Amazon Fulfillment Centre, Kemps Creek, Australia
Background
Located in Western Sydney, the 200,000-square-meter Amazon Fulfillment Centre in Kemps Creek is one of the largest and most technologically advanced warehouses in Australia. The massive facility spans four floors and integrates a robotic storage and retrieval system, making precise environmental control essential—not only for human comfort but also to protect sensitive equipment and optimize automated operations.
To support the HVAC system in such a complex and expansive building, the project team turned to FabricAir for a custom engineered air distribution solution. Recognizing the scale and technical demands of a project involving more fabric ducting than any previous installation in Australia, the contractor saw clear merit in engaging Air Conditioning Systems (ACS) not only as the supplier but also as the installation partner.
Drawing on their long-standing collaboration with FabricAir, ACS delivered a fully engineered system tailored to meet the performance requirements of this high-precision environment—ensuring seamless execution from design to installation.
Problem
Robotic fulfillment centers present a set of HVAC challenges that go beyond those of traditional warehouses. With large open-plan areas, high ceilings, and equipment that generates heat, maintaining consistent airflow and temperature control across multiple levels is critical. Uneven air distribution can lead to hot spots, cold zones, and system inefficiencies that compromise both occupant comfort and equipment performance.
The HVAC system required:
- Precise airflow control at varying heights
- Compatibility with automation and equipment layouts
- Fast turnaround on system design, production, and installation
- Lightweight, non-corrosive materials suitable for the Australian climate
Solution
FabricAir and ACS developed a fabric ducting solution using Combi 20 and Combi 30 fabrics—materials already proven in other Amazon installations by FabricAir around the world. The team conducted detailed flow analysis to determine the appropriate design parameters that would ensure consistent air velocities across all four levels of the facility.
Working closely with Qanstruct (builder), Acor Consultants (mechanical engineer), and Fredon (contractor), the project team:
- Identified and mapped more than 6,300 linear metres of duct runs across the warehouse
- Engineered each duct segment individually to ensure performance alignment with the mechanical design
- Delivered all manufactured ducts within a 3–4 week timeframe to meet tight construction schedules
- Installed the system using FabricAir’s efficient suspension system to reduce time and complexity on site
ACS managed the entire process—from design coordination to final installation—ensuring that the solution met Amazon’s rigorous quality and delivery requirements.
Results
The final installation delivers uniform air distribution across all operational zones in the facility. Fabric ducting proved ideal for the application, offering:
- Lightweight construction that reduces load on structural components
- Even air dispersion without drafts or stagnation
- Rapid, clean installation aligned with project timelines
- Durable performance suited to the Australian climate and Amazon’s operational demands
By combining global experience with local project execution, ACS and FabricAir helped create a climate-controlled environment that enhances comfort, protects automation assets, and supports energy efficiency in one of the Southern Hemisphere’s largest fulfillment centers.
