Browns Shoes - Warehouse Expansion

The presence of a protected silver maple forest on the site restricted the project’s potential footprint. To address this challenge and meet the client’s needs, GKC proposed a two-phase project: a 36,500 sq. ft. exterior addition, combined with an interior expansion through two new mezzanine levels connected to the centre’s existing mezzanine. In total, the work increased the storage capacity from 190,000 sq. ft. to 240,000 sq. ft., representing a gain of more than 25 percent in overall area.

To transfer part of the client’s inventory into the new section of the distribution centre and begin construction of the mezzanines in the existing building, phase 1 had to be completed as quickly as possible. GKC therefore selected insulated metal panels (IMPs) for the building façades to quickly seal the building. As the borough did not permit the use of these panels for main facades, the team proposed affixing perforated aluminium panels to the PMIs to serve as a cladding finish. Their high aesthetic quality ultimately convinced the municipal authorities after sustained negotiations.

The customized graphic treatment of the panels used on the extension’s main façade significantly enhances the quality of the surrounding industrial environment and provide a positive interface with Cohen Street. They also create visual continuity with the neighbouring headquarters’ glass exterior through a gradient of diamond patterns, while anthracite grey metal panels complete the design on the other sides of the building.

Installing two new mezzanine sections in the existing building introduced structural and fire protection challenges. Supporting the mezzanines, which house an automated conveyor system, required demolishing sections of the concrete slab to pour large footings and erect concrete columns for even load distribution. The slab was scanned to avoid damaging electrical conduits, and all work took place in a strictly contained environment to prevent dust from contaminating the client’s equipment.

In addition, due to technical and budgetary constraints, GKC coordinated with the Fire Protection and Code engineers to implement various measures with the RBQ for unconventional fire protection of these two storage floor levels and to ensure their evacuation within safe timeframes.

Delays in securing multiple permits and approvals (including authorization to use IMPs, acceptance of alternative measures, and negotiations with the water department regarding a stormwater retention basin) required the team to constantly adjust schedules to ensure timely delivery. This project required precise sequencing and significant coordination,” explains Tina Smith, Project Director at GKC.