PRODUCTION & STORAGE MEZZANINE FLOOR GREEN & BROWN PROJECT UPDATE
Our latest project is a two tier mezzanine floor project to create additional storage and production facilities for Green and Brown, who are a leading manufacturer of handmade home furnishings in the UK.
WHAT'S INVOLVED
We are carrying out a full design and build two tier mezzanine floor project for Green & Brown at their warehouse premises in Wakefield. They offer a comprehensive range of interior furnishings from numerous types of blinds through to luxurious curtains, all handmade here in the UK. Green & Brown are bursting at the seams and they need more production space to keep up with increasing customer demand.
The project involves the removal of existing high bay racking space and then constructing a two tier mezzanine floor in it’s place. This is to provide an extension to their production space over two floors, whilst also providing storage space on the ground floor underneath the mezzanine.
As part of the project we will also be installing all fire rating to the mezzanine floor, lighting on all floors and electrical requirements throughout. The project is due to take 14 weeks from the stripping out of the racking through to the handover of the new workspace.
WEEK
ONE-
TWO
In the first week of the project, we take down all the high bay racking that’s in the area where the new mezzanine floor facilities are to be situated. This is all neatly piled up, ready to be moved to another area of the warehouse to be repurposed at a later date.
In the second week of the project, we carry out the piling of the concrete floor to ensure that it’s strong enough to handle the load of the two tier mezzanine floor and everything that will be situated on top. This process involves the specialised cutting out of the concrete in preparation for the pile caps to be installed at the load points.
Point driven piles in the form of steel tubes are then driven into the ground to the required depth. These steel tubes are then filled with concrete. This process is all designed to accommodate the specific load requirements.
At the beginning of week three, the mezzanine steels are delivered to site and we make a start on the mezzanine build. First of all we install the cleats to the primary beams and then mark out the mezzanine column positions.
Then we manoeuvre into place the mezzanine columns and begin to install them. Over the next few weeks the beams and purlins are also installed creating the mezzanine structure. The mezzanine has been designed to match up with Green & Brown’s existing floors, so during this time we must also pack the mezzanine steelwork to meet their existing floor level.
WEEK
THREE-
SIX
WEEK
SEVEN-
NINE
During the seventh week of the project, before any work can commence, we must erect the netting and temporary edge protection on and around both floors of the mezzanine. Once that’s put up, work commences on the installation of all the purlin links throughout and following that, the installation of all the decking too. This process takes three weeks to complete.
During this time we also start the installation of the perimeter isoclad walls on the second floor. We have to ensure that the isoclad panels are cut correctly to size and also at the right angle to fix to the slope of the warehouse roof. Onto week nine and the first fix of the electrics are installed at roof level on the second floor of the mezzanine floor. The pallet gate on the second floor of the mezzanine is also installed during this week.
Now that the mezzanine structure is essentially complete and the decking is installed, it’s time to install the fire protection to the mezzanine. This involves the installation of the column cases, the fascia to the perimeter and later on in the project, the suspended ceilings underneath each mezzanine level.
The first floor perimeter walls are installed by week 11, and at the same time, the first fix of the electrics on the first and ground floor commence. The second fix of the electrics on the roof level are also completed by the end of the eleventh week.
The suspended ceiling grid installation commences during week 12 along with the installation of the other fire protective materials (column cases, fascia) to the first floor mezzanine level.
WEEK
TEN-
TWELVE
WEEK
13-
14
During the penultimate week of the project we complete the first fix of the electrics on the first floor and we start the second fix of the electrics on the ground floor. We also make a start on installing the new shelving facilities on the second floor.
In the last week of the project, all the electrics are completed and we strip out their existing pallet racking on the ground floor and install new pallet racking. The new shelving facilities are also completed, enabling us to handover Green & Brown’s new facilities to them.
The new two tier mezzanine floor provides Green & Brown with the expansion they needed. Their new production facilities will allow them to keep up with customer demand and grow their team even more.
TIME LAPSE VIDEO
We captured the entire construction of Green & Brown’s two tier mezzanine floor via our time lapse camera that we set up before the project commenced. Here’s the fourteen week project condensed into a three minute video.
PROJECT PROGRESSION VIDEO
Here’s our sneak peek into the process of constructing Green & Brown’s new production facilities through the implementation of a mezzanine floor solution. From the delivery of the mezzanine steels through to Green & Brown’s employees utilising the new space.
CASE STUDY VIDEO
On completion of the project we sat down with Job Brown, the Head of Operations and IT at Green & Brown, to discuss the project as a whole and to find out what the process of working with Nexus was like.
WHERE WE WORK
We would love to be able to help create workspaces for businesses throughout the whole of the UK but unfortunately we can’t. The extra cost to you and the fact that we wouldn’t be able to manage your project to our high standards means that we must set a limit for how far we can work. The area we cover is highlighted to the right. As you can see, we essentially work as far North as Newcastle and as far South as Birmingham. So if your business is situated in an area we cover, get in touch today to discuss your plans for your new workspace.
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