When building roofing systems for industrial and commercial use, there’s rarely a one-size-fits-all approach. Projects can shift in complexity depending on size, location, and specific operational requirements. At Brisbane Airport, BSR encountered the need for a roofing system that could keep up with non-stop logistics, Queensland’s unpredictable climate, and aviation regulatory standards. They turned to Haggarty Roofing Pty Ltd to deliver a solution that would perform reliably in this high-pressure setting.
We specialise in providing roofing solutions that meet the demands of large-scale operations. In this case, the brief was clear: develop a 6,000m² roofing system capable of withstanding Brisbane’s conditions while complying with strict airport regulations. It also had to support the fast pace of warehousing operations happening directly below.
Putting that kind of system in place required strategic planning, skilled execution, and a committed partner. Throughout the project, our team focused on maintaining safe workflows, aligning closely with all stakeholders, and ensuring tight timelines were met without compromising quality or safety.
Project Requirements
BSR needed more than just a roof. This was about creating reliable infrastructure to support high-volume freight movements around the clock. The roofing system had to offer structural resilience while conforming to strict aviation zone regulations. These requirements drove every decision on design, materials, and scheduling.
The roof had to:
- Meet aviation zone compliance, including building and safety codes relevant to airport environments.
- Withstand the harsh Queensland climate, including ultraviolet exposure, heavy rainfall, and tropical storms.
- Provide unobstructed clearance and durability to support warehouse operations below.
- Allow for fast track installation with minimal disruption to other airport activities or nearby structures.
BSR's expectations were grounded in performance and reliability. This required careful consideration of how building components work together to add operational value. Our team interpreted these expectations and translated them into a practical system plan that made long-term sense for the site.
Strategic Partnership with Xenia Constructions
Bringing a project like this together required more than technical knowledge. It needed strong project coordination and an ability to adapt to changing site conditions. That’s why we partnered with Xenia Constructions. Their experience managing complex infrastructure projects brought additional precision to the process.
Together, Haggarty Roofing Pty Ltd and Xenia Constructions shared clear project responsibilities:
1. Coordination and logistics: Xenia handled procurement timing, crane access coordination, and resource sequencing. Their role was to ensure that site restrictions, especially those around crane movement and timing in an aviation setting, were accounted for before work began.
2. Technical installation: We focused on the specialist roofing tasks. That involved calculating optimal lift sequences, sourcing industrial-grade roofing materials built for long-term performance, and assigning experienced teams to specific install zones.
This partnership allowed each team to work within its strengths. Timelines remained on track, and each site activity aligned neatly with broader operational requirements at Brisbane Airport. Having this dual management approach gave stakeholders peace of mind that both regulation and performance targets would be hit.
Execution and Installation
Installation at Brisbane Airport came with a clear set of constraints. There were crane movement limits due to the surrounding airspace, safety inspections at each milestone, and weather variables that couldn’t be ignored. Our approach was built around staged execution, where thorough planning backed every move.
Key steps included:
- Staged lift plans: Given the crane restrictions, we developed and followed a detailed plan that coordinated roof sheet lifts around airport flight schedules and ground activity. This minimised disruptions and delays.
- Progressive Inspection and Testing Plans (ITPs): Each section of the roofing install underwent continuous quality checks. Our ITP method meant we verified installations progressively rather than waiting until final works. This reduced the need for rework and provided early identification of any deviation from spec.
- Material selection: Roofing materials were chosen based on resilience against moisture intrusion, UV stability, and structural strength. Only products rated for Queensland's climate and industrial applications were used, ensuring durability with reduced upkeep.
Despite weather interruptions and tight airside rules, we completed each install phase on time and to standard. Managing sequencing around crane use and inspection intervals took planning, but it paid off by maintaining build efficiency across the full 6,000m² scope.
Results and Benefits
The roofing system is now fully operational at BSR’s Brisbane Airport facility, and it’s delivering results just as designed. From the outset, this build was framed around long-term value and safety, and the outcomes reflect that focus.
This system delivers:
- Operational improvement: With proper shelter and optimal height clearance, indoor logistics run more smoothly. The roof structure’s design reduces internal heating and suits airflow needs for high-volume processing.
- Regulatory compliance: Full sign-offs on building and aviation codes were secured thanks to design detailing and proof through ITPs. This allows BSR to proceed confidently with ongoing operations without risk of non-compliance issues arising later.
- System longevity: Materials selected for their ability to withstand Queensland’s heat, rain, and storm events ensure that the roof will last. This minimises ongoing repairs and means fewer operational interruptions moving forward.
These gains are only possible because of the careful attention paid at every stage, from collaboration and planning through to installation and inspection. The feedback from both BSR and the site management team has been positive, recognising the professional delivery and streamlined coordination throughout the process.
Delivering Reliable Roofing Solutions for Queensland's Industrial Needs
Every industrial build has its own challenges, but nothing quite compares to the constraints of building at an international airport. For BSR, it wasn’t just about putting on a roof. It was about building a reliable surface to protect and support active operations underneath, match compliance expectations, and last through Queensland’s severe weather cycles.
At Haggarty Roofing Pty Ltd, we draw from years of industrial roofing experience to meet the exact needs of clients. From fully compliant aviation projects like this one, to warehouse expansions or large-scale upgrades, we treat every structure like it will support years of front-line work. Our teams deliver technical detail with site-first awareness, making sure projects stay safe, efficient, and within brief.
If your next project calls for real performance backed by proven methodology, we’re ready to help. Whether you’re building in Logan, Brisbane, or beyond, our Queensland-tested systems can meet your operational requirements. We bring technical oversight, practical implementation, and professional installation to sites that demand seamless results.
If you're planning your next industrial build or upgrade, see how Haggarty Roofing Pty Ltd can support you with practical, Queensland-tested systems. Our experience in BSR warehouse roofing has shown how the right design and delivery can meet tough freight demands while staying fully compliant with aviation and building standards.