Big logistics operations need even bigger reliability, and McPhee's new warehouse in Berrinba was no exception. For this sprawling logistics hub, the stakes were high. Covering an area of 18,000m², the need was clear: a roofing solution that could not only withstand the challenges of the vast Queensland weather but also align seamlessly with the operational needs of a state-of-the-art facility. The project demanded precision, reliability, and a deep understanding of large-scale industrial requirements.
Haggarty Roofing Pty Ltd took on the challenge, bringing a high level of experience and technical insight. Our goal was straightforward: deliver an industrial-grade roofing system that could stand up to local climate extremes and demanding operational needs. The outcome had to be both durable and compliant, and the process needed to avoid disrupting McPhee’s logistics schedule.
Project Challenges
Installing any large-scale roof comes with its hurdles, but this one involved particularly complex demands. We had to manage not just size, but performance, timing, coordination, and compliance with regional standards.
Key challenges included:
1. Scale of Project: The sheer area of 18,000m² created significant demands on logistics, safety management, and labour coordination. Material staging, crane access, and sequencing all played a part in the overall planning.
2. Compliance Requirements: Because this was an industrial facility, every aspect of the build had to align with Australian building codes, particularly those relevant to Queensland’s weather and regional wind ratings. Overlooking even minor elements could jeopardise certification or short-term safety.
3. Logistical Considerations: The warehouse site was highly active and coordinated by Vaughan Constructions. Any disruption to the broader site activity would delay the build, so we worked in tight communication with all parties involved, including suppliers, crane operators, installation crews, and site management.
These issues were well understood from the outset, and we created a structured plan to address each one.
Innovative Solutions
Meeting the project’s challenges required more than just experience. It took detailed planning, well-documented systems, and a team-wide focus on precision.
Inspection and Test Plans (ITPs) were key to our approach. These documents laid out all stages of installation and clearly defined inspection points to match regulatory requirements. Our ITPs gave structure to the process and provided reassurance to the client that quality control was locked in from day one.
We also introduced hydraulic integration for material movement. By incorporating hydraulic lifting systems to handle bulk materials, we reduced manual handling risks and improved installation efficiency. This allowed the roofing crews to keep pace with delivery windows while maintaining high safety standards.
Staged crane lifts were vital too. With such a large roof area, not all lifting work could be done in a single move. We scheduled lifts to match structural clearances and avoided obstruction of other trades operating nearby. Crane timing had to be accurate, and coordination with Vaughan Constructions ensured we never blocked critical access points or delayed other on-site activities.
The practical implementation of these systems was what made them work. It came down to ensuring everyone knew their role well and having a constant line of communication between crews and project leads. Every plan was backed up by real-time adjustments, ensuring nothing fell behind.
Execution Excellence
The success of the McPhee warehouse roofing project wasn’t just about installing sheets of metal over a frame. Every element of construction had to be tracking to the right specification, with no room for error.
Maintaining strict adherence to the building codes set out for Queensland was central to our method. We ensured all flashings, insulation, and roof profiles were fully compliant. Our team referenced current building compliance data at every step, reducing the risk of post-installation issues and helping secure final approvals.
Timeline was another factor. The program we were following had little room for variation. Working to that level of discipline meant programming material loads and lift setups down to the hour and sequencing labour to maximise output across shifts. We kept unexpected delays to a minimum, even with Queensland weather fluctuations interrupting other areas of the build.
Another major milestone was ensuring workplace safety and minimal disruption during the entire roofing works. The site had operational teams undertaking other phases of construction at the same time. We worked in zones, staggered shifts where required, and maintained secure areas to keep other contractors unaffected. All roofing tasks were conducted in a way that kept surrounding operations running without delay.
Long-Term Benefits
Durability is always front of mind when working on machinery and logistics warehousing. The solution implemented across McPhee’s Berrinba facility provides a long-lasting system adapted for heavy-duty distribution facilities.
The roof system used in this project is a Queensland-tested solution made for industrial pressures. It's built to survive strong wind loads, intense summer rains, and the thermal movement that’s common in open steel-frame structures. Its low maintenance performance means fewer future disruptions to business and less spend over time on ongoing roof care.
Here, professional installation really makes the difference. Our approach was built around technical oversight, meaning we didn’t rely just on experience, but also on a documented process. With the inclusion of ITPs, compliance sign-offs, and staged installation records, McPhee now has a roof backed by clear evidence that each component was installed securely and correctly. This reduces the risk of future liability, warranty issues, or unidentified defects.
Our approach helps large operators like McPhee lower facilities management concerns. With less energy lost to leaks or unsealed joints and fewer callouts to detect issues later, the system continues to support the business rather than interrupt operations. That’s the benefit of getting it done right the first time.
Delivering Scalable Solutions for Logistics Hubs
At project close, McPhee’s new logistics facility stood ready to meet growing operational demands with full confidence in the infrastructure above. The industrial-grade roofing system we installed proves what can be achieved through detailed planning, open communication, and proven methods.
This project stands as a solid example of how scalable roofing can be implemented quickly and correctly, without disrupting business flow. It shows how professional installation, based on clear strategies, provides long-term reliability. Most of all, it demonstrates why working with roofing specialists familiar with Brisbane’s environmental conditions and building codes is so important when scale and compliance matter.
From initial planning through to the final inspection, our team delivered a solution that ticks all the boxes for function, compliance, and durability. For any logistics operation looking for roofing solutions that meet modern demand, the McPhee Berrinba warehouse is a reliable model. We’re proud to have delivered a facility that performs where it matters most, above your business.
For exceptional outcomes on large infrastructure builds like the McPhee logistics hub, you need solutions that deliver on scale, safety, and compliance. Learn how our proven approach to Brisbane commercial roofing can support your facility’s needs without disrupting day-to-day operations. Haggarty Roofing Pty Ltd is ready to provide a roofing system that performs reliably for the long haul.