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.
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.
Mezzanine Floor Installed For Major Logistics Company
The Technology Division of a major logistics company based in Milton Keynes took the decision to close a 200,000 ft² warehouse facility, from which it had been running an important software supplier contract.
It needed to relocate this part of the business to another existing technology distribution facility in the same town. In order to accommodate the increased business, this facility needed to increase its capacity substantially.
When the logistics company weighed up the options it became clear that a mezzanine floor within the existing facility would: provide the capacity required, would be cost-effective to install, would improve the productivity of the site and, importantly, the upgraded facilities could be brought on-stream very quickly.
The real challenge however, was to accomplish both the installation of the new mezzanine and the relocation of the warehouse stock to the new facility without disrupting either the existing warehouse operation or the service levels agreed under the software company’s contract.
It was decided to install a two-tier mezzanine to allow for further expansion in the future. This would provide an additional 37,000 ft² of floor area with a loading rating of 5.0kN/m² allowing for storage and light industrial use.
The floors had to incorporate seven staircases and six pallet gates together with full safety protection systems. Before the final specification could be agreed the concrete floor needed to be tested for strength and suitability and then detailed plans would be needed for Building Regulations approval.
In addition to the mezzanine, the main contractor was to be responsible for the efficient installation of all other services including ducting, fresh air, all electrics, fabrication of offices and a Board Room, 560 bays of shelving and fire protection including a sprinkler system.
The timescale was very tight for a project of this complexity but it was driven by the need to close the existing warehouse facility.
The logistics company invited three businesses to tender for the project. Given the complexity of the project and the very tight deadline, the customer needed to partner with a mezzanine manufacturing company that was technically competent, reliable and able to react very quickly.
A Senior Account Manager at Hi-Levels Distributor said, “In the end it wasn’t a difficult decision to go with Hi-Level. We’ve worked successfully with them in the past so we knew we could rely on them to provide the design and technical support we needed. And, as a leading manufacturer, we also knew that they could handle a project of this scale.”
Hi-Level and their Distributor were ultimately successful in the selection process due to their proactive approach, innovative thinking and flexibility. “It was their willingness to engage with us to identify the project requirements and to make positive suggestions which finally convinced us that they were the right partner for this critical project,” comments the logistics company’s Project Manager.
By the time the selection process had been completed and the necessary guarantees and warranties put in place for the landlord, the maximum site time available before the immovable deadline was just 16 weeks.
In addition to the original project requirements, tests on the concrete floor revealed the need to strengthen it considerably to take the weight of the double floor mezzanine concentrated on columns spaced at 6m intervals.
This meant that 16m piles beneath each column were needed to take the weight of the mezzanine and all this additional work had to be completed within the 16 week period.
Using its unique QD3 Pro mezzanine design management system, Hi-Level developed a programme of work that detailed precisely which elements of the build would be completed by when, and co-ordinated this plan to ensure that the work could be done without undue disruption to the warehouse, which needed to continue normal operations during the construction of the new mezzanine.
Due to the very tight deadlines, channels of communication were kept short with senior level, decision-maker contacts established to ensure that complex issues were identified and dealt with without delay.
Hi-Level took responsibility for producing detailed plans for the mezzanine and then handled all Building Regulations applications and approvals while their customer coordinated all associated services.
In order to comply with strict Health & Safety requirements at the warehouse and out of consideration for neighbouring businesses, the whole work area was protected with barriers, and sheeting was erected to limit the spread of dust from the site works.
All drilling of the concrete slab and piling work was completed by specialist contractors working overnight to limit the impact of noise, vibration and dust and Hi-Level’s installation teams worked in shifts around the clock to ensure that the project progressed according to the schedule.
As soon as the piling was completed at one end of the site, Hi-Level’s mezzanine floor installation teams started the build process working with teams of specialists installing all the other services.
Regular site meetings with all key personnel ensured that as issues were identified they were quickly resolved and, throughout the whole build process, delays were kept to an absolute minimum.
The logistics company Project Manager was delighted with the way the project progressed, “Without the direct lines of communication at all levels from the top down and the willingness to find solutions as issues arose or changes to specifications were needed, this project simply couldn’t have been delivered on time. The flexibility and excellent understanding built up between our teams ensured that the project was delivered on budget and ahead of schedule”.
The whole project from initial order to completion was delivered in just under 16 weeks. The logistics company has been able to relocate its software contract business in its entirety without any negative impact on service levels for this or any of its other technology contracts.
The consolidation of its technology distribution facilities has produced very significant operational and financial benefits. The relatively low cost of the installation combined with the efficiency gains from greatly increasing the usable space within an existing facility mean that the pay-back period on the investment will be extremely short.
Please get in touch with our sales team if you have any questions regarding previous projects.
Come Say Hi To Us At IMHX 2016
Following our success at IMHX 2013, we will once again be attending this year’s show held at the NEC Birmingham from the 13-16th September!
This year’s show is expected to have over 20,000 industry professionals in attendance, making it a great opportunity for us to showcase yet another industry first – our newly designed quoting app iQD!
Exclusive to iPhone and iPad, iQD is set to become freely available to distributors this Autumn – so watch this space!
iQD has been constructed from the ground up to allow customers to easily produce their own quotes and instant 3D renderings from the boardroom or on the go.
For us, iQD is just the beginning, we always strive to develop the latest technologies in order to continue to deliver the best-in-class customer experience for which our company is best known for!
Come and visit us at IMHX 2016 on stand 9G75! We hope to see you there!
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What our clients say
“I used Hi-Level to install a two tier mezzanine structure with fire protection and staircase enclosures. Hi-Level conducted themselves with utmost professionalism whilst on site, our health and safety policies were adhered to the letter and the finish was to a very high standard, to specification and within budget”.
“I am are absolutely delighted with the job, the floor is exactly what I had hoped it would be and the efficiency in managing the project has been excellent from start to finish. Hi-Level is to be commended on every level and stands as a lesson to us in how to run a successful business”.
“Hi-Level completed our mezzanine and did a great job and quickly installed!”.
“Hi-Level worked with Tesco 2014/15 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 standard, we are currently working with Hi-Level on other projects in 2016 / 2017″.
“Our project ran smoothly and delivered us a showroom we are proud of. We are very pleased with the results”.
“From launch Hi-Level’s staff design flare, their knowledge of what could be realistically possible at a sensible cost and their innovation helped us achieve a really robust functional design for the 30 year old facility”.
“Hi-Level’s willingness to engage with us to identify the project requirements and to make positive suggestions which finally convinced us that they were the right partner for this critical project”.
“The structure looks excellent and the customer is very pleased. Well done Hi-Level, your difficult design & manufacture issues have been very successful!”
“Great work, great team, thank you!”
“Hi-Level’s build team were very efficient and worked very well. I felt we were kept informed of what was going on. On the whole the project went very well. And now we’re getting used to the new space”.