Warehouse wall systems compared: full tilt panel, dado walls and steel cladding
By Brenscot Builders | Last reviewed September 2026
Drive through any industrial estate in South East Queensland and you will see three wall systems repeated: full-height concrete tilt panels, a concrete dado wall with metal cladding above, and a steel frame clad entirely in metal sheeting. Many buildings combine them.
None is best in every case. The right choice depends on how close the wall is to a boundary, what will happen against it inside and out, and what the building is for. This article explains each system and the National Construction Code (NCC) rule that most often decides between them.
The short answer
In a typical (Type C) warehouse, where a wall is less than 3 m from a side or rear boundary, the NCC requires it to have a fire resistance level, and a concrete panel is the most practical way to achieve that. Where walls are 3 m or more from boundaries, a Type C warehouse wall needs no fire rating and metal cladding is permitted. A concrete dado panel with cladding above is the common middle ground: concrete where forklifts and vehicles cause damage, lightweight cladding above it.
The rule that often decides: distance to the boundary
For a Type C building (which covers most single-storey warehouses), NCC 2022 Specification 5 sets the fire resistance level (FRL) of an external wall by its distance from a "fire-source feature". A fire-source feature is a side or rear boundary, the far side of an adjoining road, or another building on the same site.
| Distance from fire-source feature | Required FRL, Class 7b or 8, Type C |
|---|---|
| Less than 1.5 m | 90/90/90 |
| 1.5 m to less than 3 m | 60/60/60 |
| 3 m or more | No FRL required |
The three numbers are minutes of structural adequacy, integrity and insulation. Two related rules apply:
- Openings such as doors and windows in a wall that requires an FRL must be protected if they are less than 3 m from a side or rear boundary, or less than 6 m from another building on the site. Openings that need protection are also limited to one third of the area of that storey's external wall (clause C4D3).
- For a street frontage the distance is measured to the far side of the road, so front walls are usually more than 3 m away and are not affected. Side and rear walls are where the rules apply.
Metal cladding on steel framing does not achieve an FRL by itself. So on a tight site, where the building is pushed close to the side and rear boundaries to maximise floor area, those walls are usually concrete. On a larger site with generous setbacks, the choice is open.
In Type A and B construction (taller or larger buildings), the requirements are higher and external walls must also be non-combustible under clause C2D10. See construction Types A, B and C.
1. Full-height tilt panel
Tilt-up panels are reinforced concrete wall panels cast flat on site, usually on the building's floor slab, then lifted into position by crane and fixed to the structure. Precast panels are the same idea made in an off-site factory and delivered by truck, which limits their size. Both are designed by a structural engineer to AS 3600 (Concrete structures) and handled and erected in accordance with AS 3850 (Prefabricated concrete elements) and Queensland's Tilt-up and Pre-cast Construction Code of Practice.
Concrete walls achieve their fire resistance through thickness, cover to reinforcement and structural design under AS 3600. That is what allows them to sit on or near a boundary.
Advantages
- Can provide the FRL needed near boundaries and between tenancies
- High resistance to impact from forklifts, pallets and vehicles
- Secure, and hard to break through
- Solid, low-maintenance appearance that the SEQ market recognises and values
- Good sound reduction
Things to allow for
- Heavier walls mean larger footings, which matters on poor ground
- Panels need space and time to cast and cure on site before lifting, then a large crane for erection
- Changes after panels are cast are expensive. Door and window openings must be final before casting
- Erection is high-risk construction work that must be planned, engineered and supervised under the code of practice
- Uninsulated concrete facing the sun transmits heat. Offices behind tilt panels need lining and insulation
Best suited to: boundary walls, walls between units, multi-unit complexes, and buildings held long term or built to sell.
2. Concrete dado wall with metal cladding above
A dado wall is a concrete panel to part height, commonly somewhere around 2 to 3 m, with metal cladding on steel girts above it. The concrete takes the impacts at ground level and the cladding covers the height economically.
Advantages
- Protects the zone where damage actually occurs
- Lighter than full-height panels, so smaller footings and cranes
- Less concrete and less casting area than full tilt
- The upper cladding zone is easy to fit with louvres, translucent sheeting and penetrations
Things to allow for
- The cladding portion has no FRL of its own, so a dado wall generally cannot be used where the wall requires one
- The junction between the concrete and the cladding needs a proper flashing detail to stay weathertight
- Racking and stored goods above dado height can still damage the cladding from inside
Best suited to: walls 3 m or more from boundaries where durability at ground level matters, such as owner-occupied warehouses and workshops.
3. Steel frame with metal cladding
A steel portal frame clad in profiled metal sheeting on girts, sometimes with concrete or blockwork only around the office. The cladding is designed and installed to AS 1562.1, and the purlins and girts to AS/NZS 4600.
Advantages
- The lightest and generally the fastest system
- Lower loads on footings, which helps on poor ground
- Easy to form large openings and to extend or alter later
Things to allow for
- No FRL, so not suitable by itself for walls within 3 m of a side or rear boundary
- Low impact resistance. Internal walls need protection rails or bollards where forklifts operate
- Less secure than concrete
- In coastal areas the cladding grade must suit the environment. BlueScope's guidance (Technical Bulletin TB-1B) for COLORBOND® steel walling in standard finishes is more than 200 m from calm marine water and more than 800 m from breaking surf or exposed marine conditions, with higher-grade products required closer in
- Parts of the market see all-metal buildings as a lower grade of stock
Best suited to: larger sites with generous setbacks, cost-sensitive projects, rural and outer-industrial settings, and buildings likely to be extended.
COLORBOND® is a registered trade mark of BlueScope Steel Limited.
Which system for which situation?
| Situation | System that usually suits |
|---|---|
| Wall within 3 m of a side or rear boundary | Full-height concrete panel |
| Wall between two units or tenancies | Full-height concrete panel (fire wall) |
| Wall 3 m or more from boundaries, forklifts working against it | Dado panel with cladding above, or full tilt |
| Large site, generous setbacks, cost-sensitive | Steel frame and metal cladding, with internal protection |
| Street-facing office elevation | Concrete panels, often with glazing and feature finishes |
| Poor ground where wall weight drives footing cost | Dado or metal cladding where the fire rules allow |
Most buildings use more than one. A typical SEQ multi-unit complex has full-height tilt panels on the boundaries and between units, with a designed front elevation.
Decide the wall system with the fire strategy
The wall system, the boundary setbacks, the type of construction and the fire compartment layout all depend on each other. Choosing the wall system after the site layout has been approved often means the choice has already been made for you. We resolve them together at concept stage.
Frequently asked questions
Which is better, tilt panel or metal cladding?
It depends on the site and the use. Tilt panel is stronger, more secure and can be fire rated. Metal cladding is lighter and faster. Near boundaries the NCC usually makes the decision.
What is a dado wall?
A dado wall is a part-height concrete wall panel with lightweight metal cladding above it. It gives impact resistance at ground level without the cost and weight of a full-height concrete wall.
How close to the boundary can I build a warehouse?
The planning scheme sets minimum setbacks, which differ by council, zone and frontage. Separately, the NCC requires a Type C warehouse wall less than 3 m from a side or rear boundary to have an FRL of 60/60/60, or 90/90/90 if less than 1.5 m.
What is the difference between tilt-up and precast panels?
Tilt-up panels are cast on site and lifted into place. Precast panels are made in a factory and transported to site. The finished walls perform similarly. The choice depends on site space, programme, panel size and transport.
Are tilt panel warehouses fire rated?
A concrete panel can be designed to achieve an FRL, but it only has the rating it was designed for. The engineer designs the panel and its connections for the FRL the certifier requires.
Sources
- National Construction Code 2022, Volume One: Specification 5, Table S5C24 (Type C construction); clauses C2D10 and C4D3; Schedule 1 definition of fire-source feature, ncc.abcb.gov.au
- AS 3600 Concrete structures; AS 3850 Prefabricated concrete elements; AS 1562.1 Design and installation of sheet roof and wall cladding; AS/NZS 4600 Cold-formed steel structures
- Tilt-up and Pre-cast Construction Code of Practice 2003, Workplace Health and Safety Queensland
- BlueScope Technical Bulletin TB-1B, Steel walling products: selection guide
General information only
This article is general information based on NCC 2022 Volume One, current as at September 2026. It is not design or certification advice. Wall systems, FRLs and detailing for your building must be confirmed by your structural engineer and building certifier.
Planning an industrial warehouse?
Talk to Brenscot about your site or your requirements. Call 0480 800 077, email enquiries@brenscot.com.au, or start an enquiry. You can also read how we work.