Tesco Projects | Hi-Level Mezzanines

Tesco Projects

Introduction

Tesco originally began as a London market stall in 1919, and it wasn’t until 1924 when the company name was created; it was named after the company’s first own-brand product, Tesco Tea. Now, over 100 years later, Tesco is the largest supermarket chain in the UK and they have also branched out into mainland Europe and Asia. With over 450,000 staff and 1600 own-brand products (not to mention the thousands of other branded goods), logistics and supply chain management is a monumental challenge for the retail giant.

Over the past 10 years, we are proud to have been subcontracted to deliver a range of bespoke mezzanine solutions for Tesco as they continue to grow and become an international powerhouse. The two following case studies help showcase our expertise in delivering complex multi-tier mezzanine floors within warehouses and distribution centres.

2014 | Crick | £1, 400, 000
In Partnership with Jarvis Contracting Ltd

The Challenge

We first started providing Tesco with bespoke mezzanine floor solutions back in 2014 for their facility in Crick, Northamptonshire. This facility was for their Tesco Direct division and was to be used as a distribution centre for The Midlands.

Hi-Level were contracted to design, manufacture and install a bespoke two-tier mezzanine solution that would support the storage of small goods on the first floor and an automated garment sortation system on the second. Running alongside the mezzanine was to be a 100m fire escape corridor, completely enclosed from the rest of the structure. The landlord of the property also requested that there should be no additional features dug into the foundations, so the design team would have to produce a resolution that would allow the foundation to withstand the significant weight load.

The Criteria

The final requirements of the project were detailed as follows:

  • Bespoke two-tier mezzanine structure
  • 16, 480m²
  • 5kN/m²
  • Fire protection
  • Ancillaries: 296m handrail, 2 safety gates, 1 swing gate and 2 general access staircases

The Solution and Result

To ensure that the structure met the landlord’s request, Hi-Level’s in-house design team devised a solution where the supportive column slab would rest on another larger slab before contacting the ground. This effectively dispersed the weight load without having to dig into the site’s foundations. Traditionally, the pre-attached slab on our columns (300mm²) would suffice but, in this unique circumstance, we placed a 1000mm² slab underneath each column.

We also successfully installed a completely enclosed fire corridor escape way running the whole length of the mezzanine. This included a staircase to the bottom floor and a bridge connecting to a previously built office area inside the warehouse.

Hi-Level and our partner successfully provided Tesco with a large-scale two-tier mezzanine capable of storing numerous small goods and an automated garment conveyor system, without having to dig into the site’s foundations but ensuring it could withstand the weight load placed upon it.

Before Construction

During Construction

 

Project Completion

2017 | Daventry | £1,600,000
In Partnership with Jarvis Contracting Ltd

The Challenge

Our other large-scale Tesco project was for their Clothing Division’s storage and sortation facility in Daventry, Northamptonshire. This facility was already being used by Tesco and was previously fitted out with an extensive racking system throughout the site. Together with our partner, we were to install a bespoke mezzanine solution (Hi-Level’s task) that would accommodate a mixed of manual and automated sortation processes, including the notable construction of an intricate pre-racked clothing shuttle system (our partner’s task).

For health and safety reasons, the client also required a bespoke mesh edge protection system which would be attached to our traditional handrail and kickplate. However, our standard handrail would not successfully support the mesh so our design team would have to devise a solution. One similarity to the other project was that the landlord did not want any additional features dug into the foundations, so our team would have to place a larger slab plate underneath the column so that the foundations could withstand the structure’s weight load.

 

The Criteria

The final requirements of the project were detailed as follows:

  • Bespoke three-tier mezzanine structure
  • 23,360m² floor size
  • 4kN/m² live load
  • Ancillaries: 1600m custom edge protection with bespoke mesh attached, 1 sliding gate and 9 utility staircases

The Solution and Result

The complex pre-racked clothing shuttle system would cross multiple floors, so it was essential we communicated effectively with our partner to understand the system’s formation and elevations or descents to other floors. Only with this understanding could we effectively deliver a bespoke solution that would support the sortation system.

Hi-level’s design team successfully met the landlord’s request by implementing the same slab strategy as the Crick site; a considerably larger 1000mm² slab plate was placed in between the column’s default 300mm² slab and the site’s surface. This efficiently distributed the mezzanine’s weight load without having to dig into the foundations of the site.

To safely support and attach the mesh Tesco required to the structure’s edge protection, the Hi-Level design team had to raise the level of the handrail. Only with this custom adaptation to our standard edge protection could we meet the end user’s request and maximise the mezzanine’s safety precautions.

Upon project completion, Tesco received a bespoke three-tiered mezzanine which provided simple, safe and fast movement and sortation of products alongside a unique edge protection system which included an additional protective mesh feature. This structure enabled the installation of a highly-technical pre-racked clothing shuttle across multiple floors, whilst also permitting enough space for both planned and unplanned maintenance access.

Before Construction

During Construction

Comments from Hi-Level’s Sales Director on our Tesco Projects

Chris Baxter

Chris Baxter, Hi-Level Sales Director

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What our clients say

“Hi-Level completed our mezzanine and did a great job and quickly installed!”.
Orchard GroupProject Manager

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