Keeping the shelves bursting with enough fresh food to feed the growing number of hungry mouths in Sydney, Canberra and Regional New South Wales presented Woolworths with a logistical headache.
A new, strategically located, and extremely extensive distribution centre was required. After pinpointing Eastern Creek in Western Sydney as the site of this new project, planning how to turn this site into the soon-to be world-class Woolworths Eastern Creek Chilled and Fresh Distribution Centre began. This was when the Fielders Design Solutions Group was brought to board to help.
6,000 tonnes of fresh food processed daily
The proposed state-of-the-art, 93,000m2 facility is set to become the largest multi-storey, temperature-controlled distribution centre in the Southern Hemisphere. It’s an innovative development that will process up to 6,000 tonnes of fresh produce, including meat, dairy, and perishables, daily. Equipped with advanced refrigeration and automation systems, it will ensure optimal storage conditions and streamline distribution to Woolworths stores nationwide.
All supported by 69,000 m2 of Kingflor® System: KF70 1.0mm BMT Deckform Z350
As Jack Huang, Structural Manager for Fielders, tells us, “Fielders Design Solutions Group (DSG) was involved from the early stages of the Woolworths Chilled Distribution Centre project at Eastern Creek. We worked closely with BESIX Watpac (the builder) and Costin Roe Consulting (the structural engineer) to develop the most efficient structural solution for the suspended warehouse floors.
Throughout the project, our team provided BESIX Watpac with hands-on technical advice and best-practice guidance on using metal formwork and composite slabs. Acting on behalf of Santana Stud Welding, we also managed the Building Information Modelling (BIM) and 3D detailing for all KF70 decking – playing an active role in regular design coordination meetings to help resolve clashes and refine the overall design.”
Rigorous testing for exceptional results
“The shop drawings we produced were thoroughly reviewed by the engineers and ultimately set a new benchmark for quality in metal deck documentation,” says Jack Huang. Due to the significant structural design efficiencies offered by KingFlor KF70 over conventional metal deck profiles, it was selected as the preferred composite decking profile for the following areas of the project:
- Level 1 main warehouse
- Level 1 hardstand
- Automation pit mezzanine
- Administration building level 1
- 3 levels in the operations building
- Plant room roof.
Improved site safety with a strong, stable work surface
The KingFlor® deck provides a safe work platform, not only during placement of the KingFlor® components but also during concrete pouring. Additionally, the decking also acts as a safe canopy to protect workers below from falling objects.
The mechanical interlocking of a concrete slab and embossments of KingFlor® work as bottom tensile reinforcement in composite slab design, saving on concrete and reinforcement costs. For such a large project, this is a significant consideration – both financially and from a sustainability point of view.
Streamlined delivery strategy for time-critical implementation
During construction, Jack Huang and the Fielders’ Project Execution Manager (PEM) co-developed comprehensive material delivery strategies with the client and key stakeholders to ensure JIT (Just-in-time) deliveries of KF70 sheets to meet the project’s demanding construction program.
Jack Huang explains: “Given the tight construction schedule, we needed to develop a tailored logistics and delivery strategy, planning more than 100 deliveries with precise material quantities and JIT scheduling. Our PEM worked closely with Watpac and Santana on a day-to-day basis to ensure materials were on site when needed, helping to keep the program on track.”
Supporting the local economy, and the environment
The centre supports sustainability with energy-efficient technologies and will create numerous local jobs. During the construction phase alone, the project will generate more than 4,000 jobs and partner up with a great number of local businesses. Once fully operational in 2027, the facility will employ up to 700 people, greatly contributing to the Eastern Creek community.
Progress report:
As of the end of May 2025, DSG is proud to report that over 80% of the KF70 decks have been produced at our Emu Plains facility and delivered to site as per the streamlined JIT scheduling.
