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Mezzanine flooring case study – Warehouse Storage Solutions Ltd & Trade Mezzanines

Mezzanine flooring case study – Warehouse Storage Solutions Ltd & Trade Mezzanines

Warehouse Storage Solutions Limited is a leading supplier to the UK storage industry, specialising in the delivery of a full turnkey package. Its core services include warehouse designs, fit-outs, and repairs, utilising all types of storage – from pallet racking and shelving to bespoke storage systems and partitioning. Over the last 12 years, Warehouse Storage Solutions Limited has built a solid reputation for the provision of quality warehouse designs, on time, every time.

Design, supply & installation of warehouse solutions including racking, shelving, mezzanines & partitions.Design, supply & installation of warehouse solutions including racking, shelving, mezzanines & partitions.In September 2016, Warehouse Storage Solutions Limited was appointed by Superhire as the primary contractor for the complete redevelopment of a warehouse storage facility in North London. As Europe’s largest furniture and prop hire company for the TV & film industry, Superhire required a storage facility that would allow its high profile customers – including the producers of the Downton Abbey televisions series and the James Bond movie franchise – to view its vast range of ‘Old Times’ and ‘New Times’ stock, with no appointment necessary.

The work

The main focus of the storage warehouse would be a two-tier mezzanine platform, featuring 4 independent tower staircases and 3 integrated goods lifts. The mezzanine would be designed and installed in partnership with Trade Mezzanines Limited, and erected over five phases.

In addition to the main mezzanine, Super Hire engaged Warehouse Storage Solutions Limited to redesign and refurbish the office space on the first floor. A revised layout would give users direct access to inventory on the upper levels of the warehouse, whilst a fresh, new look would help project a modern, professional brand image to customers.

The challenge

The 13,500sq m multi-tier storage mezzanine was designed to safely accommodate both dead and live loads. This would include:

- 265 tonnes of main steelwork;
- over 2 million pieces of furniture and props; as well as
- The weight of the thousands of runners and crew, who would travel across the warehouse floors each year, with their product-laden shopping trolleys.

At the first stage of the mezzanine build, the ground works were discovered to be of poor condition. To pile into the site would prove impractical, and require an alternative technical solution. Therefore, a series of spreader plates and baseplates (at 1500 x 1500 x 20 mm and 450 x 450 x 20 mm respectively) were constructed to dissipate the maximum point load of each of the 320 steel columns, to an industry-acceptable level. The revised design would prove more cost-effective than piling, and negate potential disruption to the agreed programme schedule.

The entire build programme was 8 months from start to finish and this was too long for Superhire. Warehouse storage Solutions was given 4 months to complete the build and be ready for the transfer of materials from the old site to the new site.

In order to meet a tight programme schedule, whilst still continuing to maintain a safe and timely workflow, Warehouse Storage Solutions Limited:

- introduced a five-phased construction programme, with clear handover dates for all trades – including mezzanine installers, electricians, HVAC contractors, dry liners, ceiling and fire protection specialists;
- briefed all fitters on the required health & safety procedures and working patterns, to hit key milestones; and
- set up a dedicated project management team with responsibility for monitoring onsite progress, on a daily-basis.

The result

The warehouse redevelopment and fit-out project, including the mezzanine installation, mezzanine floor fit out and office refurbishment, were delivered in 15 weeks, due to a combination of efficient programme- and site management.

“We had to move premises as a result of compulsory purchase and had to fit out our new premises with two mezzanine floors within 5 months when usually such a project takes 9 months. We picked Warehouse Storage Solutions Ltd based on their ability to complete the project in this very tight timescale. They achieved this, and did so by working 12 hours a day for 7 days a week over the project period. Without this, we would not have been able to complete our move and we are grateful to WSSL for being so flexible during the project and allowing us access at various stages and still completing the project in almost half the usual time required.” Superhire, April 2018

“Thank you Trade Mezzanines for all your hard work in supporting us in a mezzanine build that meets all of our client’s requirements. The mezzanine redesign will help increase the longevity of the storage facility as customer numbers and stock levels grow.” Matthew Powell, Warehouse Storage Solutions Limited.

Key facts

Overall project: Complete storage design and fit out, including mezzanine installation and fire protection. Plus office redesign and refurbishment.

Total value: £4,500,000m

Location: Park Royal, London, NW10

Result: Safely delivered 7 weeks ahead of schedule to budget

Contact: Matthew Powell, MD at: [email protected]

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