Completion Date
June 2026
Duration
17 Weeks (Design + Installation)
Standards
FM Global Datasheet 8-34
Sprinkler Heads Installed
400+
Project Overview
Hall & Kay was appointed to design and install a sprinkler protection solution for a new automated storage system (Autostore) within the logistics warehouse of a prestigious UK-based manufacturing company.
H&K had originally installed the warehouse roof sprinkler system 12 months prior, and this project was an add on element looking at Automated storage using Autostore.
The Challenge
The project presented a series of complex technical and coordination challenges within the facility due the introduction of a top loading ASRS system by “ Autostore” which significantly changed the profile for the existing Sprinkler systems and this also needed supplementary measures of a requirement for a new ceiling to be installed above the Autostore, all at an extremely fast pace.
The warehouse’s existing roof height exceeded the allowable limits set out in Table 44 of FM Global Datasheet 8-34, meaning a conventional sprinkler approach could not be adopted. To overcome this, a more complex solution involving the installation of a new ceiling would be required. This introduced additional layers of design, coordination, and program management, as the project scope extended beyond a standard sprinkler installation to include full ceiling construction.
Further complexity arose at the outset when the client requested that Hall & Kay take on the dual role of Principal Contractor and Principal Designer. As this is not permissible, an alternative arrangement had to be established, requiring careful management to ensure compliance while maintaining a streamlined delivery approach for the client.
Our Solution
To address these challenges, Hall & Kay delivered a fully coordinated, end-to-end solution:
- Hybrid Sprinkler Design:
A bespoke approach was developed using FM Global Datasheet 8-34, ensuring appropriate protection for the ASRS despite the absence of LPC guidance. - New Ceiling Installation:
We provided and installed a suspended ceiling which was installed at 7.6 meters to comply with FM height requirements. Sprinkler heads were installed through the ceiling tiles to maintain effective coverage. - Principal Contractor Role:
H&K took on the role of Principal Contractor, managing all aspects of delivery. A dedicated Principal Designer was appointed on behalf of the client, ensuring full compliance while relieving the client of project coordination responsibilities. - Innovative Lighting Solution:
Clear Perspex ceiling panels were integrated into the design to allow natural light penetration from above. This eliminated the need for additional emergency lighting below the ceiling, resulting in cost savings and simplified installation.
The project was delivered within the client’s strict programme, with H&K accelerating completion and finishing two weeks ahead of schedule.
Results
- Fully compliant sprinkler protection for ASRS environment
- Seamless integration of ceiling and fire protection systems
- Programme reduced by 2 weeks
- Cost savings achieved through innovative lighting approach
- Strengthened client relationship through turnkey delivery
The project represents a highly successful collaboration, demonstrating Hall & Kay’s ability to adapt to evolving fire protection requirements, manage complex multidisciplinary scopes, and deliver innovative, compliant solutions.
The installation now enables the safe implementation of a full Autostore system beneath the newly constructed ceiling.
