Warehousing Archives | Hi-Level Mezzanines

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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.

 

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.

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.

Mezzanine Floor for the UK’s Largest Independent Freight Forwarder

  

The Challenge

To supply, deliver and install a single tier mezzanine floor, fire protection and staircase enclosures in a busy warehouse, the client needed minimal disruption and required the time frame to be met with no compromises.

The Criteria

Hi-Level Mezzanines and the distributor went through a rigorous tender process for the design, supply and installation of a 31,000 square foot mezzanine floor with a lo ad capacity of 6.0kN/m2 UDL. The brief set out by Davies Turner was for the full turnkey of designing a mezzanine floor, full 1 hour fire protection, lighting, smoke detection and stair enclosures .

With steel spans of 9,750mm x 7,800mm and a finished floor height of 4,150mm, this was not going to be a straight forward project. On inspection it was noted that the floor slab was incapable of taking the imposed floor loading. After carrying out a Geo Technical Investigation every column required piling. Hi-Level Mezzanines and their distributor were tasked with designing the piles and pile caps to take the imposed load of the mezzanine floor.

The Solution

Hi-Level were chosen by their distributor based on previous experience and a good working relationship -”Hi Level worked closely with me on getting the design right to make sure that when the floor arrived on site everything fitted perfectly. Our project manager was very professional throughout the installation and helped by going the extra mile to make sure the project was handed over earlier than the client anticipated.” said the Sales Director

The Result

The mezzanine floor was completed in September 2012 after 4 weeks onsite for the mezzanine floor and 3 weeks for the fire rating. The project was completed on time and within budget. The Hi-Level Project Manager said ‘This was a large turn key project which had phased hand over deadlines, this meant we needed to work efficiently to meet the installation deadlines. We are pleased to say that the client was extremely satisfied with the end result especially as we were able to complete the job in budget and provide an earlier handover time which meant there was no disruption to them”.

Director of Davies Turner & Co Ltd said “Davies Turner have been provided with a perfect solution to our additional floor space requirements delivered on time, on budget and with minimal disruption for such a large mezzanine project in a busy warehouse. Our time frame was absolutely critical”.

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.

Design And Production Of A 1400m² Floor For Export To Mauritania

The Brief

As part of a major warehouse equipment project, which one of Hi-Levels customers were installing for an international client in Africa, Hi-Level Mezzanines Ltd were required to design and supply a large two tier mezzanine floor.

The Criteria

The Client required a two tier 1400sqm mezzanine, staircases, handrail, pallet gates and landing access areas. The column grid design was very unusual so that it suited the client’s predetermined shelving layout. Planning and preparation work was involved to get the materials recorded & documented for export to Africa.

The Solution

For this complex job Hi-Level designed a 9.5kN/m2 heavy duty loading floor with joist centres at 400mm.

The Design also included 6m high continuous columns to make installation easier and avoid baseplates on intermediate levels. Extensive parts list and documentation was essential to allow smooth export to Africa.

The Result

The mezzanine floor was completed in February 2014 The project was completed on time and within budget. Hi-Level Mezzanines Project Manager said ‘This was a complex project with a tight deadline and for a client who expects the highest standards. We worked hand in hand with our distributors project team to ensure that this multi-tier structure was delivered on schedule and within budget. We received a glowing commendation from our client, and are currently working with them on their next export project.’

Managing Director of Hi-Levels distributor comments, “You can see from the photos that the structure looks excellent and the customer is very pleased. Well done, your difficult design & manufacture issues have been very successful”

 

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 were very professional, the lines of communication were excellent, especially the build team on site. If something was found to be compromising a solution was always found and mutually agreed by both parties. Out project was completed on time with no impact to regular business operations“.
VasantaGeneral Manager

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