Rudloff-StrongForce (RSF) has recently completed the redesign of the DHL warehouse in Penang, Malaysia. Originally designed as a cast in-situ structure, the warehouse required a complex formwork system to accommodate the 18-metre-high levels. StrongForce was called upon to provide an alternative design solution that would simplify the construction method and accelerate the site program.

Working off a 12.0m x 12.5m column grid and an imposed live load of 40kPa, RSF converted the 3-level structure from a two-way band beam design to a hybrid post-tensioning and precast concept. Using the Rudloff-StrongForce multistrand system, the 186 shell beams and 1,186 T-Slab precast elements are being post-tensioned offsite and delivered to the warehouse.

The shell beams are erected onto the pile caps (L1) and onto the column corbels (L3) using post-tensioning within the shell. They’re then infilled, making the beams a solid rectangular continuous beam. The concept reduces the precast beam weight while providing continuity for the beam frame system, allowing for a reduction in the beam’s structural depth. The T-Slab precast is then placed on the adjacent shell beams with a structural topping.

This hybrid post-tensioning and precast concept is a welcomed solution for developers and project stakeholders constructing industrial buildings, as it accommodates large loading requirements while simplifying the construction method by eliminating the requirement for a temporary formwork system. With RSF's expertise and innovative solutions, the DHL warehouse in Penang, Malaysia now boasts a more efficient and cost-effective structural system, showcasing the company's commitment to delivering quality engineering and construction solutions.