Our Work Archives | Hi-Level Mezzanines

Tileflair Transforms Industrial Unit into a Retail Store

The Challenge

As part of Tileflair’s ongoing plans to expand across the UK, they recently moved into an empty industrial unit in Oxford. Hi-Level were contracted by Locators once the initial shop fit-out was completed to create an additional shop floor area.

A bespoke design was required to provide a mezzanine that could support product displays and provide storage space for stock. It was particularly important to minimise the number of columns used to keep the ground floor area clear.

The Criteria

The final requirements of the project were detailed as follows:

  • 11.54×8.55m² floor size
  • 4.8kNm² point load
  • Ancillaries: feature staircase
  • Fire protection

The Solution and Result

Our expert engineers worked closely with Tileflair to understand all the unique requirements of their store. This included minimising obstructions on the underside of the floor to maximise space for product placement. The final design limited the number of columns installed whilst ensuring the mezzanine could maintain its structural integrity. In addition, we used OSB decking; a lightweight, easy-to-handle board which provides maximum strength and stability.

The aesthetic finish of the floor was equally as important to ensure it was in line with Tileflair’s brand and store presentation. Taking that into consideration, we used our feature handrail made from polished stainless steel. This is complimented by toughened glass panels, creating a contemporary, clean look.

 “We are delighted to have been a part of this fit-out project and working alongside Locators. Our team was able to overcome the challenges posed by the site and deliver an optimal solution”.

Jason Alexander – Hi-Level Project Manager

Please get in touch with our sales team if you have any questions regarding previous projects.

Leading UK Packaging Company Move into New Fulfilment Centre

The Challenge

Hi-Level partnered with a distributor to work with one of the leading packaging companies in the UK who are growing at a rapid pace into the international market. They moved into a newly built fulfilment centre in Bedfordshire, launching a next-day delivery service for hundreds of their products. Hi-Level were contracted to provide a bespoke mezzanine floor for storage and supporting conveyor systems.

One of the main challenges of the project was designing the mezzanine as the building structure evolved and ensuring seamless installation. In addition, a tight deadline was set that required us to finish the project promptly and efficiently.

The Criteria

The final requirements of the project were detailed as follows:

  • 16x35m² floor size
  • 5kN/m² point load
  • Ancillaries: 3 staircases and pallet gate
  • Fire protection

The Solution and Result

As the warehouse was undergoing various developments, our team worked closely with the client to ensure we could deliver the optimal mezzanine floor solution. We operated in a complex environment alongside other contractors installing a pallet racking system next to the mezzanine. This required a clear and concise project plan to minimise disruption to other workers and vice versa.

The floor was designed taking into consideration the addition of a conveyor system which would run through it. We also had to create adequate space for the storage of goods. Positioning of the columns was crucial as it ensured the mezzanine could confidently cope with high point loads and keep the ground floor access clear. In addition, we used our 38mm particle board as the decking option, hand railing customised per the client’s request and full fire protection. Ancillaries for the project included 3 staircases and a pallet gate to support with handling their large inventory of products.

As our client estimates further growth, we future-proofed the mezzanine design to enable additional tiers. Hi-Level were able to fulfil the project specifications within a quick turn around of three weeks, meeting our client’s timeline and budget.

“It’s always a pleasure when we can provide our client with a mezzanine floor solution to help with their challenges. Although we had to work within an evolving building structure against a short time frame, our team once again showed their ability to deliver an excellent service”.

John Davis – Hi-Level Commercial Director

Please get in touch with our sales team if you have any questions regarding previous projects.

 

Global Transport & Logistics Company Expand with New Warehouse Facility

The Challenge

Hi-Level were the selected mezzanine floor provider for a global transport and logistics company. The company recently built a new warehousing facility in Peterborough to further enhance services for their logistics division. Based on previous successful projects and our ability to execute design briefs, Butler & Willow partnered with us again to create a three-tier mezzanine area for handling goods and supporting lightweight conveyor systems. Hi-Level were faced with the challenge of providing flexible working space within a tight deadline.

The Criteria

The final requirements of the project were detailed as follows:

  • 1381m² floor area per tier (4143m² total)
  • 8kN/m² point load
  • 4 safety pallet gates per tier
  • 2 tower staircases
  • Ground floor column guard

The Solution and Result

The three floors were created to maintain their structural integrity across the entire mezzanine floor through crucial positioning of the columns. In addition, the ground floor area was kept brace free to provide maximum flexibility for storage. Ancillaries for the project included full edge protection, tower staircases for both utility and general access, as well as safety gates per tier to ensure goods could easily be moved between the mezzanine and pallet racking. As always, safety measures were taken to ensure the mezzanine was fit for purpose. Due to the busy nature of the warehouse, we installed our safety guard system to increase the level of protection for the columns upholding the mezzanine.

The build complied with the relevant building regulations and included full fire protection. Our expert team was able to execute a design which was both practical and efficient through meticulous planning and attention to detail.

We were able to finish installation within the allocated time frame of 6 weeks to the complete satisfaction of our client.

Testimonial

“Hi-Level has previously worked with our client in delivering a mezzanine solution for their warehouse operations. Our client partnering with us again is a testament to Hi-Level’s ongoing commitment to a high standard of workmanship and providing a quality service.”

Clyde Finch – Hi-Level Project Manager

Please get in touch with our sales team if you have any questions regarding previous projects.

UV Technology Experts Hanovia Maximise Warehouse for Additional Storage

The Challenge

Hi-Level worked with Hanovia UV Ltd to supply, deliver and install a single level mezzanine structure as an additional practical space to their ground floor. Our client has been at the forefront in developing and building highly efficient UV technology systems. Their operations centre in Slough had unused vertical space, thus a mezzanine was the ideal solution to help facilitate their growth and boost productivity.

Hanovia had to maintain their normal operating hours throughout the installation and a schedule had to be devised to ensure we completed the project on time with minimal disruption.

The Criteria

The final requirements of the project were detailed as follows:

  • 299m² mezzanine floor area
  • 7.5km² load bearing for storage
  • One-hour fire protection
  • LED lighting and small power

The Solution and Result

Our designers developed a bespoke mezzanine which was seamlessly integrated into Hanovia’s warehouse. A key aspect of the specification was strategically placing the columns to avoid obstruction to their existing pallet racking storage and regular operations. The 38mm particle board was used for the project, a popular choice for environments where strength and durability are essential whilst also being cost effective. Per our client’s request, the board was covered in linoleum to increase the durability of the floor, ease maintenance and improve the final aesthetic look. In addition, ancillaries for the project included a specialised pallet gate for bulky goods, general access and utility staircases and full edge protection. Such ancillaries had a blue powder coated finish to suit Hanovia’s brand colours.

We complied with Building Regulations to provide a suspending ceiling for up to one-hour fire protection. This was complimented by LED lighting on the underside for ease of use.

Hi-Level’s close-knit team of experts successfully created a bespoke design, unique to Hanovia’s premises and specific requirements. Hanovia requested a quick turnover which was met from point of order to installation, ensuring minimal disruption to their operations. As a result, we were pleased to have completed the project promptly to our client’s absolute satisfaction.

Hi-Level Project Manager Comments

“This project was a testament to Hi-Level’s ongoing commitment to a high standard of workmanship and providing a quality service. Our team worked closely with our client to deliver a future-proof solution to their space challenges.”

Adrian Williams – Hi-Level Project Manager

For more information on any of our projects, call our sales team today.

International Electronics Supplier Expands Operations to New Heights

The Challenge

We were the selected mezzanine floor provider for an international supplier and manufacturer in the electronics industry. As the company continues to dominate their market, they required a mezzanine floor area to elevate their operations to new heights in Warrington.

Maintaining productivity levels was essential to the client and their ongoing work during warehouse operating hours. In addition, the existing shelving units could not be disturbed or dismantled during the installation process.

The Criteria

The final requirements of the project were detailed as follows:

  • 138m² mezzanine floor area
  • 4.8kN/m² load bearing for storage
  • Minimal disruption to productivity
  • Safety pallet gates for handling heavy goods
  • Custom colour to match corporate identity

The Solution and Result

Our engineers worked closely with our client to provide a bespoke mezzanine that could comfortably sit above their existing shelving units to create a new functional loading area. Using our standard 38mm particle board, our floor was the perfect affordable and practical solution for their storage plans.  As always, we provided full customised options to the industrial general access staircase, edge-protection system and pallet gates for all their heavy loading. Following our client’s request, each of the ancillaries were finished in a vibrant yellow powder coating with full gloss retention.

The project was expertly wrapped up in two days as our installers worked alongside the client’s team during their operating hours. As a result of close communication throughout the project, we were able to fulfil their specifications to our continuous high-quality standards within the allocated time.

Client Operations Manager Comments

“Hi-Level were very efficient with little disruption to the warehouse working practices”

Please get in touch with our sales team if you have any questions regarding previous projects.

 

Team BRIT Expands Workshop Space with Mezzanine Flooring

The Challenge

A branch of the charity Kart Force, Team BRIT inspires people with disabilities, PTSD and mental health issues by demonstrating what can be achieved through motor-sport.  Team BRIT aims to be the first ever all-disabled team to take part in the world famous Le Mans 24hr endurance race.

The team uses world-leading hand control technology to allow its disabled drivers to compete equally with able-bodied drivers.  It aims to revolutionise the motor-sport industry and to show injured military personnel & disabled people that they can achieve what they never thought possible.

As Team BRIT grow and undertake more exciting challenges, they were beginning to reach their site’s capacity and wanted to utilise their vertical space. Hi- Level were approached and we were delighted to help optimise their current workshop with a mezzanine area for additional storage.

The Criteria

Team BRIT required a mezzanine to be seamlessly integrated in their current workshop. The new floor space had to enable shelving and the storage of various car parts.

The final requirements of the project were detailed as follows:

  • 12.3m x 6.6.m Mezzanine Floor Area
  • Clear Ground Floor Staircase Access
  • High Point Loads

The Solution and Result

The mezzanine extension was a successful one-day installation, causing minimal disruption to Team BRIT. The flooring consisted of our quality particle board, a versatile decking suitable for most storage applications. This was complemented by a powder coated staircase for a highly durable, aesthetic finish and equipped with handrails for full functional use in the workshop.

By working closely with our client in the details and specifications of the design, we were able to deliver the perfect solution in doubling their floor space and providing them operational access on both the ground floor and the mezzanine.We ensured the installation was completed securely as Team BRIT carried out further refurbishment in their workshop.

We were pleased to have provided a mezzanine floor to the complete satisfaction of Team BRIT and fulfil all their specifications.

Dave Player, Team BRIT CEO & Founder Comments:

“Team BRIT took another major step forward by securing our own workshop, rather than paying companies to provide us with their services.  As we are growing so fast, we needed to plan for when we take on our next race car, which requires more workshop space.  This is where Hi-Level came to our rescue by offering their expertise and building the extra floor space we need.  We are totally chuffed with our new mezzanine addition to our garage! It looks amazing and has created so much extra floor space. We’re very thankful to Hi-Level who expertly installed this in a flash. Thank you very much – we have room to grow and to a bigger and better Team BRIT now!”

 

Please get in touch with our sales team for more information regarding any of our projects.

 

 

Concrete Composite Decked Mezzanine for Jaguar Land Rover with Martins Fixings

The Challenge

Hi-Level worked with Martins Fixings to provide a mezzanine floor installation for Jaguar Land Rover as they expand their pre-production line in Coventry.

A bespoke design was required to provide a mezzanine over a single level that was future proof to produce additional storage for the parts department. It was particularly important to provide clear areas on the ground floor so that production equipment could be incorporated and positioned where required.

Hi-Level’s creative approach and previous success in providing mezzanine floors to fulfil highly specific requirements were the leading factors for undertaking such a project.

The Criteria

The final requirements of the project were detailed as follows:

  • Decking to take very high point loads across the entire area
  • Clear areas to the ground floor for maximum flexibility
  • Positioned on the existing low capacity floor slab

The Solution and Result

Polished concrete composite decking was incorporated into a wide span steelwork structure. This highly durable product is extremely strong and robust, incorporating a concrete topping cast onto metal decking. Additional qualities such as water resistance, sound proof and fire protection made it perfectly suited for the project. The decking created a multipurpose mezzanine area that could confidently cope with the high point loads of their various equipment. The wide span structure beneath created a workspace comparatively free from vertical obstructions giving maximum flexibility to JLR for further storage below.

The wide spans resulted in markedly fewer ground floor columns than typical which in turn generated higher than usual column loads for the existing slab to cope with. Hi-Level’s solution was to design and supply pile foundations beneath the column baseplates creating a seamless integration into the existing slab. JLR were able to maintain their productivity levels and use the building throughout the project.

Hi-Level installers worked as part of an overall team in a fully programmed project involving many other trades to deliver the final product on time and fully fitted for immediate occupation by JLR. The works were integrated into a closely controlled working schedule within a fully functioning building which necessitated Hi-Level working out of hours and providing an accelerated build with no disruption to JLR’s day-to-day activities.

Adrian Williams, Hi-Level Project Manager Comments:

“This was a project where Hi-Level’s expert engineers produced a design that was greatly beneficial to JLR’s productivity and overall logistical performance. We ensured that we met all the specific requirements Jaguar Land Rover had set out with minimal disruption to their operations. Both Hi-Level and our client were delighted with the finished product”

 

Please get in touch with our sales team if you have any questions regarding previous projects.

Three Mezzanine Floors for Alliance Healthcare With Bowmer & Kirkland

The Client & Challenge

Hi-Level were delighted to have been successfully chosen to design, build and install three individual mezzanine floors for pharmaceutical organisation, Alliance Healthcare in Preston, Lancashire. This particular build was conducted through construction services group, Bowmer & Kirkland who Hi-Level have worked with previously on several other projects.

The Criteria

The project was divided into three individual mezzanine floors designed to sit seamlessly alongside an existing structure within the client’s warehouse.

The floor specifications were as follows:

  • Floor 1 – 700 sqm 
  • Floor 2 – 300 sqm 
  • Floor 3 – 100 sqm 

The mezzanines were part of an overall reworking of the clients materials handling program. As such, they were designed to be uniquely shaped with specific steel-work arrangements to provide support over an existing conveyor system. In addition to the floors, Hi-Level supplied fire rated columns with protection.

The Solution & Result 

The mezzanines were built out of hours to ensure no disruption to the warehouse operations workers during the daytime. Shortly after the project finished, Hi-Level designed and installed a supplementary external galvanised staircase.

As always, Hi-Level’s superior build quality and attentive installation management made for another successful project – leaving both parties happy!

Take a look at the finished product below:

Please get in touch with our sales team if you have any questions regarding previous projects.

Warehouse Mezzanine Floor For Bullen Healthcare

The Client & Challenge

Bullen Healthcare a family owned medical supply company approached Hi-Level last year to design and install a mezzanine floor within their Liverpool warehouse.

The Criteria

The client required the mezzanine to be built above an existing shelving layout within the warehouse, with minimal disruption to the ongoing work during warehouse operating hours.

The final specfications of the mezzanine floor project were detailed as follows:

  • 700 sq metre mezzanine floor
  • Fully fire rated
  • LED lighting underneath the mezzanine structure

The Solution & Result 

In order to cause no disruption to the warehouse workers normal routine the entire build was conducted during night-time hours. As a result the project was completed swiftly over a 6 week period.

Adrian Williams, Hi-Level Operations Manager comments: “The floor construction for Bullen Healthcare ran smoothly from start to finish, with the install completed overnight no disruption was caused to the clients regular picking and packing routine, a big accomplishment for a live operating warehouse. Hi-Level and the client are extremely happy the finished mezzanine floor”.

Take a look at the finished product below:

Please get in touch with our sales team if you have any questions regarding previous projects.

Logistics Distribution Centre Mezzanine Floor With Magrock

The Client & Challenge

Building contractor Magrock invited Hi-Level to tender for this particular floor after being dissatisfied with a previous mezzanine floor supplier, who failed to meet their requirements. The end client, Clipper Logistics are a UK leading logistics solutions company.

The Criteria

Clipper Logistics required the mezzanine floor within a new distribution centre for one of their clients.

The final requirements of the project were detailed as follows:

  • Mezzanine Floor – 34m x 12m
  • Featuring 1 extra width general access staircase and 1 galvanised utility escape staircase
  • Side mounted handrail painted to the clients specification
  • Chamfered and countersunk fixing in base plates

The Solution & Result 

Despite delivery and installation being on a tight timescale, the build program was completed over a period of 9 days, finishing in December 2017.

“Hi level were appointed to carry out a single story extension within a live warehouse environment.  The project was delivered on time and to a high standard throughout.  This was our first project with Hi level and we would not hesitate using them again as their attitude from tendering the project through to completing the works was second to none.  Thank you to everyone involved” David Brewer, Construction Director – Magrock

Take a look at the finished product below:

Please get in touch with our sales team if you have any questions regarding previous projects.

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“The Hi-Level team have been helpful and efficient on this project – they have delivered a 1st class installation”.
Acro EnvironmentalProject Manager

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