Torresan Estate's new Stage 2 wine storage warehouse sits alongside their first facility, with a canopy protecting transfer of product from one to the other. The facility is cut into the hillside to minimise visual impact to local residents, and offers natural climate control inside the warehouse.
This diagram indicates a clever solution to ensure neighbours maintained their line of sight across the McLaren Vale valley. This was achieved by excavating down into the hillside to construct the new warehouse and therefore lowering the height of the building. Please Note: Diagram not to scale - indicative only.
Large scale undercover access enables easy movement between warehouse facilities. Note the seamless and ridge-free cement floor, which reduces noise levels and wear and tear on forklifts.
Wineries and transport companies visiting Torresan Estate storage facilities now find it even easier to swiftly load their product for transport due to this large flow through, undercover loading dock.
Rainwater from the new warehouse is collected for onsite use. This photo further shows how cutting the building into the hillside enabled the roofline to remain low and minimise impact on local residents and visitors to McLaren Vale.
Clever design of the roof structure and supports led to only 8 support columns being required, offering greater storage layout flexibility, plus a more open access environment for forklift traffic.
With vast floor space and only 8 columns required to support the roof structure, Torresan Estate bottling plant offers an extensive capacity for storage of their customers' products. The structural design reduced the number of support pillars needed, reducing material costs substantially, which enhances the project viability and value for money.
This cleverly designed 'W' shape canopy enables large scale transport trucks easy access to the unloading area and protection from the weather elements.
This image demonstrates the vastness of the storage space under the canopy. Torresan Estate are able to fit 6 full pallets of bottles stacked one on top of the other under the height of the canopy.
This large stormwater mitigation tunnel was installed under the new Warehousing facility to ensure runoff waters from surrounding homes opposite Torresan Estate move more freely to the ponds and creek below the facility, reducing local flooding impact.
South Australia’s Torresan Estate’s wine / beverage bottling and labelling plant at McLaren Vale has been enjoying much growth of late, leading to their need to expand storage facilities.
Many wineries and local producers utilise Torresan Estate’s bottling and labelling facilities, but struggle to find storage space for their bottled products. Torresan saw an opportunity to also offer storage solutions by expanding their own storage and logistics facilities.
This project took about 18 months from the client’s first concept briefing with Woolcock Construction, through design, costing, approvals and construction, to handover.
Stage 1 Construction – This stage spanned 10 months and was completed in early 2019. It included substantial excavation, large retaining walls; construction of a 5,000m2 warehouse with significant water management provisions, and a separate 1600m2 canopy for empty bottle storage.
Stage 2 – With concepts and development applications pre-approved during Stage 1 planning, future construction of another large warehouse alongside Stage 1 can begin at the client’s request. Additionally, infrastructure for this was put in place during Stage 1 works.
Numerous challenges were identified during discussion with the team at Woolcock Construction.
Neighbours’ Appeal to Maintain the View
Torresan Estate were sympathetic to the neighbouring residents and tourist accommodation business, noting that construction of the proposed warehouse had the potential to obstruct views across the valley to facing hills; views that encouraged patronage to the business.
The Woolcock designers worked closely with planning consultants, and during initial site inspections presented credible solutions to satisfy all needs.
Firstly, the finished height of the warehouse could be lowered by nearly three metres by excavating below natural ground level. This ensured neighbours' views were preserved, as illustrated in the photo gallery.
Secondly, building below ground level leverages on natural cooling and stability of warehouse temperatures. This provides for greater control of the warehouse environment, reduces the need for air‑conditioning, and assists in maintaining ideal conditions for the storage of wine products.
A major win for all.
The final design improved vehicle flow throughout the site, lowered road levels where possible and included planting many trees. This reduces overall vehicle movement, and uses ground levels to provide a sound baffle, which helps minimise traffic noise.
The greening commitment by Torresan Estate has also met major goals in their continuing management of land degradation, and reduces their carbon footprint.
Complicated stormwater requirements on this site were identified before starting the project.
Issues included substantial runoff from the roadway and neighbouring properties in addition to water falling on the site, and complexities surrounding future buildings.
A large capacity underground drain was installed diagonally beneath the warehouse following the natural watercourse, to accommodate current and future stormwater demands. The drain is part of a substantial filtration system including a large pond that enables the runoff water to be filtered before it enters the creek system in the valley below.
Rain water from the warehouse roof area is captured and chanelled into five large rainwater tanks with a combined capacity of nearly 350,000 litres. This water is filtered and reused on site.
New Empty Bottle Storage Zone
With repeated expansion and installation of new machinery at this Torresan site, it became necessary to move empty bottle stocks to an outside area.
To address this, Woolcock Construction were asked to design a new storage area, for which a 1,600m2 canopy was constructed with allowance for six-high pallet stacks.
The cantilever canopy was designed to require minimal support columns. This provided cost savings on materials and construction time, maximises the usable storage area, and offers greater flexibility for manoeuvring trucks and forklifts.
The warehouse structure also employs minimal support columns in order to take full advantage of the space, maximising storage options and minimising forklift obstacles. Additionally, with reduced number of slab joints, the fibre cement slab permits smoother forklift operation and reduced wear and tear.
The defining attribute of the warehouse construction however, is the 100mm thick Kingspan panels on the roof and walls. This provides insulation characteristics similar to a coolroom, enabling superior climate control of the building.
In summary, a combination of clever design, good planning, and the building experience of Woolcock Construction has delivered another successful project on time and within budget.
Our client is very happy with the new facility and grateful for the can-do approach of Woolcock Construction to overcome the challenges that this site presented.
If you have a project in the pipeline, Woolcock’s team would love to hear from you. Sit with us to talk through options (obligation free) to see how our experience can meet your needs and maximise your investment options.
Please give us a call on (08) 8193 9600