Steelwork for Europe’s largest AutoStore
Since 2023, MiTek has delivered steel support solutions for more than 15 AutoStore installations. Notable among them is the project for a multinational fashion retailer at its new 120,000-sq-m distribution centre in Czechia. This new fulfilment facility features advanced technologies designed to store and distribute fashion items in the most efficient way possible. MiTek’s scope of supply included not only mezzanine platforms but also a range of structural solutions to support the automation. This includes an AutoStore system – believed to be Europe’s largest at the time of construction – that comprises 2,500 robots and 500,000 bins.
MiTek’s steel structure for the AutoStore includes tunnels to house conveyors, workstations and replenishment areas; vaults for goods lifts; and walkways at the perimeter of the grid to enable maintenance and provide escape routes. In addition to the need to account for seismic activity due to the earthquake risk in central Europe, the steelwork had to comply with extremely tight tolerances – as little as 0.3mm in some places – to ensure optimal performance of the robots.
Installation of steelwork for an AutoStore system
Other steel structures supplied by MiTek at the site include a mezzanine for hanging garment automation and a two-tier system to support conveyor lines and spiral chutes. In total, MiTek installed 32,000 sq m of mezzanine on multiple levels. The scale of the project demanded meticulous planning. There was an early setback when it was discovered that the concrete floor needed to be reworked in order to meet the tolerances of the AutoStore. The MiTek team quickly reorganised logistics and reconfigured work programmes in order to get the project back on track. Following successful delivery – on schedule – of this site, MiTek is now implementing a similar installation for the client in Poland.
Retail automation on a vast scale
Another large and challenging project recently was for Home Bargains, the UK's largest privately-owned retailer. To realise its ambitious growth plans, the company has invested in a new, 24/7 distribution centre in Warrington to supply over 300 of its stores and its growing e-commerce operations. Working in partnership with system integrator, Witron, Home Bargains designed one of the most automated distribution centres in Europe. MiTek was appointed to design and install the mezzanine solution at the 79,000-sq-m site.
The challenge of this project lay in both its scale and the complexity of the integration. MiTek’s bespoke steel structures support the automation, which includes the tallest non-clad-rack pallet store ever installed by Witron, tote storage systems, pallet and tote conveyors, transfer cars, pallet elevators and pick stations. Together, these technologies enable up to 80% of order fulfilment at the site to be automated.
Construction of Home Bargains’ new DC in Warrington
Design and delivery of 30 steel platforms totalling almost 25,000 sq m required MiTek to supply around 350 staircases. MiTek’s engineers developed a new staircase design that enabled some pre-assembly, making installation easier and faster. Additional load-spreading beams were installed on top of the mezzanine to support pallet conveyor loading, while shallower beams ensured minimum clearance height below. Heavy-duty, 2.5-metre-tall edge protection was used to mitigate the risk of pallet loads falling from the conveyors.
With some 20 trades installing various equipment on site, space was extremely limited. Detailed planning, a phased approach and excellent communication were essential to success.
