Automation Archives | Hi-Level Mezzanines

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.

Three Tier Floor For Online Retail Giant ASOS

The Client & Challenge

To provide a practical solution for expanding the scope of the client’s 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 client’s 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 client’s original brief of creating space for the new conveyor systems”.


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

Automation Mezzanine Floor For Next Retail Distribution Centre

The Client

Next is one of the UK’s best known fashion retailers. They were converting a warehouse into a new distribution centre at Wath Upon Dearne, near Rotherham.

The Project

Next contracted with one of Hi-Level’s distributors, who subsequently brought us on board as their mezzanine supplier. The distributor acted as the interface with the client, overseeing the complete design co-ordination process, while Hi-Level provided the mezzanine design and carried out the installation.

The project included a two-tier, 24,000²m mezzanine floor capable of bearing a load of 6kN/m² to support a specialist conveyor belt sortation system that transports goods around the warehouse in preparation for dispatch to stores and mail order customers.

The sortation system was installed above the mezzanine floor on all three levels, while cable trays from the external electricity supply were channelled under the floor to feed specific areas. Both requirements necessitated the use of additional joists at key sections of the floor and specialist knowledge.

The mezzanine design comprised fire protection, including staircase enclosures – The images show the scale of this floor!

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

2000m² Floor for VOW Retail

The Client & Challenge

To supply, deliver and install a single tier mezzanine floor within the ‘Goods In’ area for VOW Retail. The floor would extend from the existing mezzanine floor to the 2 hour fire wall at the opposite side of the warehouse all whilst keeping the conveyors running throughout the build period.

Hi-Level’s Project Manager commented “When I first saw the warehouse working in full flow I thought this install would be ‘challenging‘ to say the least”.

The Criteria

The customer required a single tier mezzanine floor measuring 2,023m² with a floor level of 6.5m. The floor needed to be installed directly over a working goods in /out department which would continue to run during the build. The floor was required to take a load of 5kN/m2 with back to back joists that were up-rated for conveyor loads.

The Solution

Hi-Level were chosen based on previous experience: “We used Hi Level before during an extension to our existing mezzanine floor and found them very professional“. Hi-Level planned a six week programme of work that detailed precisely which elements of the build would be completed and when. This was in part due to the in-house design management system Hi-Level has developed, called QD4 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 Vasanta at the quotation stage of the project.

The Implementation

Once both parties were happy with the programme of work, installation commenced in November 2013.

Hi-Level undertook the design, sourcing and manufacturing.

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

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What our clients say

“Hi-Level worked with Tesco on a Clothing Project and installed two 8100sqm mezzanine floors. Hi-Level delivered a smooth installation programme on time, within the agreed budget and to a very high standards.
TescoProject Manager

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