Costco Docklands
Kingspan K-PIR Wall Panels and K-PIR ColdStore Panels enabled rapid construction and energy efficiency for an international retailer’s largest Australian warehouse. Prefabricated and modular, they reduced labor, maintained thermal performance, and supported sustainable, temperature-controlled operations across the facility.
Costco's largest Australian warehouse showcases how high-performance insulated panel systems can accelerate construction, enhance energy efficiency and deliver a durable, brand-led retail environment.
Costco has opened its largest warehouse in Australia, replacing its original Docklands facility in Melbourne. The new development strengthens the company’s local presence while expanding its operational capacity with specialist areas including a tyre centre, bakery, food court, and Australia’s largest fuel station featuring 38 filling positions. Beyond retail services, the project has also delivered significant economic impact, generating over 2,000 construction jobs and more than 300 permanent roles, reinforcing its role as a major community and employment hub.
To meet strict program and branding requirements, the design focused on speed, efficiency, and consistency. The façade features clean white and red vertical panelling aligned with the retailer’s global identity, while fast-track construction was enabled through the use of K-PIR Wall Panels. Their modular, prefabricated format allowed rapid installation, with teams achieving high daily output and reducing time spent working at height. Installed by Span Construction & Engineering, Inc, the system helped accelerate project delivery and achieve earlier weather-tight enclosure compared to traditional methods.
‘‘I believe that the long-term benefits of utilising Kingspan Panels is not just the construction, but the ongoing cost savings too. Achieving the R-Values allows us to minimise the energy bills and running costs. It’s a huge saving over the years.’’ - Roberto Gutierrez, associate director of GroupGSA, the Architects for the project.
Performance was a key driver throughout the build, particularly for temperature-controlled environments within the facility. Internally, K-PIR Coldstore Panels were used to maintain stable chilled conditions, supporting operational efficiency and food safety. With high R-values delivering strong thermal performance, the design reduces energy loss and long-term running costs. As noted by GroupGSA, investing in high-performance building systems provides ongoing operational savings, demonstrating how upfront design decisions directly influence sustainability and lifecycle efficiency.
Project Details:
Sector: Retail & Commercial
Location: Ardeer, Victoria
Architect: Group GSA
Products: K-PIR Wall Panel & K-PIR Coldstore Panel
Watch the Testimonial
Hear Roberto Gutierrez (Associate Director, GroupGSA) and Carlos Esguerra (Senior Project Manager, Span Construction) discuss how Kingspan Insulated Panels helped to efficiently construct a key Australian location for a world-renowned international retailer.