Are you planning to construct a building? Whether it’s a warehouse, production facility, or sports building, the entire process requires proper preparation, knowledge of procedures, and good organization. If this is your first such investment, you might feel overwhelmed by the number of decisions to make. That’s why we’ve prepared a practical guide to help you understand the step-by-step process of building a hall and what to focus on to avoid potential problems..

Needs analysis and project preparation

The first step in constructing a building is defining its purpose. Will it be a warehouse, a production site, or perhaps a sports facility?

This will determine several construction aspects, such as:

• The size of the building,
• Types of materials used,
• Layout of rooms and installations,
• Additional equipment (e.g., ventilation, heating, or cooling systems).

At this stage, it’s worth seeking help from architects and designers who can create a project tailored to your needs while meeting technical and legal requirements. Remember that the building must comply with local zoning plans and construction standards.

Obtaining necessary permits

Constructing a building requires notifying the authorities or obtaining a building permit. For this, you’ll need to submit:

• A construction project,
• Documents confirming ownership of the land,
• Geotechnical opinions about the soil,
• Other required attachments (e.g., approvals from utility providers).

Getting a permit can take several weeks, so it’s wise to plan this stage well in advance. If the formalities seem overwhelming, consult a company specializing in comprehensive project management. We work with partners who can handle permit applications and the necessary documentation on your behalf.

Site preparation

Before construction begins, the site must be properly prepared. This includes:

• Leveling the ground,
• Removing vegetation, rocks, and other obstacles,
• Conducting soil tests and reinforcing the foundation if needed,
• Preparing utility connections (water, electricity, gas).

A well-prepared site is key to a smooth construction process.

Foundation construction

Foundations are the cornerstone of any building, providing structural stability. Depending on the project, different types of foundations may be used, such as:

• Slab foundations,
• Footings,
• Strip foundations.

This stage involves earthworks like excavation and laying the foundation.

Construction of the framework

Once the foundations are complete, the next step is erecting the load-bearing structure. If you’ve chosen our THORSTEEL steel buildings, the components are fully prefabricated, significantly speeding up the process. In just a few days, the building begins to take shape.

Construction starts with site measurements, followed by anchoring. In most bulding types, the columns are installed first, then the roof structure. Depending on the building size, we use diesel lifts, telescopic handlers, cranes, or other equipment suited to the location and specific construction type.

Wall and roof installation

After the framework is erected, walls and the roof are installed using materials like:

• Sandwich panels,
• Trapezoidal metal sheets,
• PVC materials.

Additional equipment is also installed, such as:

• Windows,
• Doors,
• Gates,
• Skylights,
• Gutters,
• Flashings.

Technical installations

At this stage, the building needs to be equipped with selected systems to ensure its functionality. The most important installations include:

• Electrical systems,
• Ventilation and air conditioning systems,
• Water and sewage systems,
• Fire protection systems,
• Any specific technological systems (e.g., for production).

Well-planned installations ensure the building’s usability for years to come.

Technical inspections and final formalities

Once construction is complete, technical inspections must be conducted to confirm compliance with the project and applicable standards. After obtaining all the necessary documents, you can officially start using your new building.

Summary

Constructing a building is a significant undertaking, but with proper planning and cooperation with the right specialists, you can navigate the process without major issues. It’s essential to define your needs clearly at the beginning and involve professionals who can assist at every stage—from design to final inspections.

If you have any questions or need support with your building construction project, feel free to contact us. Your building can be built faster and more efficiently than you might think!

Fire protection for the structure and cladding of a steel building is crucial to ensuring the safety and durability of the building in the event of a fire. Effective protection of the building’s structure from fire not only prevents rapid fire spread but also provides sufficient evacuation time and minimizes damage.

Fire safety is based on several fire protection aspects: fire reaction class, fire resistance, and smoke-tightness of materials and structures.

Fire reaction class

The fire reaction class defines how a material reacts to fire—whether it ignites easily, contributes to fire and smoke spread, and how quickly it burns. The classification of building materials according to fire reaction is determined by the EN 13501-1 standard, which includes Euroclass designations ranging from:

• A1 – Non-combustible materials,
• F – Highly flammable materials.

Each class corresponds to a different level of combustibility, as well as the emission of smoke and flaming droplets.

Fire resistance

Fire resistance refers to the ability of a structure or material to maintain its load-bearing and protective functions for a specified period during a fire. Fire resistance ratings are indicated by the letters REI followed by the number of minutes (e.g., R30, R60, R120), where:

• R – Fire load-bearing capacity: how long the structure retains its load-bearing properties during a fire.
• E – Fire integrity: whether the structure prevents flames and hot gases from penetrating.
• I – Fire insulation: the structure’s ability to limit heat transfer.

Smoke-tightness

Smoke-tightness refers to the ability of materials and structural elements to prevent the spread of smoke during a fire. Smoke poses one of the most significant dangers during a fire as it contains toxic substances that can threaten human health and life.

Materials are also categorized based on smoke emission (e.g., s1 – minimal emission, s2 – moderate emission, s3 – high emission) and the release of flaming droplets (d0 – no flaming droplets, d1 – few flaming droplets, d2 – significant flaming droplets).

Fire protection for steel structures

To ensure fire safety, we use intumescent paints that create an insulating protective layer when exposed to high temperatures. The benefits of these paints include easy application, aesthetic finishes, and compatibility with various types of buildings.

When exposed to heat, these paints expand and form a thick protective layer that insulates the steel, slowing its heating. This prolongs the mechanical integrity of the steel, allowing more time for safe evacuation and firefighting efforts.

Sandwich panels and fire protection

Sandwich panels are a popular building material, especially for structures such as steel buildings, warehouses, and industrial buildings. Their lightweight design, quick installation, and excellent insulation properties make them a favorite choice across many industries. However, due to their specific characteristics, fire protection for sandwich panels must be addressed at the building design stage.

Choosing the right insulation core, adhering to regulations, and implementing additional protections help minimize fire risk and safeguard both people and property.

Key factors in fire protection for sandwich panels

Insulation core

• Polyurethane Foam (PUR/PIR):
  • PUR is flammable and may emit toxic smoke when burned. PIR, a modified version of PUR, offers improved fire resistance but still falls short of mineral wool.
• Mineral Wool:
  • A non-combustible material that provides the highest level of fire protection. Panels with mineral wool cores are used in buildings requiring high fire resistance ratings.

Tailored solutions for every building

Each building requires an individual approach. Consult with us to choose the solution that best meets legal requirements and the specific needs of your structure. This ensures your building will not only be functional but, above all, safe.

The cost of constructing such a facility depends on numerous factors, including the purpose of the building, its location, size, materials used, and potential fire protection requirements.

Factors influencing the cost of a steel building:

1. Type and purpose of the building

The cost of constructing a warehouses, especially “cold warehouses,” is significantly lower compared to production buildings, which typically require greater insulation or fire protection measures. Therefore, multifunctional industrial buildings can be several times more expensive than storage halls.

2. Location

Costs may vary significantly depending on whether the building is built in a city or a rural area. Factors such as access to utilities, the number of permits required, and the density of surrounding buildings influence costs. Local soil conditions also affect expenses due to the complexity of earthworks and foundation construction.

3. Size of the building

The size of the building is one of the primary cost determinants. Larger buildings result in higher overall project costs; however, the price per square meter typically decreases with increased surface area. This is because fixed costs, such as crane mobilization, machinery transport, and technical design, are distributed over a larger area.

4. Type of structure

Steel structures are highly popular due to their affordability and faster construction compared to concrete alternatives. Options include various frame types, such as welded frames, trusses, or frames made of hot-rolled profiles (mainly I-beams). By analyzing span, height, and load requirements, we always select the most economical design for the client.

5. Installations and equipment

The amount of required installations and additional equipment depends on the building’s purpose. A basic warehouse for bulk materials or floor-stored goods may only need one gate, adequate access and emergency doors, and a lighting system. These costs are relatively low compared to the overall budget.

However, more complex buildings, such as production facilities, require extensive installations, including electrical systems, fire protection, plumbing, ventilation, and heating. Additional requirements, such as elevators, ramps, skylights, or windows, may also increase costs.

6. Fire protection and safety standards

The location of the building relative to nearby buildings, the number of employees, or the type of stored materials may necessitate additional fire safety measures. While a standard steel building is inherently non-combustible, additional systems such as sprinklers, smoke ventilation, or fire-resistant coatings may be required to meet specific safety regulations.

7. Finishing and Add-Ons

After the building is constructed, additional features such as exterior lighting, security camera systems, fire signage, company logos, or even advertising banners are often added. These should also be accounted for in the budget.

Summary

As shown, the cost of constructing a building can vary significantly based on the factors listed above. The base price of a warehouse measuring approximately 1,000 square meters can start as low as 400 PLN/m². However, this does not include costs for ground preparation, legal and construction formalities, or additional installations.

A comparable insulated industrial building costs closer to 1,000 PLN/m², covering the steel structure, cladding, joinery, delivery, and assembly. Including all the elements involved in constructing an industrial facility—from earthworks to all necessary installations—the total project budget can range from 1,000 PLN to 4,500 PLN per square meter.

We encourage you to use our contact form or reach out via phone or email for a free quote and technical consultation regarding your hall project.

Constructing a steel building is not just an investment; it’s a process that requires careful planning. Regardless of your industry, it’s essential to focus on several key aspects to select a solution that best meets your expectations. Here are practical tips to help you make the right choice.

Define the purpose of the building

The first step is determining what the building will be used for. Key questions to ask yourself include:

• What will be the primary function of the building – a warehouse, production facility, sports venue, or logistics center?
• What features are most important to you? For example: proper thermal insulation, ample internal space, or the ability to expand in the future.
• What technical requirements need to be met, such as height, load capacity, or access to technical installations?

The more specifically you define your needs, the easier it will be to customize the building design to your expectations.

Choose the right construction technology

The choice of construction technology should depend on your requirements, budget, and the time you can allocate for the project.

Our solutions include:

1. ThorSteel buildings – Durable and quick to assemble, these modular steel buildings are versatile enough to serve as industrial, warehouse, office, or even sports facilities. 

   Features:

   • • Flexible configurations
     • Extreme snow load capacity – up to 700 kg/m²
     • Nearly unlimited span and height options
     • Multi-story buildings
     • Skylights and smoke vent options available 
2. Aluminium temporary buildings – A quick and economical solution using prefabricated elements designed with Thorflex Air or Thorflex technology.
   

   ThorFlex Air:

   • Ideal for industry and sports
   • Lightweight PVC pneumatic roofs
   • Rapid assembly – up to 1,000 m² in just eight hours
   • Innovative aluminum structures – no cranes needed
   • Interchangeable wall coverings (PVC, trapezoidal sheet, ABS panels, glass facades, sandwich panels)
   • Modular components for easy resizing

   ThorFlex:

   • Perfect for events
   • Suitable for self-assembly

Specify the building dimensions

Properly planned dimensions ensure that the building is functional both now and in the future. Consider the following:

• How much space do you need for your activities or storage?
• Should the building allow for easy future expansion?
• What minimum technical dimensions are required, such as height for large vehicles?

Assess to the construction cite

Not all land is immediately suitable for construction. Ensure the following:

• The plot is prepared – the ground is level, stable, and easily accessible.
• Utilities like water, electricity, and sewage are available.
• The location suits your business needs – proximity to transport routes is crucial for logistics warehouses.

If additional ground preparation is needed, such as soil reinforcement, factor this into your schedule and budget.

Customize the building equipment to your needs

The functionality of a building depends on more than just the structure – equipment is equally important. Pay attention to the following details:

• Insulation – thermal and acoustic, suited to internal conditions.
• Doors, gates, and windows – their placement and specifications should align with your operations.
• Lighting – both natural (e.g., skylights) and artificial.
• Technical installations – such as ventilation, air conditioning, fire safety systems, or production lines.

Plan your budget and timeline

Constructing a building requires thorough financial planning. When selecting a solution, consider:

• Construction costs
• Operating costs – insulation and energy-efficient solutions can reduce maintenance expenses.
• Timeframe – our prefabricated technologies enable fast production and assembly, critical if you’re working on a tight schedule.

Remember, opting for cheap solutions may lead to higher long-term costs. Choose proven technologies and materials for the best value.

Work with an experienced contractor

A reliable contractor is the key to success. When choosing a company to construct your building, consider:

• Their experience with similar projects.
• Reviews and feedback from other clients.

Summary

Choosing a building tailored to your needs involves careful consideration of many aspects – from its purpose and construction technology to location and equipment. The key to success lies in clearly defining your expectations and working with experienced specialists.

An appropriately designed and constructed building will not only meet your requirements but will also serve as a durable and functional investment for years to come. If you have any questions or need assistance selecting the perfect building, reach out to us, and we’ll help bring your vision to life.

Whether constructing either a temporary or permanent structure— it is a strategic investment that requires careful planning and compliance with UK planning and building regulations. Understanding when planning permission is required and what documentation is involved can streamline your construction process and avoid delays.

Do You Need Planning Permission?

In the UK, planning permission for steel buildings is typically required if the structure alters the external appearance of a site or is intended as a permanent building. Certain temporary steel buildings, such as portable storage units or site cabins, may fall under Permitted Development Rights, especially in agricultural or industrial contexts. Always confirm with your Local Planning Authority (LPA) to ensure compliance.

Key Steps in the UK Planning Process

1. Design and Prepare Your Planning Application

Architectural drawings must detail the proposed steel building’s layout, elevation, dimensions, and intended use. These designs should adhere to UK Building Regulations, covering fire safety, structural performance, and accessibility.

2. Conduct Site and Environmental Assessments

Depending on the building type, land use, and location, you may need:

• Geotechnical surveys for foundation design
• Flood risk or biodiversity impact assessments
• Noise and traffic studies for permanent steel buildings used commercially or publicly

3. Consult Local Planning Policies

Check your LPA’s Local Development Plan to ensure your project meets local zoning and land-use criteria. A Design & Access Statement will help justify the development’s scale, appearance, and impact on surroundings.

4. Submit the Application via the Planning Portal

You’ll need to include:

• Site plans and elevations
• Ownership certificates
• Any necessary supporting documents for temporary or permanent steel buildings
• Payment of the applicable planning fee

5. Public Consultation and Approval

Your application may be open to public comment. Decisions generally take 8 to 13 weeks depending on complexity, especially for large steel structures or long-term installations.

Post-Approval: Building Regulations for Steel Buildings

Once planning permission is granted, all steel buildings—whether temporary or permanent—must meet Building Regulations Approval. These regulations ensure the structure is safe, energy-efficient, and suitable for its intended use.

• Notify your Building Control Body (local authority or approved inspector) at least two working days before construction starts.
• Compliance is particularly crucial for permanent steel buildings, which must account for thermal performance, fire resistance, and structural load-bearing criteria.

Professional Support for Smooth Delivery

From navigating planning permission for temporary or steel buildings to ensuring full regulatory compliance for permanent installations, professional guidance makes all the difference. With Thorspan qualified architects, engineers, and planning consultants to help submit robust applications and deliver high-quality outcomes.

Are you planning to set up a warehouse or optimize space in an existing facility? One of the most critical components of any warehouse is the racking system. It determines how much inventory you can store, how quickly you can access it, and whether your logistics will run smoothly without interruptions.

But how do you choose the right type of warehouse rack? Not all systems are the same, and the choice depends on the type of goods, available space, and the operational style of your warehouse. So, what are the most popular types of racks, and how are they used?

Pallet Racks – Perfect for heavy and large goods

If your warehouse handles goods on pallets, pallet racks are a must-have. They are designed to provide stable and convenient storage for pallets of various sizes. Depending on your needs, you can choose:

• Selective Pallet Racks – A classic choice, ideal for easy access to every pallet. These are perfect for warehouses with high product turnover.
• Drive-In Racks – The best option when you need to maximize available space. Pallets are stored one behind the other, enabling storage of large quantities of low-turnover goods.
• Flow Racks – Equipped with roller systems that allow pallets to move toward the picking side automatically.

Pallet racks are ideal for logistics centers, production facilities, and wholesale warehouses, where large quantities of palletized goods are stored.

Shelving Racks – For small items and manual picking

Is your warehouse filled with smaller items? Shelving racks are a versatile solution suitable for various industries, from e-commerce to brick-and-mortar stores.

• Standard Shelving Racks – Perfect for manual order picking. Their simple design and adjustable shelves ensure convenience.
• Adjustable-Height Shelving – Adaptable to the dimensions of stored items, maximizing the use of available space.

Shelving racks are an excellent choice for e-commerce warehouses, archives, and the automotive industry, where many small items need organized storage.

Cantilever Racks – Essential for long items

If your warehouse stores long and bulky items, such as pipes, beams, or boards, cantilever racks are the solution you need. With an open structure and cantilever arms, these racks make loading and retrieving products – even with unusual dimensions – straightforward.

Cantilever racks are perfect for construction companies, industrial material warehouses, and woodworking shops.

Mobile Racks – Maximum space efficiency

Have limited warehouse space? Opt for mobile racks! Mounted on rails or wheels, these racks can be moved to create access aisles only where needed, utilizing space to its fullest.

This is an excellent solution for archives, pharmaceutical warehouses, and small warehouses in the food industry.

High-Density Storage Racks – Maximize vertical space

No room to expand your warehouse horizontally? Look upward! High-density storage racks enable the use of the entire height of your warehouse. These racks are accessed using forklifts or automated systems.

This solution is ideal for large logistics warehouses and distribution centers where maximum storage capacity is crucial.

Automated Racking Systems – The future of warehousing

Dreaming of full automation? Automated racking systems work seamlessly with warehouse management systems, robots, and sorters, enabling quick and accurate order picking. This solution increases efficiency and eliminates human error.

Automated racks are perfect for businesses investing in modern technologies and requiring high productivity – from e-commerce to large production warehouses.

How to choose the perfect racking system?

When selecting warehouse racks, consider the following key questions:

• What do you store? Are your goods palletized, small items, or long elements?
• How much space do you have? Is your goal to maximize space utilization or ensure quick access to items? What size racks suit your space?
• What is your inventory turnover?
• Are you planning automation?
• What is the weight of your goods? What load capacity should the racking system have?

Properly chosen warehouse racks are the key to efficient space management and improved workflow organization. Remember, a good storage system is not just about capacity but also about easy access to goods, safety, and convenience for your employees.

Regardless of the storage system you choose, don’t forget about safety – regular technical inspections of the racks, proper labeling, and employee training are essential. An efficiently organized warehouse is the foundation of success in any industry!