8,000 Sq Ft Warehouse Addition

A Tale of Engineering Ingenuity and Architectural Vision

In a busy industrial hub, a bold vision took shape: expand an existing commercial facility by 8,000 square feet without disrupting daily operations. What seemed simple soon became a structural engineering challenge—an 80-foot clear span in wood construction, a feat rarely seen outside steel framing.

To achieve this, the team used a 6-ply engineered girder truss system with advanced fastening and laminating techniques for strength and stability. Beneath the floor, Creatherm insulation and PEX tubing were installed for radiant heating, powered by dual boilers delivering nearly 200,000 BTUs. Safety upgrades included a fire suppression system with a dedicated water main, meeting strict commercial building codes.

The roof posed another challenge: three intersecting planes created a water trap. Through custom roof drainage design, the space became attic storage and a mechanical room, adding functionality without sacrificing design. Underground plumbing was also prepared for a future ADA-compliant bathroom, ensuring accessibility.

This project wasn’t just an addition—it was a masterclass in structural engineering, energy-efficient construction, and future-ready design. It stands as a testament to perseverance, creativity, and the relentless pursuit of excellence in commercial building expansion.

Special Features

Commercial Building Expansion

  • Added 8,000 sq. ft. to an existing facility while keeping operations fully functional.

Structural Engineering Achievement

  • Delivered an 80-foot clear span without intermediate posts—a rare accomplishment in wood construction.

Advanced Girder Truss System

  • Installed a 6-ply engineered girder truss spanning 80 feet.
  • Utilized a complex fastening and laminating process for superior load-bearing strength.

Radiant Floor Heating Integration

  • Preserved existing hydronic heating system.
  • Added Creatherm insulation, PEX tubing, and dual boilers for enhanced energy efficiency.

Fire Safety Upgrade

  • Installed a dedicated water main to support a full fire suppression system.
  • Ensured compliance with NFPA standards.

Roof Drainage Solution

  • Engineered a custom water diversion system for three intersecting roof planes.
  • Converted the space into attic storage and a mechanical room.

Accessibility Improvements

  • Prepared underground plumbing for a future ADA-compliant bathroom at work level.

Business Continuity

  • Maintained full operational functionality throughout the construction process.

Key Project Stats

Type - Warehouse Addition

Location - Grabill, Indiana

Completion Date - November 2025

Square Feet
0 k

80ft Clear Span

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