Warehouse platform cutting & replacement, Dammam
- Client
- Sahil Distribution
- Location
- Dammam
- Year
- 2022
- Duration
- 6 weeks
- Platform replaced
- 640 m²
- Night sequences
- 5
Corroded 640 m² platform cut out and replaced in six weeks inside an operating warehouse.
The challenge
A mezzanine platform in a Dammam warehouse had corrosion at the column connections and was closed by the client’s engineer. Picking continued directly below the work, the existing frame could not take temporary loads from the replacement, and the stair and edge protection had to match the original fire strategy.
Our approach
We built a load path for the temporary works around the existing frame, cut the old platform into drop-sized sections with vacuum-shrouded saws to control dust, and lowered sections by forklift through the pick-face rather than over it. The new platform was erected in bolted sections overnight in five sequences, and the replacement stair and guardrails were tested against the fire strategy before handover.
The result
Six weeks with picking live the whole time: 640 m² platform replaced, zero dust damage claims, zero lost-time injuries across 4,100 safe man-hours at a peak crew of 14 — and the engineer’s closure certificate issued in the same week as completion.
Scope delivered
- Temporary works load-path design
- Vacuum-shrouded sectional demolition
- Drop through pick-face by forklift
- Bolted replacement platform (five sequences)
- New stair & fire-compliant guardrails
- Engineer inspection & closure certificate
Picking never stopped and the closure certificate came the same week. We scheduled the second platform immediately.Warehouse director · Sahil Distribution