Project background
As one of Australasia’s largest self-storage providers, National Storage continues to expand and optimise its network of facilities to meet growing residential and commercial demand. At their Tullamarine site in Melbourne, the team set out to increase usable space and improve on-site efficiency.
With the addition of a breezeway with a floor-to-floor exceeding 7 metres to accommodate a drive-through format, the project team sought a solution that could meet tight spatial parameters and support fast installation, without increasing cost or complexity.
The Fielders solution
To meet the structural and construction demands of the Tullamarine upgrade, the project team selected SlimDek 210®, a long-span steel formwork system purpose-built for multi-storey, steel-framed environments.
Capable of achieving unpropped spans up to 7 metres, SlimDek 210® eliminated the need for back-propping in the drive-through areas, helping maintain clear height and reduce site congestion. Its unpropped design allowed the team to commence fit-out works beneath the slab within days of pouring.
For a facility requiring both high-clearance access and rapid turnaround, SlimDek 210® offered the dual advantage of structural simplicity and program efficiency, helping keep the build moving without compromising the design intent.
Project execution
Delivering two suspended floors within a live storage facility required careful coordination across design, engineering and construction teams. From early planning to slab pour, Fielders played a hands-on role in supporting the build process, including provision of specific details, review of the final design drawings and ensuring SlimDek 210® was installed to specification.
“Key priorities included coordinating shop drawings, managing subcontractors, and ensuring the system was installed in line with the Fielders QA checklist, ready for concrete pour,” said Robin Ranjit, Project Engineer at Hutchinson Builders.
The Fielders team provided detailed installation guidance, facilitated workshops with principal contractor Hutchinson Builders and structure subcontractor GIGIX, and was available throughout for site inspections and design queries.
The SlimDek 210® installation followed a clear, repeatable process. It allowed for streamlined QA checks and consistent slab preparation. This set the stage for a faster overall program with minimal disruption to follow-on trades.
Outcomes
The use of SlimDek 210® delivered clear structural and program benefits for the Tullamarine expansion. With unpropped spans reaching over 6 metres, the system allowed for faster pours, immediate access beneath the slab, and a noticeable reduction in on-site congestion.
“This system allowed us to go directly under the slab the day after to commence cleaning, which then the next day allowed works to commence underneath at a quicker pace,” said Ranjit.
Eliminating the need for back-propping improved site safety and freed up internal space, minimising clashes with other trades and allowing the program to progress without delay. Follow-on works could be scheduled with greater confidence, contributing to a smoother, more controlled construction phase.
Key outcomes:
- 7,500m² of suspended floor area installed with no back-propping required
- Unpropped spans of up to 6.2 metres achieved
- Early under-slab access allowed fitout to begin within 48 hours of pour
- Reduced site congestion and improved safety
- Project delivered on time and within budget
Learning
While SlimDek 210® was a new system for some installers on site, the learning curve was short and well-supported. Once the installation process was understood, the system proved simple and highly efficient to work with.
“Once the installers understood the system, it was efficient and straightforward. The installation guide and the Fielders team made a big difference,” said Ranjit.
Clear documentation, upfront workshops and ongoing technical support from Fielders helped streamline the construction process and reduce the potential for on-site delays. The project demonstrated the value of early engagement between product suppliers, engineers and contractors, particularly on jobs involving specialist systems.
The experience also reinforced how proactive supplier involvement can simplify installation and support more predictable delivery on future projects.
Conclusion
The success of the Tullamarine suspended floors came down to smart system selection, clear communication, and practical on-site support. With SlimDek 210®, the project team delivered a structurally efficient solution that aligned with National Storage’s budget, operational needs and tight construction program.