more expensive than basic policies with limited coverage. It's essential to strike a balance between adequate coverage and affordability. Discuss your specific needs with your insurer to tailor a policy that provides the necessary protection without overburdening your budget. The Insurance Council of New Zealand (ICNZ) provides guidelines on understanding policy terms and coverage options. Under-Insurance Risks The COVID-19 pandemic has underscored the risks of under-insurance. High inflation, supply chain disruptions, and extended building costs have all contributed to increased claims costs. Ensuring your building's sum insured reflects current building costs is critical to avoid under-insurance, especially for specialised equipment and machinery that may have longer replacement times and higher costs. Recent data from the Reserve Bank of New Zealand shows an increase in construction costs by approximately 8% over the past year, highlighting the importance of regularly updating your insurance coverage to reflect these changes. Regulatory Compliance Compliance with local building codes and regulations can influence your insurance costs. Buildings that adhere to the latest safety and construction standards are generally viewed more favourably by insurers. Non-compliance or failure to meet regulatory requirements can result in higher premiums or even difficulty in obtaining insurance coverage. Ensuring that your building meets all necessary regulations not only promotes safety but also helps in managing insurance costs. The upcoming Financial Markets (Conduct of Institutions) Amendment Bill will further emphasise the need for compliance and may impact how insurance products are priced and offered. Deductibles Choosing a higher deductible can lower your insurance premiums. The deductible is the amount you agree to pay out of pocket before your insurance coverage kicks in. By opting for a higher deductible, you take on more risk, which can result in reduced premiums. However, it's important to choose a deductible that you can comfortably afford in the event of a claim. Balancing deductibles and premiums are a key consideration in managing your insurance costs effectively. Risk Management Practices Implementing effective risk management practices can have a positive impact on your insurance costs. Conduct regular risk assessments to identify potential hazards and take proactive measures to mitigate them. Employee training programs, routine safety inspections, and emergency preparedness plans are all part of a robust risk management strategy. Demonstrating to insurers that you have comprehensive risk management practices in place can lead to lower premiums and better coverage terms. Insurance Provider Finally, the choice of insurance provider can also affect your insurance costs. Different insurers have varying risk appetites, pricing models, and discount programs. It's crucial to shop around and compare quotes from multiple insurers to find the best coverage at a competitive price. Working with an experienced insurance broker can help you navigate the options and identify the most suitable insurance provider for your specific needs. Conclusion Understanding the factors that affect the cost of insurance on commercial and industrial buildings is essential for effective budget management and risk mitigation. By considering the building's location, construction, size, usage, safety measures, and more, you can make informed decisions that optimise your insurance expenses. Implementing risk management practices and maintaining compliance with regulations further enhances your ability to secure affordable and comprehensive insurance coverage. Remember, the right insurance policy is a critical component of protecting your investment and ensuring the long-term success of your business.

Extending your commercial building could be a decision you’re making to improve its functionality, safety or aesthetics. At XL Structural, we’ve done multiple extensions, but the question "do I need to bring the entire building up to code?" often comes up with our clients. This is a common concern among building owners and managers, and it's crucial to understand the implications of New Zealand's Building Code and local council regulations to navigate your extension smoothly. This article will look at the considerations surrounding compliance and provide insights to ensure your project progresses smoothly and successfully. Understanding the New Zealand Building Code The New Zealand Building Code (NZBC) sets out performance standards that all new building work must meet. It ensures buildings are safe, healthy, and durable. The NZBC is divided into two main sections: the mandatory provisions and the acceptable solutions and verification methods. These cover everything from structural stability and fire safety to accessibility and energy efficiency. When you're renovating, the key principle to understand is that any new work must comply with the current NZBC. However, this doesn't mean you must upgrade the entire existing building. The extent to which you need to comply with the NZBC depends on the scope of your renovation project. Compliance with NZBC During Renovation There are several scenarios to consider when deciding whether you need to bring the entire building up to code: Minor extensions and maintenance If your extension involves minor repairs or maintenance, such as painting, replacing fixtures, or patching walls, you typically won't need to upgrade the entire building. These minor works are generally exempt from needing a building consent under Schedule 1 of the Building Act 2004. However, any new construction or installation must still meet current NZBC standards. Alterations When you're making more significant alterations, the requirements become more stringent. According to Section 112 of the Building Act, if you're altering a building, you must ensure that: The building, as altered, complies with the NZBC provisions relating to means of escape from fire and access and facilities for people with disabilities. The building, as altered, continues to comply with the other provisions of the NZBC to at least the same extent as before the alteration. Change of Use If your extension involves changing the use of the building, the requirements are even more comprehensive. A change of use could mean converting an industrial space into a commercial office or vice versa. Under Section 115 of the Building Act, you must ensure the entire building complies with the relevant provisions of the NZBC for its new use. This includes structural performance, fire safety, access, and facilities for people with disabilities. Local Council Regulations In addition to the NZBC, local council regulations also play a crucial role in your renovation project. Each city council in New Zealand can have specific bylaws and district plans that might affect your extension. For instance: Different Councils will have different requirements: These regulations can impact various aspects of your project, including zoning, heritage considerations, and specific environmental standards. Resource Consents: In some cases, you might need resource consent in addition to a building consent, especially if your renovation impacts the environment or involves significant changes to the building's footprint. It's essential to check with your local council early in the planning stages to understand these requirements and ensure your project aligns with both national and local regulations. You can find out more about the various councils' rules and regulations with our planning guides for industrial zones here. Balancing Compliance and Practicality The phrase "as nearly as is reasonably practicable" often comes up when discussing compliance with the NZBC during extensions. This means there's some flexibility based on practicality and cost. However, this doesn't mean you can ignore safety and essential performance standards. When deciding what is reasonably practical, consider: Risk to life: Safety features such as fire escapes, alarms, and structural integrity must always be prioritised. Technical feasibility: Sometimes, the physical constraints of the existing building make certain upgrades impractical. Cost: While cost alone isn't a justification for non-compliance, disproportionate costs relative to the benefits might be considered. Practical Steps for Compliance Conduct a thorough assessment: Before starting your renovation, carry out a detailed assessment of your building. This should include structural evaluations, fire safety assessments, and checks for accessibility and other compliance areas. Engage professionals: Work with architects, engineers, and building compliance experts to ensure your plans meet NZBC standards. At XL Structural, we guide you through the process, ensuring your renovation meets all necessary codes. Develop a compliance strategy: Create a strategy, or a GAP Analysis, that outlines how you'll address each compliance requirement. This might include phased upgrades or alternative solutions that provide equivalent performance. Consult with local authorities: Regularly communicate with your local council to ensure your plans are in line with their specific requirements and to avoid any surprises during the approval process. Document everything: Keep detailed records of all assessments, decisions, and communications. This documentation will be crucial if there's ever a question about compliance. Extending a commercial building can be a significant undertaking, but understanding the requirements of the Building Code and local council regulations can help you navigate the process more smoothly. While you may not need to bring the entire building up to code, any new work must comply with current standards, and certain situations, like a change of use, may require more comprehensive upgrades. By conducting thorough assessments, engaging the right professionals, and developing a clear compliance strategy, you can ensure your extension not only meets regulatory requirements but also enhances the safety, functionality, and value of your building. Remember, each project is unique, and it's crucial to seek tailored advice for your specific situation. XL Structural may be able to assist you with your extension project. If we're not the right fit, we'll gladly refer you to someone who can best meet your needs. Book a meeting with our team to explore your options.

New Zealand’s construction industry has suffered high rates of business failure and liquidation recently, with businesses of all sizes, operating across all sectors of the industry, being affected over the last few years. People looking to build can be excused for proceeding with caution – the prospect of building in today’s climate can be daunting. However, understanding and recognizing the factors behind these business failures and taking proactive steps to work with a stable construction business can help you protect your investment and have a smooth construction experience. In this article, we’ll explore why there are such high failure rates in construction businesses, especially in the current financial climate, and what to look out for to ensure your next building project does not fall victim to one of them. Why do construction businesses fail? Underpricing and cost blowouts due to small project margins The cheapest quote isn’t always the one you should go ahead with. The industry is notorious for its low profit margins. This lack of financial flexibility, combined with often tight project timelines, puts an enormous strain on companies, making them extremely vulnerable to unforeseen project issues. Contractors often come unstuck when they can’t accurately price risk or incorporate a sufficient, sustainable profit margin into their projects. In extreme cases, they might submit very low bids intended to secure the work, but then try to increase margins to acceptable levels through variations or by pressuring subcontractors, which can compromise quality. When a project runs over budget, the financial strain can quickly become unmanageable. This can lead to delays, disputes, and companies going out of business. Contractors who underprice projects often hope to make up for the low bid through variations and additional work, but this strategy is fraught with risk and increasingly untenable in a competitive market. Warranty claims If a construction company is not diligent in its work, defects and faults can arise after the project is completed. Addressing these issues can be costly and time-consuming, eating into the company's profits and cash reserves. Issues always come up from time to time, so you want a company that is in it for the long term. If not priced properly, there will be less goodwill to come back and fix what they are legally obliged to. Choosing a company committed to long-term relationships ensures they will address any warranty claims with care and responsibility. Impact of inflation, market fluctuations, and fixed price contracts The construction sector is highly susceptible to inflation and market fluctuations. During periods of high inflation, the cost of raw materials and labor can increase dramatically, but these costs cannot be passed on to the client if the contract is fixed. This mismatch can quickly erode profit margins. Fixed price contracts are a double-edged sword. They provide you as the client with certainty but place contractors at significant risk. However, risk for them can mean risk for you. Fixed price contracts mean that while the cost of labor and materials continues to rise during a construction boom, the agreed-upon price remains the same. This creates a significant financial burden on contractors, who bear the brunt of it. This tension can lead to disputes, project delays, and financial losses for construction companies. In the current inflationary environment, you should be aware that a 'fixed price' doesn't mean there isn't conditions in the small print that allow for extra costs to be passed on. There can be significant clauses added around what are provisional sums, price escalations, or exclusions, there may still be cost blowouts and opportunities for variations to be charged. Both parties need to understand what the risks are and what the contractor is doing to try and mitigate them. Because it’s tricky to predict how much a build will cost, these contracts can put your entire project budget at risk. Growing too quickly It’s important to be cautious of construction companies that are growing too quickly. Rapid growth can be as dangerous as stagnation. When a business takes on more projects than it can handle, it becomes overextended, increasing the risk of going under. Problems often arise when a company tries to grow too fast without having the necessary resources, manpower, and ability to manage that growth. Expanding into new geographic areas or taking on larger projects without proper planning can lead to logistical challenges, quality issues, and financial strain. A company that grows incrementally and methodically is more likely to have tested and proven processes in place, ensuring a more sustainable approach to business expansion. What should you look out for before employing a construction company? To safeguard your building project, you need to be vigilant and proactive. Here are six things you can do before signing on the dotted line with a construction company for your next project. Do your due diligence Look into the company’s past customer feedback to gauge their reliability and quality of work. Investigating their relationships with suppliers and subcontractors can provide insights into their operational stability and reliability. Researching the company’s history and the profiles of its directors can help you understand their track record. Look for any patterns of financial instability or legal disputes, as these can be red flags. Considerations on liquidity issues and cash flow management Understanding the company's financial health is critical. Investigate their liquidity and cash flow management practices. Large deposits upfront and unrealistic timeframes can be a red flag. It's important to understand the payment terms and that payments are staged to tie in with project milestones. This will ensure the contractor remains financially stable and incentivised to complete the work on time. You could also ask subcontractors and other suppliers if they’re paid on time by this business. Delayed payments can indicate cash flow problems and can lead to delays in your project as well. Significance of having in-house teams vs. reliance on subcontractors Companies with in-house teams offer greater control over quality and timelines. This can mean more predictable costs and outcomes, as the company directly manages its workforce. You can benefit from a streamlined communication process, reducing the chances of delays. In-house teams are particularly beneficial for projects requiring consistent quality and specialised skills. There can be the efficiencies of repetition where in-house staff are very efficient and skilled in particular fields. Companies with more done in house – or vertically integrated, can often bring cost efficiencies as there is less ‘margin on margin’. But there is an overhead competent to manage this inhouse works Firms that rely heavily on subcontractors may be able to offer more competitive pricing due to lower overhead costs. However, this can introduce variability in work quality and potential coordination challenges. Heavy reliance on subcontractors can result in less accountability and higher risks of project delays. The financial risk here lies in the potential for unforeseen expenses if subcontractors do not meet the project standards or timelines. Generally, if a company has some core competencies in-house which allow them to bring value, they may bring in contractors for specialized areas or more local contractors. Evaluating their capacity Research and careful planning are crucial when entering new markets or types of construction to ensure the company is not overextending itself. Rapid company growth can sometimes indicate that processes have not been tested and proven. Carefully evaluate a company’s capacity before committing to a project. Look for signs that they are expanding methodically and have the necessary infrastructure in place to support their growth. Incremental growth, rather than a sudden leap from small projects to multimillion-dollar ventures, shows a more sustainable approach. Review contracts thoroughly Contracts are the backbone of any construction project. Ensure that they are clear, comprehensive, and legally binding. Seek legal advice to review contracts to ensure your interests are protected. Clear contractual terms help prevent misunderstandings and disputes during the project, providing a safeguard against potential conflicts. Understand how contracts can be administered. Have someone on your side who understands construction on bigger projects to ensure your interests are protected and to help navigate any complexities. Industry context and financial stability Consider the broader industry context and the company's financial stability. Mispricing and inadequate contingency planning can lead to significant challenges. Be cautious of so called ‘fully fixed price' contracts, especially during market downturns and inflationary periods. Look for a company or contract structure that shows where the budget risks lie, and how these will be mitigated as early as possible in the project – rather than just being a variation at the end. Come to an agreement with the contractor so that they are not passing all the risk of blowouts onto you – but are also not overextending and putting themselves at risk. By understanding these factors and taking proactive steps to assess and select your construction company, you can significantly reduce the risks associated with your building project. Careful planning, thorough research, and a cautious approach can help ensure a successful and smooth construction experience.

In the early stages of planning industrial or agricultural buildings, the team here at XL Structural Steel are regularly asked about bird-proofing. Bird-proofing is a consideration in quite specific environments and circumstances. For some, it doesn’t even factor but for others, it’s a primary concern. In this article, we explore all the various options for bird-proofing your building and what will work best for you. So why should you bird-proof your industrial building? Generally, people are concerned about bird-proofing when they have had a problem in the past. This could be from birds nesting above equipment and causing damage from acidic bird droppings. It could be a health concern, particularly in food processing areas, where birds could transmit harmful diseases. It can also be aesthetically unpleasant when birds fly about and nest inside a building. Agricultural Buildings Agricultural buildings seem particularly prone to attracting birds because there are more birds in rural settings. Additionally, these sheds often have a food source that attracts birds such as grain, seeds, produce, or animal feed. If birds can roost on the rafters of the shed, it is likely that whatever is below will end up covered in bird droppings, which will corrode the paintwork of tractors, vehicles, and machinery, or damage produce. Industrial Buildings In an industrial building, it is vital to consider bird-proofing options when your operations require doors to be left open, you have open canopy areas, or you have product or machinery that is likely to be impacted by birds and their droppings. Bird Proofing options There are various bird-proofing options available in New Zealand that are suitable for a range of applications and have varying degrees of success. Some of these options include: Bird Brush for Roller Doors and Sliding Doors Starting with the basics, Bird Brush installed on the tops of Roller Shutter doors is a good starting point for bird-proofing your building. Bird brush is a dense bristle strip that is fixed at the top of the door close to the gap between the curtain and the door framing. While this method does go a long way to prevent birds from entering, it is not 100% effective. Bird brush installed to warehouse/factory doors may provide enough bird-proofing for your industrial buildings if your proposed new building is going to be fully enclosed, the doors will predominately remain closed, and the potential damage from birds within your building is low. Birdproof Rafter & Purlin Design The two areas birds typically nest in are open sections in the rafters and purlins. Structures using universal beams and open cold rolled sections are particularly prone to birds. To properly birdproof, closed sections need to be used for rafters and purlins and the roof bracing needs to be installed on the top of the structure. As many of our customers are concerned about bird proofing, we have a unique structural design using an RHS rafter (rectangular hollow section), and Steelbone enclosed purlin that creates a genuinely zero-bird perch rafter/purlin design. This design gives a premium long-term solution without the need to retrofit alternatives. However, there are more costs associated with this option as the Steelbone purlins use more material than an open purlin. Timber Purlin At XL Structural Steel, we also use a timber purlin with our RHS rafter to create a bird-proof solution. A timber purlin works well on smaller bays up to six metres in width (timber is typically available up to 6m lengths). We find that some building owners and users like to have some timber in the structure as it has a nice feel in terms of the environment. Find out more about the pros and cons of different purlin options here. Bird Netting Bird nets can be retrofitted to existing buildings and are used to prevent birds from roosting and nesting under canopies, or on top of rafters and purlins. This can be a cost-effective way to bird-proof your building after it is built. The downside of netting is that the birds can sometimes find a gap in the netting, get stuck and die. Netting throughout the building can also be visually unappealing. Other Retrofit options Pest control services have other retrofit solutions available such as: Bird spikes: Provide a harmless and non-disruptive bird deterrent typically used on the exterior of the building to protect against larger birds. Bird repellent gel: This is a sticky repellent gel that can be applied to perch areas such as beams or bracing elements to prevent birds from landing and roosting. Sound deterrents: Utilising a bird's sensitive hearing and natural alertness to noise, sound deterrent scarers use specific tones and frequencies to repel a variety of birds. However, these sounds can be annoying to staff working in the building. Cheap Lining Options In some instances, our team have seen plastic or paper lining fitted to the underneath of the purlins. While this can be a cheap upfront cost to retrofit, this is a very short-term solution as it can deteriorate and sag. Birds could also find a way to get above these linings, leaving you with dead birds and a far less desirable look. Canopy lining using Aluminium Composite Panels Another option is lining the underside of the canopy with Indurabond cladding or similar cladding products. Being a solid material, this comes up looking sharp and is a long-term solution. This is especially beneficial when you are looking for a clean design under your canopy or when there is a structural requirement for C-section purlins, typically in order to get a greater span between bays. SUMMARY Choosing the right bird-proofing solution depends on your building's unique needs, budget, and preferences. In many cases, people choose to simply bird-proof the open space that is most at risk from birds. Here are some projects we have worked on where bird-proofing was a consideration: Attach2 included XL Structural Steel’s enclosed purlin solution in the open canopy. However, they didn’t require a bird-proof solution within the enclosed building. Compac Furniture used an Induracore lining to the open canopy as the bay spans were too large for an enclosed purlin. Shade System required a zero bird perch rafter to ensure the environment was birdproof. Kiwi Lumber Masterton required a zero bird perch rafter to ensure birds couldn’t perch as the building was not able to be fully enclosed. It is important to consider bird-proofing options when planning and designing your new industrial building. Bird-proofing can maintain the long-term value of your property, save significant maintenance costs, and protect your assets and employees’ health. There are various bird-proofing options available from retrofit options to XL Structural Steel’s unique RHS rafter with enclosed purlins system. By choosing the right solution, you can prevent bird infestations, save property maintenance, and enjoy long-term savings. Get in touch with the XL Structural Steel team today to discuss your particular requirements and we can advise in detail.

Over the years we have seen and used numerous purlin types. Each has its pros and cons depending on your budget and requirements. In this article, we will review the pros and cons of key purlin types so you can be informed when deciding what purlin type is best for your next industrial building project. What is a Purlin? A purlin is a horizontal framing member, usually spanning between rafters or portals, and provides support for the roof cladding. Here is a photo pointing out where you'd see purlins: You can view more building terms in our commercial building glossary. Key types of purlins include: Steelbone enclosed purlins. C section purlins. Timber purlins. RHS purlins. Tophat purlins. Steelbone Purlin The Steelbone purlin is an enclosed V-shaped purlin manufactured from a high-tensile galvanised steel coil. The Pros of steelbone purlins As the purlin is an enclosed section it removes the typical perch areas available to birds. When the building is designed with the Steelbone purlins resting between the rafters coupled with XL Structural Steel's unique RHS rafter profile and flat roof bracing set above the purlins, it creates a genuinely zero-bird perch rafter/purlin design. The Steelbone purlin also minimises potential dust or material build-up. Because of the strength of the profile, it can typically be spaced further apart than other purlin types. the Cons of steelbone purlins The sizes currently available in the Steelbone purlin mean the purlins can typically span up to 8.5m. In some instances, this means that more portals may be required in a larger building due to this limitation. As the Steelbone purlin is an enclosed section it uses more steel per linear meter than open-profile purlins — this typically means it will cost more. With the above factors in mind, the Steelbone purlin is a great option for agricultural building uses where perching birds are a known problem as birds can cause significant damage to machinery and valuable products. It is also a suitable option for open buildings or industrial canopies where birds have unlimited access to the building. This is because the Steelbone purlin system prevents birds from being able to perch in the rafter space. If you're looking for a building with clean lines, is aesthetically pleasing, and has an architectural look, Steelbone purlins are a great choice. Typically this purlin option wouldn’t be for someone who is looking for the cheapest purlin option and doesn’t see the value in the above advantages. C Section Purlin The C section purlin is one of the most common purlin profiles used for large-scale industrial building projects. This is a high-tensile galvanised steel profile and is available in sizes from 150-400mm deep and in a variety of gauges to suit the engineering requirements of the building. The C section purlin also has a range of name abbreviations depending on the supplier. These include MC purlins, CLR purlins, and DHS purlins. the Pros of C section purlins C section purlins can optimise the building design by utilising the large range of profile depths and purlin thicknesses. It is an efficient, lightweight roll-formed purlin system and the open C section profile uses less steel per lineal meter than a comparable enclosed purlin. the Cons of c section purlins The most notable downside to C section purlins is that they're not perch-free. The open profile leaves the ability for birds to perch in the purlin and potentially cause issues with bird droppings and mess. Requires fast bracing/speed bracing between purlins. The C section purlin is a great option for industrial buildings and commercial buildings where it is important to optimise the building's design efficiencies and where birds are not likely to be an issue. Image above: Permacrete - Factory Gisborne || Image below: Warehouse Storage - Masterton Timber Purlins Timber purlins are less common in the industrial building market however XL Structural Steel's parent company Alpine Buildings NZ Ltd typically use timber purlins in their farm storage buildings and lifestyle buildings. the Pros of timber purlins Limits noise: The external roofing is fixed to timber instead of steel. ‘All-steel’ sheds tend to be noisier, especially in wild weather where you can get a ringing effect. However, timber framing noticeably softens the sound, making it great for noisy workshops. Birdproof design: The timber purlins coupled with the RHS portal system that XL uses gives the ability to create a zero-perch rafter design. Easy to modify: The timber purlins make internal fixings such as wiring easy to install. Insulation: Timber is known to be a better insulator, which helps the shed stay at a more consistent temperature. It also minimises condensation or ‘shed sweat’. the Cons of timber purlins Bay size is limited to between 4.5-6.0m (timber lengths). Smaller purlin spacing means more purlins are required. XL has utilised the timber purlin successfully in a number of industrial workshops across New Zealand. These applications have had up to 6m wide bays which optimises the number of truck bays that can be designed into the building length and keeps within the parameters of the timber purlin. Timber purlins are a great option for noisy workshops as it softens the sound and gives an ambient feel. Timber purlins are not a suitable option when looking to maximise the bay widths. RHS Purlin The RHS (rectangular hollow section) purlin is a structural steel purlin and would be considered a premium purlin option. This option would typically be used in the building design where other purlins don’t meet the engineering requirements. The pros of rhs purlins Strong: Compared to other roll-formed purlins the RHS purlin is very strong and can be used where “compression struts” are required to assist with the bracing elements of the building. Birdproof: The RHS purlins coupled with the RHS portal system that XL use, give the ability to create a zero-perch rafter design. Larger purlin spacing: Due to the strength of the RHS purlin, typically larger spaces between purlins can be achieved. the Cons of rhs purlins This type of purlin would typically cost more than roll-formed purlins. Typically the RHS purlins are used in applications where the roll-formed purlins (c section purlins) cannot meet the engineering design requirements for particular locations of the building or to gain larger spacing between purlins. Tophat Purlin The Tophat purlin is often seen used on lightweight roll-formed buildings. the Pros of tophat purlins It has a very lightweight profile. The Cons of tophat purlins The Tophat purlin profile is typically designed to sit above the rafter: This forms a significant bird perch. Lowers the usable headroom. Not usually able to be used on large spans due to the tendency for the purlin to twist and fail. Tophat purlins are a suitable option for some residential and lifestyle shed designs but would typically not be the best option for an industrial building, or buildings engineered for high building loads. Image sourced from Metalcraft. Image sourced from Shed Boss. In conclusion, there are a number of purlin types available. As explained, the purlin that will best suit your next project will depend on your specific project requirements and priorities. If you are in the process of planning a new industrial or commercial building you may also be interested in our articles on the most efficient way to design an industrial building or the cost per m² of a commercial or industrial building. Alternatively, please feel free to reach out to the team directly.

When you're designing an industrial workshop or factory in cold regions, one of the key factors to think about is how you’re going to keep staff warm and comfortable. As an employer, you have a duty of care to your staff to keep them safe. By managing the temperature inside your workshop, you can improve the morale and productivity of your workers. This can not only improve health and safety outcomes but also makes good business sense and is key to upholding performance and attracting and retaining top talent. People working in uncomfortably cold environments are more likely to behave unsafely because their ability to make decisions or perform manual tasks deteriorates. Equally, the consequences of cold conditions, such as patches of ice, can raise the risk of accidents, and staff are more likely to fall sick with prolonged exposure to the cold. So, what's the best way to maintain these temperatures? There is an extensive range of heating options available for your workshop, we’ll explore them in this article and look at the advantages and considerations for each of them. Why is it difficult to heat workshops and industrial spaces? High ceilings trap heat The average workshop can often be over 7m at its highest point. As warm air naturally rises, it causes pockets of heat to linger near the roof and away from the spaces where it is most needed. Doors constantly open and close The nature of workshop operations require doors to usually be kept open which allows the warm air inside to easily escape. Flexible heating demands Often, heat is required in specific zones, for a certain period, adding to the complexity of industrial warehouse heating. large spaces Growing spaces add to the cost and difficulty of warehouse heating, as bigger floor areas need more warm air, as well as solutions for heat distribution. Besides heat, what do I need to consider? When selecting a heating system for your workshop, consider things like: Energy efficiency Opting for systems with minimal environmental impact and maximum energy efficiency. Cost-effectiveness Balance upfront costs with long-term savings and operational efficiency. Comfort and safety Prioritise systems that provide consistent warmth without compromising safety or obstructing workflow. Customisation Systems that offer flexibility in temperature control and zoning to meet specific workspace requirements could suit your workshop. Understanding your options Heated floors Heated floors are a common method for providing warmth in cold-region workshops. Hydronic underfloor heating is much more efficient and has much lower running costs than electric underfloor. At XL Structural, we have specified many workshop projects in Southland that have included hydronic underfloor heating systems which work by circulating warm water through pipework enclosed in the concrete floor slab. The heat can be provided by specially designed air-to-water or ground source heat pumps, or by boilers fuelled by gas, diesel or wood. Hydronic heating offers several advantages: Ground-up heating: Ensures tools and surfaces remain warm. Comprehensive warmth: Heats both air and floor surfaces, creating a comfortable working environment even at very low air temperatures. Consistent distribution: Provides uniform heat distribution throughout the workspace. Energy efficiency: Efficiently warms the space while operating silently and without obstructing work areas. Zoning and control systems: Allowing different areas of the workshop to be heated independently. What can I use to heat the underfloor system? To run an underfloor heating system, you can use heat pumps, waste oil burners, or boilers to supply heat. Often the heat source is determined by the availability of fuels in the area and businesses that have access to cheap waste oil or is a byproduct of their operations for example, could use a waste oil burner. However, typically heat pumps have lower running costs and are better for the environment compared to boilers. What floor covering works well with an underfloor heating system? Concrete floors have high thermal mass, meaning they can absorb, store, and distribute heat effectively. This characteristic of concrete enhances the performance of underfloor heating systems by providing a stable and consistent temperature throughout the workspace. Additionally, the thermal mass of concrete helps to regulate indoor temperatures, reducing energy consumption and increasing comfort. Infrared heaters These heaters are usually mounted on the ceiling or wall and emit radiant heat, ideal for spaces with large air volumes. This radiant heat transfer provides rapid warmth without heating the surrounding air extensively. The heaters create zones within the workshop, reducing energy consumption by only heating necessary areas. Additionally, smart control systems enable precise temperature management and zoning, allowing users to tailor heating levels to specific areas of the workshop. Radiators Radiators are heated with hot water and offer the flexibility to adjust temperatures on a per-room or per-radiator basis, making them suitable for spaces with varying heating needs. They don’t however offer any air exchange and can result in heat loss in the boiler house and from the pipes to the radiator. Cost considerations To determine the cost of heating your workshop, you must evaluate various factors, including the type of heating system and the size of the space. In 2023 XL ran budget number comparisons to add a heated floor to a 1,000 sqm workshop project in Central Otago. These numbers came out as: To heat the floor using underfloor heat pump water heater with an insulated subfloor $182,000 +GST Upgrade roof cladding and wall cladding to 100mm thick PIR cladding $293,000 +GST Budgeted upgrade cost $475,000 +GST Running the numbers for upfront costs is an important consideration. However, care must be taken to calculate how heating costs and maintenance costs for the heating system will develop in the future, as well as the upfront costs for the system. Insulation and compliance Having insulation in your workshop enhances energy efficiency and helps maintain a comfortable temperature, potentially reducing heating costs in the long run. While insulating the roof and walls alongside floor heating may seem logical, from a compliance standpoint it may not be obligatory, allowing for standard cladding without insulation. For more on insulation options, read our article here. Chatting with an industry expert who understands your needs can help you find the right solution for your workshop. Contact our team of experts today to discuss your next project. Alternatively, for more information about designing a commercial building in colder regions, read our article on Commercial Warehouse Building Design Considerations for Colder Regions.

Large-scale construction projects stand in a class of their own, requiring materials that are flexible, efficient, and durable to meet the demands of these buildings. Precast concrete walls are known for their many benefits and standing out as a versatile, reliable material in a commercial space. Precast concrete walls are concrete structural elements cast and cured in a controlled manufacturing environment, which are then transported to the construction site for installation. At XL Structural, we’ve worked on many projects that have spec’d for precast walls. We’re often asked why people would go with precast concrete over other methods, and whether building with precast is the right option. While precast walls can cater to your specific operational needs and provide extra advantages over and above other concrete and building materials, it isn’t a solution for every project. In this article, we explore when and why using precast wall(s) in your industrial commercial build is a good idea. We also outline key considerations and what to expect when you do. Same but different: Precast vs Tilt up concrete Often confused because of their shared use in construction, precast and tilt-up concrete differ significantly in the way they are manufactured. Off-site pre-casting involves pouring concrete in a controlled factory setting, ensuring quality control, and minimising waste. In contrast, tilt-up construction involves casting panels on-site before lifting them into place, offering a practical solution for remote sites far from precast facilities. However, they do present challenges, such as slower progress and potential quality compromises due to uncontrollable site conditions. Since pre-casting off-site offer strong cost and quality control advantages, it is generally the preferred option. Why Choose Precast WAlls? durable Precast concrete walls are one of the most durable wall systems. They can endure vehicle impacts and require minimal upkeep compared to other cladding, making them ideal for industrial settings. Even in demanding and high-use equipment environments, they maintain their appearance and strength, due to their steel reinforcing and high strength/MPA concrete to meet modern building and earthquake codes. Versatile and visibly appealing Precast walls offer a unique blend of design flexibility and aesthetic appeal. With the ability to be made in various heights, shapes, and sizes, they give builders and architects the freedom to create visually striking buildings. Additives and customisation techniques can be used in a factory environment, allowing you to pick from almost endless designs and finishes so the product aligns with your brand. Examples of this can be as simple as painting, right through to surface finishes like exposed aggregate, wood grain, or etched in murals, logos, or names. Secure The strength of precast concrete adds a level of security that can prevent both break-ins and resist most impacts. This means it isn’t susceptible to vehicle ramming, cutting into, or unscrewing cladding panels to gain access. Precast concrete has also become a default material for creating storm shelters. For your larger construction project, precast concrete will deliver a safer product that can withstand the harshest of elements and unforeseen circumstances. Engineering insights The controlled production process ensures consistent quality and precision, reducing gaps or inconsistencies during installation. As the walls are cast, they can be designed precisely to what is needed. Due to its strength, precast concrete can be used in load bearing walls, reducing the amount of steel required. This delivers a cost saving as well as a robust building structure. Precise engineering means the walls are made to exact specifications, contributing to its structural integrity. Reinforcement is also specified precisely by the engineer to account for wind, earthquake, and seismic loads. There have been considerable increases to the loads and requirements following the Christchurch earthquakes, where a lot of concrete structures performed poorly. Reinforcing is also part of the offsite manufacturing process, which adds to the efficiency of pre-casting offsite. Precast concrete is resistant to fire, making these walls an excellent fire safety measure. Combined with the right insulation and panelling on walls and ceilings, it can limit a fire’s ability to spread between rooms and provides continuous support to the structure even under extreme heat conditions. It will come as no surprise that precast concrete walls are also excellent sound barriers. They absorb, block, and reflect sound waves, reducing the impact of noise from within the building, and reducing any outside noise. Cost vs time The installation speed of precast panels can shave months from a construction schedule, drastically reducing the construction financing cost. Analysing the costs of your precast concrete wall accurately will help you understand the expenses within the project's full lifespan. It's also important to consider the initial costs against long-term savings in maintenance, durability, and energy efficiency offered by precast concrete. Effective budgeting ensures your project stays financially viable, while maintaining quality and safety. It also allows for smarter financial choices, pinpointing areas for cost optimisation without affecting the project's integrity or timeline. Planning for precast Walls Precast walls are often required in certain industrial builds to meet fire safety requirements. Engineers and fire designers will assess and calculate the specific requirements for your project. At XL, we have in-house fire design expertise so we can review your project and determine what is required. To find out more about what your options are, read our article on fire here. Your engineer will also consider if the weight of your panels will have any implications on the foundations of your building. While panels generally require concrete cantilevered foundations for fire rating compliance, when subjected to seismic loads, it's more efficient for panels to be bolted to a steel structure to maximise the efficiencies of the building foundations. In instances where precast walls are used in areas with poor ground conditions, specialised foundations such as piles may be needed to support the additional weight effectively. Designers need to carefully optimise the foundation designs to accommodate the requirements of precast walls and ensure the structural stability of the building. The choice of precast concrete walls for your industrial build demands an assessment of multiple factors. While precast concrete can present advantages, it's important to be aware that it may not be the perfect solution for every project. Before committing to precast concrete, you should weigh up its benefits against the specific needs of your build, with the help of a designer, engineer and build team or lead consultant. At XL Structural, we're committed to guiding you through this decision-making process, providing expertise and insight tailored to your unique project needs. If you're planning your next industrial building project and want to speak to an expert about the process, reach out to our team today. For more details on the cost of choosing precast concrete walls, try our budget estimator tool to see estimated costs for your project.