Project Updates

Storage & Office Mezzanine Floor – Western Automation Project Update

By May 13, 2019 No Comments


We are implementing an office and storage mezzanine floor project for the premier distributor of HVAC, commercial heating spares and electrical automation in Yorkshire

Western Automation Logo


We are currently in the process of implementing an office and storage mezzanine floor design and build project for the leading distributor of HVAC, commercial heating spares and electrical automation in Yorkshire. Western Automation are on the move to a brand new warehouse premises in Leeds. But before they move in to their empty warehouse, they need us to create their new facilities.

The project will involve the creation of a 107 square metre storage mezzanine floor and an office mezzanine floor totalling 70 square metres. On the ground floor we are creating a knock through to their existing office facilities, giving the offices a nice open plan feel. This will create a ground floor office for up to eight employees. Rounding out the ground floor facilities we are creating a breakout area, a kitchen and an additional WC.

Whilst on top of the mezzanine floor we are a creating a large meeting room, another breakout area and three individual offices. The project will take nine weeks to complete and as part of the project we are also providing all warehouse lighting, air conditioning, power and data.


Once the site is set up in regards to the CDM regulations to ensure the health and safety of everyone on site, we get to work on creating the knock through in their existing ground floor office block. By utilising a structural engineer we calculated the size of the lintel required to ensure we created the biggest knock through that we could. The process involves acrow propping the opening, chiseling through the wall, knocking out the breeze blocks, installing the lintel and finishing off the edges.

Once this is complete, the mezzanine floor materials are delivered to Western Automation’s new warehouse. The rest of the first week consists of installing the office mezzanine floor steels and laying down the decking, ensuring that the new office mezzanine floor matches up with the roof of their existing office block.

Lintel Installed at Western Automation
Mezzanine Floor Build At Western Automation
Decking & Fascia Install
Office & Storage Mezzanine For Western Automation
Fork Lift Truck Driver Installing Mezzanine
Western Automation Office Mezz Build
Office Mezzanine Steels Erected
Mezzanine Decking Install Western Automation

At the beginning of week two we make a start on installing the 107 square metre storage mezzanine floor. Whilst underneath the office mezzanine floor that is now erected, we start to install the suspended ceilings followed by the ventilation and air conditioning facilities.

Plumbing works commence including all waste pipes and cold water supplies and by the end of the week, the storage mezzanine floor is complete with handrails, pallet gate and the lighting underneath. We also complete the installation of a bespoke florescent lighting layout above the storage mezzanine floor and around the outside of the office mezzanine floor.

Heading into week three and the perimeter walls are going up for the office mezzanine floor. These are standard stud and track walls that form the ground floor office, WC and kitchen area. This week we are also fire rating the mezzanine floor and plastering the internal side of the perimeter walls.


Storage Mezzanine Build Western Automation
Office Build Western Automation
Storage Mezzanine Decking Western Automation
Perimeter Wall Install
Western Automation Partitioning
First Floor Perimeter Wall
Perimeter Wall Nearing Completion
Western Automation Week Three


In the final five weeks of the project, we concentrate on the inside of the office mezzanine floor facilities and finishing off the perimeter walls. Because the perimeter walls are adjoining to the underside of the warehouse roof, we need to install a deflection head. The perimeter wall sits inside this and when the building moves due to the wind, the deflection head moves up and down over the wall to prevent it from cracking.

The installation of this is quite an intricate process and it takes time to ensure it’s installed correctly. Once the studs are aligned inside the head, the wall is double boarded with two layers of plasterboard either side to provide the wall with it’s one hour fire rating. Fire regulations state that any facilities that exceed more than 20% of a building’s footprint must be fire rated, so the installation of a fire rated jumbo wall that separates the office facilities from the rest of the warehouse provides this protection.

Once this process is complete, the internal partition walls start to go up and are decorated. Whilst the installation of all smoke detection, power and data requirements are completed. Windows are then cut out in the perimeter walls to allow light into the office facilities and the staircase leading to the first floor office facilities is installed.

Western Automation Storage Space
Storage Mezzanine at Western Automation
Corridor Build
Ground Floor Office Facilities Taking Shape
Western Automation Nearing Completion
Meeting Room Build Western Automation
Ground Floor Office Build
Office Mezzanine Floor Bulkhead Completion


We set up a time lapse camera to capture the office and storage mezzanine floor build for Western Automation from start to finish and with the project now complete and Western Automation all moved in, we can share it with you.


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Zak Lewis

Author Zak Lewis

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