Manildra Sunshine Sugar Warehouse/Refinery Extension, Auburn, NSW

Sector

Industrial

Location

Auburn, NSW

The project involves the extension of the existing Manildra Sunshine Sugar warehouse and refinery located at 312 Parramatta Road, Auburn, NSW.

The scope includes the construction of additional warehouse space, a new two-storey office area (~184 m²), an expanded internal warehouse floor (~782 m²), and an on-grade car parking area with 18 new spaces. The facility is used for the storage and processing of sugar and flour, incorporating liquidisation processes for industrial distribution. The extension aims to enhance operational efficiency while ensuring compliance with fire safety regulations.

Key challenges:

Safety and compliance: Extended travel distances within the warehouse exceeding BCA limits (50 m to the nearest exit instead of 40 m, and 75 m between alternative exits instead of 60 m).
Architectural constraints: The location of the fire hydrant booster and sprinkler booster assembly does not comply with the BCA requirement for visibility from the main building entrance.
Site access limitations: Vehicular perimeter access is constrained due to the presence of railway tracks on the western façade, and the fire brigade must reverse at the southern end.
Fire suppression and detection: The need for a performance-based solution to integrate fire detection, sprinkler, and alarm systems across both the new and existing structures.
Operational continuity: The project required careful fire safety planning to maintain warehouse operations during construction.

Key solutions:

Optimised egress strategies: A performance-based approach demonstrated that the inclusion of a smoke detection and alarm system offsets the extended egress distances by enabling earlier fire detection and occupant warning.
Enhanced Fire Brigade access measures: Weatherproof block plans and strobe lighting at the fire hydrant and sprinkler booster assemblies ensure easy identification and access for fire brigades.
Perimeter access adaptations: The fire brigade’s ability to access the site is maintained through alternative vehicular paths, despite constraints on the western and southern façades.
Comprehensive Fire Suppression System; Installation of a new sprinkler system in accordance with AS 2118.1:2017 and an upgraded fire hydrant system for the entire building, enhancing fire response capabilities.
Fire alarm monitoring and communication link upgrade: Integration with AS 1670.3:2018 ensures compliance with monitoring standards for immediate emergency response.

Key outcomes:

Successfully achieved compliance with BCA Performance Requirements through fire engineering analysis.
Mitigated risks associated with extended travel distances via an enhanced fire detection system.
Ensured fire brigade access despite site constraints through strategic design solutions.
Integrated fire suppression measures, improving safety across both the existing and new warehouse sections.
Facilitated seamless project execution while maintaining operational continuity.

This extension project successfully balances operational needs with stringent fire safety requirements. The innovative fire engineering solutions ensure regulatory compliance while optimising egress, fire suppression, and emergency response measures. The project sets a high standard for industrial fire safety, demonstrating excellence in engineering and design integration.

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