The mezzanine project presented a significant challenge due to its vast scale and the intricate integration required. Spanning 25,000 sqm, the steel support structure was erected within a massive 450m by 190m warehouse. This state-of-the-art distribution center is equipped with the latest in automated technology. The successful delivery of the mezzanine solution was driven by MiTek's engineering expertise, meticulous planning, and a phased approach, ensuring the project was completed on time despite its complexity.
Let the facts speak for themselves:
The Customer
One of the largest privately-owned retailer in the UK, the copmany operates around 600 stores, in addition to online sales. With the aim of selling branded goods at the lowest possible prices, the company offers a wide product range across groceries, homeware, health & beauty, electricals, toys, stationery, leisure and garden.
The Project
The client has been one of the UK's fastest-growing companies in recent years. With ambitious plans to grow its retail estate to 1000 stores, the retailer decided to construct a brand-new, 24/7 distribution centre near Warrington. Working in collaboration with a leading system integrator, the build of a state-of-the-art DC featuring a high level of automation, supported by MiTek’s steel mezzanines went under way.
The Challenge
The challenge of this project lay in its scale and the complexity of the integration. As well as the tallest non-clad-rack pallet store that the automated technology provider had ever installed, the automation included pallet & tote conveyors, transfer cars, pallet elevators and pick stations. Space on site was limited due to some 20 trades installing equipment such as sprinklers, lighting and emergency power. Meticulous planning and a phased approach were key to MiTek’s success in delivering the mezzanine solution on time.
The 85,500 m2 DC measures features:
→ 30 steel platforms
→ 7.5 km of pallet conveyors
→ 350 staircases.
The Solution
To speed up installation at this vast site, MiTek developed a new design of staircase that features some pre-assembly. Other special requirements catered for by MiTek in this project include:
→ Additional load-spreading beams installed on top of the mezzanine to support loading of 16 kN/m2 on the pallet conveyor
→ Minimum clearance height below the mezzanine, achieved through the use of shallower beams
→ Additional steelwork in selected areas to support Davit-arm cranes
→ Taller columns for the building’s pit areas
→ Use of heavy-duty, 2.5-metre-tall edge protection to mitigate the risk of pallet loads falling from the conveyors.
The Benefits
The mezzanine solution enabled the integration of the intralogistics automation across the various floors in the new facility. Other benefits include:
→ Rapid and efficient processing of orders, even during peak periods
→ Optimal space utilisation
→ The highest levels of workplace health and safety
→ Maximum productivity from its investment.
“The challenge of this project lies in its scale: some columns are over 12m tall and the design features about 350 staircases and 28.5 km of handrail. Despite its complexity, the project has gone really well so far.”
Bart Pulles, Operations and Sales Manager, MiTek
“Key to the smooth running of the mezzanine build has been meticulous planning in a phased approach. We’ve held weekly co-ordination meetings with the customer to review our designs and share feedback. We’ve also thought about the details to save time on site. For example, we’ve used a new design of staircase that features some pre-assembly to make installation easier and faster.”
Bart Pulles, Operations and Sales Manager, MiTek
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