Our Work Archives | Hi-Level Mezzanines

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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.

Retail Mezzanine Floor For Jollyes – The Pet Food Superstore

The Client & Challenge

Hi-Level were chosen to provide the mezzanine floor element as part of a larger store refurbishment for Jollyes – The Pet Food Superstore for their branch in Tonbridge, Kent.

Jollyes are one the UK’s largest pet supplies stores. Founded in 1971, Jollyes now operates 61 chains across the country specialising in everything pets from food to accessories.

The Criteria

The client required a mezzanine to provide additional retail space whilst housing a small grooming facility ‘The Pamper & Groom Spa’. The mezzanine was also required to accommodate a new staff room and toilet facilities.

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

  • Mezzanine Floor – 11m x 12.5m
  • 2 Staircases – 1 Feature at the front and 1 Standard at the back
  • Glass Balustrade

The Solution & Result 

The project was completed over a week and finished in August 2017. All aspects of the build remained within the allocated time-frames and a high-quality finish resulting in a visually pleasing but practical new retail space for the client.

 

 

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

Three Tier Floor For Online Retail Giant ASOS

The Client & Challenge

To provide a practical solution for expanding the scope of the clients current automation and warehousing process.

The Criteria

The overall purpose of the project was to create space for several new conveyor systems, provide additional storage and overall streamline the automation process inside the clients current distribution centre. The client, a global leader in online retail maintained production during the building work to ensure demand continued to be met.

The Solution & Result 

The project was divided into three phases which involved the design and installation of a three tier mezzanine floor. The new floor was specifically designed to connect to an existing structure within the distribution centre.

  • Phase 1 – 4,500m², 3-tier, 1st level maintenance of conveyors, 2nd level storage, 3rd level Storage
  • Phase 2 – 2,000m², single tier, maintenance of conveyors
  • Phase 3 – 2,300m²,  single tier, maintenance of conveyors

The project was completed over a 4-month period, finishing in April 2017. Hi-Level were among several providers including electricians, conveyor manufacturers, fire protection services and integrators all contributing to the overall scheme.

Hi-Level project manager Adrian Williams reflects on the project, “This project was multi-phased and involved working within a busy warehouse environment. Over the 14 phases we faced considerable challenges that we ultimately overcame with careful consideration and planning. As always Health and Safety was a prime concern for us, particularly with several tradesmen working within the same area at one time. Overall, we are happy with how the project went, each main phase was completed on time and we accomplished the clients original brief of creating space for the new conveyor systems”.

Another excellent automation mezzanine floor from Hi-Level!

 

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

Double Mezzanine Floors For Bread and Pastry Specialists Celtic Bakers in London

The Client & Challenge

To design, supply and install two individual mezzanine floors for client Celtic Bakers, a North London based wholesale bakery specialising in hand-crafted breads, cakes and patisserie.

The Criteria

The client wished to increase their storage capacity whilst also separately creating a space for employees to change into their uniform before and after work.

The Solution

  • Design and build two separate floors.
  • The smallest floor measuring 5.2m x 8.5m, and designed as a changing space for bakery employees.
  • The second floor, measuring 10.95m x 13.8m, and designed as a space to hold additional storage.
  • Include bio-degradable food safe ceiling tile suitable for a bakery environment, as well as fire protection and additional staircasing.

The Result

The floor was finished on time and in budget at the beginning of 2017, resulting in another champion installation from Hi-Level!

Tom Russell Director of Celtic Bakers comments, “We are very impressed with both mezzanines, the quality is excellent, thank you to hi-level”.

 

 

 

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

Storage Floor For Popular Gift and Homeware Brand

The Challenge

We came together with STS Storage to construct large floor for London based gift and homeware brand.

The Criteria

After growth in sales the client was keen to increase their storage capacity and decided a mezzanine floor would be the most practical solution for their new warehouse.

The Solution

  • To build a mezzanine floor of 61m x 18.5 m x 3.35 m.
  • Three staircases allow for minimum congestion.
  • To include underside fire protection.
  • Link the new floor to the existing 1st floor office area.
  • Extra ancillaries include handrail and pallet gates.

The Result

In April 2016 the project was wrapped up in under 3 weeks during a ‘fast track’ installation process, and as you can see from the images we are very pleased with the end result!

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

Major Multi-National Retailer Construction

The Challenge

A multinational retailer, which designs, produces and distributes branded fashion clothing for men and women, through a network of branded retail stores in the UK, Europe and North America, wished to consolidate its warehousing operations.

In an effort to streamline its operations and bring stock control back in-house, the retailer decided to relocate the staff, resources and stock from two third party distributor sites located in East London to a third warehouse. To do so, it was necessary to maximise the internal space at the site by multi-tiering the interior space.

The Criteria

The retailer put out a tender for a two-tier mezzanine floor measuring 30 metres wide by 90 metres long which would take a load of 4.8 kN/m². This had to incorporate four staircases and seven pallet gates on the first floor, and a variable column grid to include a single column spacing which was wider than the others running through the centre of the ground floor.

This column had to provide six metres clearance for the storage and manoeuvrability of a bespoke machine. In addition, cut-outs had to be incorporated into the mezzanine floor to allow garments to be transported from the ground to the top floor and allowances made for a garment conveyor belt system.

The Solution

Hi-Levels customer invited wholesale mezzanine floor suppliers to partner with it to pitch for the warehouse contract. Because of the nature of the build, they sought a specialist provider that would be able to deliver to the prescribed specifications. It considered proposals submitted by Davicon and Hi-Level Mezzanines.

The customer selected Hi-Level based in part on its previous experience of working with us as the two have worked on a variety of projects over the past six years. “We knew from previous experience that Hi-Level could fulfil the task. We trade with them very often so we’re very relaxed about that,” said the Sales Director

Hi-Level designed a fourteen week programme of work that detailed precisely which elements of the build would be completed and when. But the overriding factor was down to Hi-Level’s competitive quote.

This was in part due to the in-house design management system Hi-Level has developed, called QD3 Pro, which automatically works out the best design for the floor given the technical and operating parameters within the design

brief. This factored in current steel prices, manufacturing and installation team availability, using a single set of data supplied by the customer at the quotation stage of the project.

Hi-Level also worked on specifications for the building regulations process. In addition to incorporating all of the specified design features, Hi-Level included top of the range products such as Class ‘O’ Spreader Flame decking which would meet the stringent fire safety and health and safety rulings imposed on the conversion by the local planning authorities. “They provided us with the necessary drawings and calculations which we in turn passed on to the customer,” says Lilley.

The Implementation

Hi-Level undertook the sourcing and manufacturing of materials plus the installation of the floor while their customer were on site project managing. There were five development phases to the mezzanine build. In addition, Hi-Level also coordinated its activities with the other building contractors. “Lighting, sprinklers, other electrical works, smoke detection systems, they were all going on at the same time. And a lot of those services ran through the mezzanine floor levels so Hi-Level released areas of the floor to them when they were completed,” explains the customers Sales Director

Throughout the building process, Hi-Level had many channels of communication with their customer allowing them to benefit from the supplier’s expertise. “They provided us with technical advice in terms of determining what the floor loading would be and how much it could take to enable the main contractor to work on the floor. And in terms of liaison on site and doing the job it was very helpful. We had a weekly chat with the guys that were on site actually building it,” Said the customer.

Plus they had regular contact with the Sales and Marketing team back at base. “The service offered was most helpful because we had one primary point of contact and our account manager gave us a consistent line of communication. We get costings via the office through him and he came to see us to check we were getting what we needed when we needed it,” they explained.

Hi-Level has also provided customer after-care, returning to site to address any issues. “If there was a sharp edge that was just an oversight, they organised the guys that installed the floors to come back in and clean-up and tidy these edges. In the last three months if there has been a specific problem or difficulty they have organised someone to come back in and take a look at it,” he praised.

Results

The mezzanine floor was completed by ourselves on budget and two weeks ahead of schedule in just under twelve weeks. This achievement illustrates the effective working relationship between Hi-Level and its customer which ultimately paid dividends for the retail customer.

Centralising the warehouse and distribution facilities has enabled the retailer to benefit from reduced overheads, economies of scale and has provided it with a single site in the UK from which to provision its network of branded retail stores and department store franchises.

The installation of the mezzanine infrastructure in the leased premises allowed the company to design the interior to its precise needs. It is now able to utilise state of the art technology, such as a conveyor and hanging garment storage system, as a result. And the site has provided it with a pleasant, efficient and profitable environment from which to coordinate UK operations.

 

 

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

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