Live-site warehouse roof retrofit, Dammam
- Client
- Sahil Distribution
- Location
- Dammam
- Year
- 2023
- Duration
- 11 weeks
- Roof upgraded
- 9,400 m²
- Night bays
- 16
9,400 m² roof upgraded over a 24/7 distribution centre with zero night-shift noise stoppages.
The challenge
A Dammam distribution centre running three shifts wanted stronger purlins, new sheeting and better drainage — without a single hour of closure. Night noise limits ruled out impact work after 22:00, and any open roof area had to be shut before each morning shift at 06:00.
Our approach
The programme was built in 600 m² night bays, each covered by a temporary weather lid before 06:00 and handed back clean every morning. Purlin strengthening used bolted sister sections rather than welded plates to kill night noise, sag rods and bridging were completed with the sheet, and gutters were re-laid to a corrected fall with new outlets. A supervisor walked the handback checklist with the client’s shift lead each dawn.
The result
Eleven weeks, 9,400 m² upgraded, zero closures and zero noise stoppages, every bay handed back by 06:00 as agreed, zero lost-time injuries across 15,100 safe man-hours — and the maintenance agreement was extended by two years.
Scope delivered
- Night-bay phasing with 06:00 handback
- Bolted sister-section purlin strengthening
- Sag rods & bridging completed with sheet
- Full sheet replacement, bay by bay
- Gutter re-lay to corrected fall & new outlets
- Dawn handback checklist with client shift lead
Three shifts, zero closures, and every dawn the checklist was already signed. We extended the contract on the spot.Regional facilities lead · Sahil Distribution