Promat case study shows passive fire protection design for Warrington tyre distribution centre

Promat delivers tailored fire protection for Warrington tyre warehouse

Promat has developed a passive fire protection design for Stapleton’s Tyre Services as the company moves into a refurbished 255,000 sq ft distribution centre at Hardwick Grange in Warrington.

The project forms part of a wider refit of the warehouse, with fire protection measures required to meet Building Regulations while supporting Stapleton’s operational needs.

According to Promat, the brief combined full compliance with a need to maximise usable floor area and maintain a tight project schedule.

The passive fire protection package was therefore designed around the specific geometry and construction details of the existing building.

Promat stated that early involvement at the design stage allowed its team to produce a technical specification in a short timeframe.

This specification set out where fire performance requirements could be met using a more space-efficient solution than the original proposal.

Case study focuses on mezzanine performance and retained value

The warehouse includes a three-storey mezzanine structure that Stapleton’s wished to retain as part of the move to Hardwick Grange.

James Glover, Senior Contracts Manager at ISS Property, said: “A key challenge of the move to the Hardwick Grange distribution centre was making sure the existing building retained a 3-storey mezzanine structure to maximise the storage space and retain the mezzanines original value.

“So, we were keen to see how experts in key areas such as passive fire protection could help to both streamline the project and make our use of the building as efficient as possible.”

Promat was asked to review the original fire protection concept, which included a suspended ceiling beneath the mezzanine comprising four layers of gypsum boards.

This suspended ceiling would have been time consuming to install and would have added weight to the mezzanine structure.

According to Promat, the additional loading from the original ceiling design would have reduced the live load capacity of the mezzanine to the point where it was no longer viable for Stapleton’s intended use.

The company therefore developed an alternative based on PROMATECT 250 to maintain the required 90 minutes’ fire performance while preserving live load conditions.

PROMATECT 250 replaces suspended ceiling system

Promat advised that PROMATECT 250 was selected as the core product for the mezzanine fire protection system.

The company said this solution removed the need for the four-layer gypsum suspended ceiling that had been specified previously.

PROMATECT 250 was installed in a single or double layer direct-fix arrangement rather than as a suspended ceiling.

Promat stated that this configuration reduced installation time and helped lower labour costs on the project.

The firm added that PROMATECT 250 is lighter than a multi-layer gypsum build-up, which supports a more favourable live load condition for the mezzanine.

According to Promat, the board comprises autoclaved calcium silicate spheres bound in a mineral matrix and has been specifically tested for mezzanine applications.

The resulting design was intended to deliver the 90 minutes’ fire performance required while taking up minimal space within the warehouse envelope.

Product supply, site support and contractor feedback

Promat worked with sub-contractor Archway Building Services to progress the passive fire protection specification.

The company said it provided the evidence needed to demonstrate the proposed PROMATECT 250 system could meet the fire performance requirements.

This allowed Archway Building Services and the wider project team to move forward quickly with the warehouse refurbishment.

Promat reported that it arranged a quick turnaround on product manufacture so the boards could be delivered to site in line with the installation programme.

The firm also carried out multiple site visits by its technical staff to check that the system was installed in accordance with the specification.

Harvey Brown, National Specification Manager at Promat, said: “Warehouses and distribution centres like Hardwick Grange must comply with stringent Building Regulations regarding fire safety, which can mean taking up space that would otherwise be useful for the occupants.

“By getting involved from the specification stage, we were able to provide Stapleton’s with a more space-effective way of complying fully with fire regulations.

“The passive fire protection expertise we have in-house meant this could be done in a tight timeframe, supplying a bespoke design that draws on best practice from other similar developments.”

Barry Simpson, Director of Archway Building Services, added: “The quick, accurate response we got from Promat was very welcome in allowing the initial specification to meet the requirements for the building and ensure the passive fire protection design would offer the level of protection needed, while also helping to save space in the warehouse.

“This means the risk of fire can be managed with minimal impact on day-to-day operations.”

Warehouse case study for passive fire designers

This project sets out how Stapleton’s Tyre Services, Promat and Archway Building Services approached passive fire protection within a large distribution warehouse that already contained a three-storey mezzanine.

Fire engineering consultants and building services engineers can see how an existing mezzanine structure was retained by replacing a heavy suspended ceiling design with a direct-fix PROMATECT 250 solution.

The case study details how a 90 minutes’ fire performance requirement was met while maintaining mezzanine live load capacity and usable storage space.

System installers and fire-protection contractors may be interested in the use of a lighter board product to reduce installation time and labour costs on a live refurbishment programme.

Architects and facility managers responsible for warehouse refits can refer to this example when assessing how early engagement with a passive fire protection supplier can support project scheduling and compliance.

The description of product manufacture, delivery to site and ongoing technical visits outlines a service model that may be relevant to other large warehouse schemes.