ALSONSHARDWARE
Warehouse Shed Repair and Maintenance
Client SectorMajor Industrial Logistics & Warehousing Hub
Site LocationHeavy Industrial Estate, Karachi
Turnaround Duration18 Days Turnkey
Quality VerificationCertified Handover
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Technical Authority // Field Context
Project Scope & Operational Context
At a premier 60,000 sq ft logistics distribution and freight forwarding warehouse hub in Karachi industrial estate, Alsons Hardware contracted to execute comprehensive structural reinforcement, steel roof truss strengthening, leak rectification, and high-build anti-corrosion protective coatings. Years of harsh monsoonal downpours, coastal humidity, and atmospheric chemical exposure had corroded structural C-purlins, rusted roof fastener joints, and created severe roof sheet perforations resulting in high-value inventory water damage.
Our structural engineering crew replaced weakened steel sections with hot-rolled structural mild steel, welded high-yield reinforcement gusset plates conforming to AWS D1.1 structural welding standards, and retrofitted corrosion-proof EPDM-gasket self-drilling fasteners across the entire roof envelope. We prepared steel surfaces to SSPC-SP 3 standards and deployed commercial airless spray pumps to apply a dual-coat protective system: a 120-micron zinc phosphate epoxy primer topped by an aliphatic polyurethane weather finish, delivering 100% water tightness and a 10-year structural warranty.
This warehouse infrastructure rehabilitation project demonstrates Alsons Hardware's comprehensive industrial civil, structural steel, and facility maintenance capabilities across Pakistan. Beyond logistics warehouse shed repair and truss reinforcement, our engineering contracting divisions provide turnkey facility solutions—including pre-engineered building (PEB) erection, industrial roof waterproofing and elastomeric coatings, structural steel fabrication, overhead crane gantry repairs, and anti-corrosion protective painting across industrial estates in Karachi, Lahore, Faisalabad, Hub, and nationwide.
Client SectorMajor Industrial Logistics & Warehousing Hub
Site LocationHeavy Industrial Estate, Karachi
Turnaround18 Days Turnkey
HandoverCertified
TECHNICAL METROLOGY // AUDITED BENCHMARK
Technical Metrology & Quality
Engineering Properties & Standards
Calibrated mechanical tolerances, material benchmarks, and regulatory compliance standards verified on-site:
Facility Footprint Covered
Over 60,000 Square Feet of industrial warehouse
Structural Steel Welded
High-yield structural mild steel profiles & gussets
Protective Primer Coating
High-build Zinc Phosphate Epoxy Primer (120 µm DFT)
Weather Topcoat System
Aliphatic Polyurethane UV-resistant finish (60 µm DFT)
Roof Fastener Upgrade
Corrosion-proof EPDM-gasket self-drilling hex fasteners
Governing Standards & Codes
AISC Steel Construction Manual Guidelines • SSPC-SP 3 Power Tool Cleaning • ISO 12944 Paint Protection of Steel Structures
Diagnostic Analysis
Engineering Challenge & Deployed Resolution
Diagnostic failure mechanisms analyzed on-site and the turnkey engineered countermeasure deployed by Alsons Hardware.
CARGO DAMAGE HAZARDFAILURE MECHANISM
Purlin Corrosion & Monsoonal Roof Leakage
A heavy 60,000 sq ft logistics warehouse experienced dangerous structural corrosion across roof purlins, holes in galvanized roofing sheets resulting in cargo water damage, and sagging portal frame joints.
•Extensive rust perforation across galvanized roof sheeting causing costly inventory loss
•Deflected and corroded C-purlins threatening localized roof collapse under storm winds
•Loose and missing fasteners allowing water intrusion along main portal frame rafter lines
ALSONS STRUCTURAL REMEDIATIONDEPLOYED RESOLUTION
Truss Gusseting, Welding & 2-Coat Protection
Deployed certified structural welders and coating specialists to reinforce steel gusset plates, replace deteriorated purlins, patch perforated sheets, and apply multi-coat zinc phosphate and polyurethane protective systems.
✓Weld reinforcement of portal frame rafters with high-yield structural mild steel plates
✓Replacement of corroded roofing sheets and installation of EPDM-gasket self-drilling fasteners
✓High-pressure airless application of zinc phosphate primer and aliphatic polyurethane topcoat
VERIFIED SITE OUTCOME:100% water tightness achieved across 60,000 sq ft facility with 10+ year corrosion warranty.
Engineering Sequence
4-Stage Execution Workflow & Milestones
Executed in strict accordance with Alsons Hardware industrial standard operating procedures and site safety protocols:
01
STAGE // 01ULTRASONIC SURVEY
Structural Deflection & Steel Thickness Survey
Inspected steel column thickness using ultrasonic thickness gauges and laser levels, mapping structural sag across trusses and rafter lines.
Ultrasonic Gauge & Truss Sag Audit
02
STAGE // 02STRUCTURAL WELDING
Steel Purlin Replacement & Gusseting
Replaced rotted C-purlins with hot-rolled structural steel sections, welded reinforcement gusset plates, and torqued high-strength 8.8 grade bolts.
Certified Structural AWS D1.1 Welding Sign-Off
03
STAGE // 03AIRLESS COATING
Zinc Phosphate Priming & Rust Treatment
Cleaned structural steel to SSPC-SP 3 standard and applied high-build zinc phosphate epoxy primer (120 µm DFT) using industrial airless sprayers.
120 µm Primer Dry-Film Thickness Verified
04
STAGE // 04WATERPROOFING
Roof Fastener Sealing & Topcoat
Installed EPDM self-drilling hex fasteners, applied elastomeric flashing membrane over sheet laps, and sealed with aliphatic polyurethane topcoat.
Flood Testing Passed & Warranty Commissioned
On-Site Field Photography
Field Operations & Site Visual Records
High-resolution photographic documentation captured during turnkey field execution, specialized plant operations, and project delivery.
STRUCTURAL DEFLECTION AUDITFIELD REF-01ARCHIVE LOG 01 // FIELD RECORD
Truss Sag Laser Deflection Mapping
3D laser survey and elevation profiling of structural roof trusses to calculate dead-load sag and deflection vectors.
PORTAL FRAME WELDINGFIELD REF-02ARCHIVE LOG 02 // FIELD RECORD
High-Yield Structural Gusset Welding
AWS D1.1 certified field welding of high-yield steel reinforcement gusset plates to strengthen rafter-to-column joints.
AIRLESS COATING & SEALINGFIELD REF-03ARCHIVE LOG 03 // FIELD RECORD
Airless Zinc Primer & Polyurethane Sealing
High-build airless application of 120 µm zinc phosphate epoxy primer and UV-stabilized aliphatic polyurethane weather finish.
Technical Advisory & FAQs
Frequently Asked Engineering Questions
Authoritative answers to common procurement, engineering standards, and execution queries regarding industrial shed structural repair:
How do Alsons Hardware structural welders reinforce sagging warehouse roof trusses?
We utilize laser level datum lines to establish original roof pitch, install hydraulic jacking props to relieve dead loads, and weld high-yield structural steel gussets and sister C-purlins adhering to AWS D1.1 specifications.
What paint system is applied to prevent rust corrosion in coastal industrial warehouses?
We apply a heavy-duty two-coat industrial system: a high-build zinc phosphate epoxy primer (120 microns DFT) for galvanic rust inhibition, topped by a UV-stabilized aliphatic polyurethane coat (60 microns DFT) for chemical and weather defense.
Can warehouse shed repairs and roof waterproofing be executed without halting inventory operations?
Yes. Our contracting teams utilize internal safety netting, catch decks, and compartmentalized overhead work zones, allowing warehouses and distribution hubs to operate normally without inventory disruption.
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