Flooring Solutions | Multi-Level Light Gauge Steel Flooring Solutions

Project Summary: Con-form Group delivered a comprehensive DiamondSteel© flooring solution for a logistics facility expansion, incorporating mezzanine floors for additional storage capacity, subfloor systems for office areas in challenging ground conditions, and deck framing for loading dock platforms. The integrated steel frame systems provided rapid installation while meeting diverse structural requirements across the complex facility expansion.

Timber house floor framing under construction

Project Challenge

The logistics facility required a complex multi-level expansion to maximise storage capacity within height-restricted zoning constraints while accommodating challenging site conditions including poor soil drainage and varying ground levels. Traditional timber and concrete solutions would have required extensive site preparation, longer construction timelines, and ongoing maintenance concerns in the demanding industrial environment.

The project needed to integrate office accommodation requiring stable, level floors above problematic ground conditions, high-capacity mezzanine storage areas capable of supporting heavy warehouse loads, and robust loading dock platforms exposed to constant truck traffic and weather conditions. Time constraints were critical as the facility needed to maintain operations during construction while completing the expansion before peak seasonal demand. The solution required seamless integration between different floor types while meeting strict Australian Standards for industrial and commercial construction.

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Key Challenges:

Maximise storage capacity within height-restricted industrial zoning constraints
Address poor soil drainage and varying ground levels across expansion site
Integrate office, warehouse, and loading dock areas with different structural requirements
Maintain facility operations during construction with accelerated installation timeline
Provide long-term durability in demanding industrial environment with heavy load requirements

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Solution

Con-form Group's integrated DiamondSteel© system provided the ideal multi-application solution, combining custom-designed mezzanine frames capable of spanning up to 10 metres for maximum storage efficiency, subfloor systems that elevated office areas above problematic ground conditions, and robust deck framing for the loading dock platforms. The ultra-lightweight G550 galvanised steel construction enabled rapid installation while providing superior load-bearing capacity compared to traditional materials.

All components arrived as prefabricated modules with pre-punched service holes and flared edges for seamless integration of electrical, plumbing, and HVAC services. The modular design allowed different areas to be constructed simultaneously, minimising disruption to ongoing operations while the corrosion-resistant steel construction eliminated maintenance concerns in the challenging industrial environment.

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Solution Benefits:

Mezzanine frames with 10-metre spans maximised storage density within height constraints
Subfloor systems elevated office areas above poor drainage conditions without extensive site preparation
Integrated deck framing provided robust loading dock platforms resistant to heavy truck traffic
Prefabricated modules reduced total installation time by 70% compared to traditional methods
Zero maintenance steel construction eliminated ongoing costs and facility downtime

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Services Rendered

Con-form Group provided complete turnkey delivery for this complex multi-level project, with specialised engineering teams designing integrated floor systems that optimised each area's specific requirements while maintaining structural continuity across the facility. Our design team developed comprehensive shop drawings coordinating the seamless integration of mezzanine, subfloor, and deck systems with existing infrastructure and new service requirements. The project included detailed scheduling to minimise operational disruption while maximising construction efficiency across multiple work zones.

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Services Included:

Multi-application engineering design optimising mezzanine, subfloor, and deck frame requirements
Integrated shop drawings coordinating structural connections and service routing across all floor systems
Specialised project management maintaining facility operations during accelerated construction timeline
Professional installation using modular assembly techniques minimising site disruption and construction time
Load testing and certification verification for industrial storage and office applications

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Building

The project was completed at a regional logistics and distribution facility in western Melbourne, Victoria.

November 3, 2025

https://con-form-group.webflow.io/products/floors/mezzanines