In June 2024, Xinguangzheng delivered a 50x100x8m steel structure workshop in Kampala, Uganda. Spanning 5,000 square meters, it includes a 7.5x100m mezzanine for elevated storage and oversight. The workshop features integrated steel railings and staircases on the mezzanine, built with durable galvanized steel to withstand Uganda’s equatorial humidity, heavy rains (up to 1,800mm annually), and temperatures ranging from 18°C to 30°C. It is designed to support light manufacturing, particularly garment production and related operations.
Customer Demand
The client, a Ugandan manufacturing startup in the Nakawa industrial area of Kampala, specializes in garment production. To meet growing East African trade demands under the AfCFTA, they needed to expand from a small shed to a larger, more robust workshop. Their requirements included:
- A 50x100m footprint with an 8m eave height to accommodate sewing machines, cutting tables, and other garment production equipment.
- A 7.5m-wide mezzanine spanning the full 100m length for inventory storage, such as fabric rolls, finished garments, and supervisor offices.
- Safe access via stairs and railings.
- Clear spans for efficient movement of materials and finished products.
- Corrosion-resistant cladding to combat Lake Victoria’s misty air.
The project had a tight budget of under 2.5 million USD and a strict deadline before the June dry season. Site challenges included soft red soils prone to erosion and seismic activity up to 5.5 magnitude from the Rift Valley.
After blueprint reviews and soil tests, Xinguangzheng proposed a bolted prefab steel workshop. This design integrated a multi-level mezzanine for 20% more usable space, galvanized components for 50-year durability, and modular stairs and railings compliant with Ugandan building codes.
Solutions
Xinguangzheng used Q355B portal frames with Z-purlins, tailored for Uganda’s manufacturing hubs. All components were prefabricated in a yard near Entebbe, adhering to ISO 9001 and Uganda National Bureau of Standards (UNBS) for wind (1.0 kN/m²) and seismic resistance. Shipment via Mombasa port minimized delays, while on-site bolting ensured quick assembly and seamless mezzanine integration.
Core Specifications:
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Dimensions and Layout: 50m wide x 100m long, 8m eave height, 5% roof pitch. The mezzanine (7.5x100m) is elevated at 4.5m, creating an open ground floor and a 750 sqm upper platform for storage and offices.
Structural Components:
- Frame: Q355B galvanized portal frames with bolted connections. The mezzanine is supported by secondary beams, with a load capacity of 25 kN/m² on the upper level and 40 kN/m² on the ground floor.
- Roof and Cladding: 0.7mm color-coated galvanized sheets with polyurethane insulation (R-value 3.8). Side walls use 0.5mm sheets with insect screens.
- Foundation: Isolated pile caps with embedded bolts on a 200mm reinforced slab, designed for expansive clay soils.
- Mezzanine Features: A 7.5m-wide platform with 1.1m-high steel railings (galvanized tubing, 100mm spacing) and two 3m-wide staircases with anti-slip treads and handrails.
Custom Functions:
- Access: Wide roll-up doors (6m x 6m) at both ends and emergency exits on the mezzanine with fire-rated cladding.
- Ventilation: Roof monitors and wall louvers improve airflow by 25%, with provisions for exhaust fans.
- Electrical: LED fixtures provide 300 lux on the ground floor and 250 lux on the mezzanine, with conduits for machinery hookups.
Implementation Process
The workshop was completed in three phases over four months, leveraging local labor in Kampala to save 30% on costs.
- Prefabrication (1 month): Factory cutting, galvanizing, and mock-up of the mezzanine and stair assembly, including load tests.
- Site Preparation (10 days): Pile driving and slab pouring, with drainage channels to prevent flash floods.
- Erection and Fit-Out (2 months): Portal frames were erected in 12 days, mezzanine decking and railings bolted in 10 days, and cladding completed. Stairs were installed with safety checks.
- Commissioning (1 week): The workshop was handed over in June 2024 after seismic simulations and mezzanine capacity trials.
Results
Since its launch in June 2024, the workshop has significantly boosted the client’s garment production operations:
- Productivity: The mezzanine adds 15% more storage without taking up floor space, enabling 40% faster order fulfillment for over 500 workers.
- Cost Efficiency: The total cost was 2.3 million USD, 8% under budget. The bolted design reduces maintenance costs by 25% in humid conditions.
- Resilience: The structure withstood heavy July rains with no leaks, and the railings ensure safe mezzanine use. It has a projected lifespan of 50 years.
- Sustainability: Insulated cladding reduces cooling needs by 20%, aligning with Uganda’s green manufacturing incentives.
Xinguangzheng delivers custom Metal Workshop Buildings for Ugandan industries. Contact us for your mezzanine-equipped designs.
Sarah Nakato, Production Manager: Xinguangzheng’s workshop, with its solid mezzanine and stairs, has been a lifesaver. Built tough for Kampala’s rains and delivered right on time in June 2024, it has made our lines run smoother, kept our team safer, and is already paying off big in exports!
