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sales@avantauk.com 2 AvantaUK Ltd isan independent companywithover 25 years of experience in designing and sourcing equipment. Long term partnership arrangements and rigorous appraisal of our portfolio of extensive manufacturing partners ensures that our clients have access to high quality and competitively priced standard and non-standard products. Our specialities include mezzanine floors, storage systems (including warehouse shelving, pallet racking, longspan shelving and mobile shelving systems) and interior solutions (including office partitions, office storage, steel partitions, mesh security cages and workbenches). We cover the whole of the UK and work closely with the major manufacturers offering warranty, peace of mind and on going support. See more case studies at www.avantauk.com Some of our clients...
www.avantauk.com 3 Turnkey warehouse interior fit out: capacity, control, and room to grow CLF is a leading UK wholesaler of premium health and wellness products spanning sports nutrition, organic and health foods, vitamins and supplements, personal care, household essentials and, increasingly, chilled and frozen ranges. In 2025 the employee‑owned business committed to a major relocation to support growth, moving less than a mile to a new, Grade‑A logistics facility on the outskirts of Southampton. Avanta UK was appointed to deliver a full interior fit out — from storage design to offices and services — enabling CLF to increase stock density, streamline picking, and scale chilled and frozen operations while keeping day‑to‑day service to retailers uninterrupted. The new site Unit 3, Quest 271, Nursling is positioned close to the M271 and the Port of Southampton, making it ideal for inbound and outbound flows. The buildingprovides 62,574 sq ft (approx. 62–63k sq ft) with 12m eaves, a 48m yard, 4 level‑access doors, 5 dock levellers, 100 car spaces and 20 EV chargers. It is built to high environmental standards, achieving BREEAM ‘Excellent’ and EPC A, with roof‑mounted solar PV and a 600 kVA power supply. Objectives • Increase capacity significantly without moving to multiple sites. • Support SKU growth especially chilled and frozen — while improving pick speed and accuracy. • Create safe segregation between people and MHE, with clear routes and protection. • Deliver quickly and in phases so service levels for CLF’s 210+ colleagues and customers were maintained. What we delivered Pallet storage and VNA operation We installed a Very Narrow Aisle (VNA) racking scheme rising to 12m, providing 6,500 pallet locations. The configuration maximises the building’s clear height, protects throughput with guided MHE, and leaves headroom for future re‑slotting as product profiles change. Rack‑end protection, aisle signage and full location labelling were included to aid induction and reduce picking error. Three‑tier fire‑rated mezzanine To unlock high‑value small‑parts storage and value‑add space without extending the footprint, we installed a three‑tier, fire‑rated mezzanine totalling 5,000 m². Access is via three staircases with multiple pallet gates, comprehensive handrail, and 2.2m‑high mesh edge protection to arrest the fall of small items. Fire strategy elements include a suspended ceiling to the underside, column casings to protect primary steel, fascia/bulkhead closures at exposed edges tomaintain fire integrity, and fire‑rated partitioning to enclose stair cores. Longspan shelving and pick faces Across the mezzanine levels we supplied and installed 700 bays of longspan shelving, with three bay types to accommodate pallets as well as mixed carton sizes for efficient case‑ and each‑pick. Aisle markers and barcode labels align with CLF’s location logic for faster onboarding and fewer mispicks. Offices, welfare and M&E integration On the ground floor we completed a full office fit out — meeting rooms, production, transport and warehouse offices, toilets and canteen — alongside an open‑plan first‑floor office with new floor finishes and decorations. All mechanical and electrical services (HVAC, lighting, emergency lighting, power, fire detection and plumbing) were installed, tested and commissioned to deliver a modern, compliant working environment. Finishes included epoxy flooring in designated areas for durability and hygiene. Protection, segregation and specialist works To enhance safety, we added barriers, a freezer roof handrail, and extended 2.2m mesh to mezzanine perimeters. Pedestrian routes, pallet staging and transit areas were clearly marked to separate people and plant and to simplify traffic management during peak activity. (Whitewall installation by others.) CDM ROLES — CLEAR AND COMPLIANT Principal Designer (PD) Avanta UK was appointed as PD, coordinating health and safety in the pre‑construction phase. In practice, this meant working with CLF and specialist designers to remove or reduce foreseeable risks in the layout — from mezzanine fire strategy and stair enclosure to racking interfaces, lighting clearances and MHE movement — and ensuring the right information flowed to the site teams before works began. Principal Contractor (PC) Avanta UK also acted as PC, leading site safety during construction. We produced the Construction Phase Plan, set permit and induction regimes, sequenced trades (for example, integrating high‑level lighting with racking set‑out), coordinated temporary works and welfare, and maintained daily briefings to keep the programme safe and predictable. The result was a well‑controlled build with a clean handover. Phasing and programme From early survey to go‑live, we planned the work to protect CLF’s service promise. Early site set‑out brought forward key enabling activities, while the build was sequenced to keep critical areas available. Stock migration and WMS labelling were coordinated in step with commissioning so that changeover was smooth. The full programme ran to 24 weeks. Outcomes for CLF • Capacity uplift: The move delivers a 63% increase in floor area versus the previous site, enabling 120% more stock holding and a broader brand portfolio — particularly in chilled and frozen. • Operational control: VNA with clear labelling and defined pick faces shortens walk time and simplifies induction for new starters. • Safety and compliance: Fire‑rated mezzanine construction, protected edges and defined routes improve day‑to‑day safety and audit readiness. • Sustainability and cost‑to‑serve: A modern envelope (BREEAM Excellent, EPC A), solar PV and EV infrastructure contribute to CLF’s long‑term efficiency goals.
sales@avantauk.com 4 Three Tier Fire Rated Mezzanine Longspan Shelving & Pick Faces Ground Floor Office Fit Out VNA Racking with 6500 Pallet Locations
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www.avantauk.com 11 Large Warehouse Interior Storage Systems Project Avanta UK Ltd, a Leeds-based specialist in warehouse storage equipment, successfully completed a second large-scale project for a major British mobility retailer. Working alongside the principal contractor, Avanta was responsible for the design, supply, and installation of a comprehensive interior storage solution. Project Components Site Set-Out and Demarcation Working in collaboration with the Principal Contractor and the Mechanical & Electrical Contractor, Avanta was tasked with marking out the VNA (Very Narrow Aisle) portion of the warehouse. This early demarcation enabled floor grinding and high-level lighting containment to be completed several weeks ahead of the pallet racking installation. To ensure precision, we utilised a state-of-the-art site demarcation tool. Multi-Tier Mezzanine Floor A fire-rated, two-level mezzanine floor (plus ground level) was installed, creating 1,400m² of additional usable space. The structure included compliant handrails and mesh panels to prevent items from falling from height. • Personnel access via two staircases • Goods access via four pallet gates • Boxed products were decanted via two designated chutes Very Narrow Aisle (VNA) Pallet Racking System Designed to accommodate over 7,000 pallets, the VNA racking system stands 10.5m high with clear entry beams at multiple levels (1800mm to 9000mm). • Future-proofed with readily available spare parts for reconfiguration • Rack-end barriers installed as standard • Full location labelling included Longspan Shelving System 266 bays of longspan shelving (2145mm high x 1800mm wide x 600mm deep) were installed across mezzanine levels 1 and 2. • Designed to store approximately 6,000 boxes • Each location labelled for easy identification and rack end aisle signage Partitioned Work Areas Two workshop areas were created beneath themezzanine using single-skin steel partitions and mesh panels. CustomWorkbenches 40 bespoke workbenches were supplied, split into two types tailored to specific tasks. Floor Markings & Coatings Approximately 250m of walkways, pallet zones, and hatched areas were marked throughout the warehouse. • Resin coating applied to the concrete mezzanine surface Signage & Labelling • All pallet and box locations barcoded • Compliant signage installed at aisle ends Flex Guard Barriers & Column Protection 35m of protective barrier installed along ground floor walkways and forklift charging areas. Conclusion Mezzanine floors offer a practical way to expand warehouse capacity without the need to relocate. As business needs change, the space can be reconfigured to support increased storage or new operational areas. Project Highlights • 1,400m² fire-rated two-tier mezzanine floor • 7,000 pallet locations in VNA racking • 6,000 box locations in longspan shelving • 40 bespoke workbenches supplied
sales@avantauk.com 12 Multi Tier Mezzanine Floor Very Narrow Aisle Pallet Racking 266 Bays of Longspan Shelving Flex Guard Barriers & Column Protection
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www.avantauk.com 19 Latest Mezzanine Production from Avanta UK Introduction: An industry-leading technical services company recently relocated to a new facility at a prominent UK studio complex. With a vast inventory of heavy specialist equipment, the client required a significant increase in storage capacity to support its operations. Project Overview: Working alongside a global real estate consultancy, the client identified a mezzanine floor installation as the most effective solution. This flexible infrastructure allows for future adaptability and supports evolving operational needs. Mezzanine Floor Details: A mezzanine floor and intermediate level between main floors was chosen for its ability to maximize vertical space without altering the building’s footprint. Its relocatable nature also supports long-term flexibility and lease compliance. Project Award: Following a competitive tender process, Avanta UK Ltd was selected to deliver the project. With a tight lead time and complex requirements, Avanta’s experience in turnkey storage solutionsmade themthe ideal partner. Avanta’s Turnkey Solution Included: • Mezzanine Floor: A 2,000 square meter fire-rated mezzanine, standing 5.2m to finished floor level and 4.7m clear underneath ideal for pallet racking and large equipment storage. • Access: Three staircases for personnel and a vertical goods lift plus pallet gate for load access. • Fire Rating: One-hour fire rating achieved through fascia, column casings, a suspended ceiling, and two fire lobbies. • Lighting & Electrical Installation: A premium electrical system featuring Thorlux intelligent lighting, high-efficiency LED fittings with daylight harvesting and presence detection, and emergency lighting compliant with CIBSE standards. Power distribution was tailored to the facility’s operational needs. • Floor Protection: Heavy-duty 2.5mm industrial vinyl specified by the real estate consultancy to protect the mezzanine deck. • Pallet Racking: Avanta designed, supplied, and installed British-manufactured adjustable pallet racking to match existing systems, with configurations up to 4m high. • Additional Works: Included Armco barrier and column protection, and relocation of existing racking. Project Management: Avanta UK acted as Principal Contractor for the 12-week project, managing all Health & Safety responsibilities and maintaining a constant site management presence to ensure smooth delivery.
sales@avantauk.com 20 2,000 Square Meter Mezzanine Floor Up to 4 Meter High Pallet Racking Barrier & Column Protection Three Staircases & Vertical Lift
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www.avantauk.com 27 Multi-Level Picking Structure for 3PLUK Avanta UK was invited to propose a suitable storage solution for use at a new Wrexham facility, home to the rapidly growing fulfilment specialist 3PLUK, and their sister brand, Shape Fulfilment. Since 2010, 3PLUKhas beenhelpingecommerce brands reach their potential through providing reliable order fulfilment services. With UK & EU fulfilment hubs, 3PLUK specialises in helping ecommerce brands upscale, to go from selling 50 items per month, to 50,000. With such a wide variety of both existing and potential customers, 3PLUK required a storage solution that would optimise storage density and order velocity, particularly for such a wide range of products that can vary in size and shape. Avanta UK proposed a multi-tier pick structure to utilise theavailable height, tobe constructed from pallet racking, as well as incorporating a mezzanine floor for loading and marshalling areas. The racking structure with adjustable beams enables customisation if the product profile changes, such as in the event of a new contract win for the client. Levels can be converted from narrow shelving to storage for pallets if required. The Multi-tier structure, has a footprint of 48.7m length x 28.9m wide with ground and 2 walkway levels at 2,435 and 4,835mm. This gives the client circa 4200m2 of storage space. Ground and level 1 was to store boxes and a variety of pick totes. The top level had extended racks with garment rails to store specific longer garments for a particular client. The design included a flat chipboard surface to all walkway levels using Class O foil backed boards enabled the smooth operation of pump trucks and mobile pick steps / trolleys. The structure incorporated a multi-level mezzanine floor with access via 4x staircases for personnel and 2x pallet gates for loads. Safety perimeter handrail and mesh fitted to prevent the fall of small items was supplied and installed by Avanta. As part of this project, Avanta designed, supplied and installed a run of additonal pallet racking outside of the structure for bulk storage with upright guards and anti-collapse mesh. The new storage and fulfillment facilty has enabled 3PL to attract multiple new clients with specific areas with the structure dedicated to each client with different storage requirements.
sales@avantauk.com 28 Multi Tier Mezzanine Floor Safety Perimeter Handrail and Mesh Circa 4200m2 of Storage Space Footprint of 48.7 x 28.9m
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www.avantauk.com 33 2000m² Additional Floor Space Created For A UK Leading Specialist The client, is the UK’s leading business with 30 UK Depots that are serviced from a National distribution centre based in the UK. The client hadanurgent requirement to increase storage capacity within a new warehouse whilst an existing warehouse was being refurbished. Avanta UK successfully tendered for the design, supply and installation of a fire rated two tier mezzanine floor. The mezzanine was required to store a mixture of bulky items with shelving for small items to the top level and pallets of stock to the ground floor. Mezzanine floors are an excellent way of increasing storage by utilising the height in the building. Mezzanines are flexible in their usage can adapt as the business requirements for storage change over the coming years. Approximate measurements of the mezzanine are 2 levels at 60m in length x 18m wide, giving the client over 2000 m² of additional usable space. The finished floor levels are at 4.5m for the first floor level and 7.5m for the second floor level. Decking to both levels is from 38mm thick tongue & groove “P6” Grade Particle Board. Edge Barrier protection included 2,200mm handrail mesh, bolted to the structural handrail posts. This is to prevent the fall of small items off the mezzanine. Personnel access is via 2 Staircases including, 1x standalone set into a 1 hour fire enclosure and load access provided by 4x bespoke pallet gates. Working in conjunction with the Avanta fire engineer ensured the floor achieved local brigade compliance as the floor is fire rated to 60 minutes. Fire rating is achieved by utilising column casings, suspended ceiling and fire enclosures. Avanta worked closely with civil engineers at the design stage and with the Main Contractor during the project who provided a clear working area with scaffold hoarding around perimeter ensuring safety of client personnel. The project timeline included 4 weeks to manufacture the floor and 8 weeks installation with a break for other contractors to first fix their services. In addition to the floor, Avanta supplied and installed runs of longspan shelving to the top level and labels.
sales@avantauk.com 34 38mm Tongue & Groove Decking Multi-level Mezzanine Floor 4x Pallet Gates for Loads Fire Rated to 60 minutes
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www.avantauk.com 41 New Retail Operations Centre (R.O.C.) Middlewich After an extensive property search, Jet2 successfullyacquiredunit 11 of TritaxSymmetry Park in Middlewich. The unit is 149,000 sq ft and is perfect in size and location for the client’s intended use of the facility – A dedicated centralised Retail Operations Centre (R.O.C.). The R.O.C. is the centralised location servicing eleven regional UK airport locationswith sealed carts of in-flight retail goods. This includes the storage, sortation, picking and despatching of gifts, fragrance, and snacks in sealed carts to be sent to the in-flight regional operations teams. This iswith theaimof delivering the right products at the right time for customers and thus improving overall customer experience, eliminating stock out situations. There will be circa three thousand carts in circulation e.g., split between own vehicles, on aircraft and at the R.O.C. Creating an End-to-End Logistics system. This is thefirst centreof its kind in theUKaviation industry taking in house control enabling Jet2 to stock, manage and distribute millions of in-flight retail products for passengers to consume. This major development offers Jet2 more control over the operation and offers significant cost savings. Avanta UK Ltd worked very closely with Jet2 and in conjunction with Hatmill (Supply Chain & Logistics) equipped the premises internally and externally with a comprehensive turnkey package to enable Jet2 to have a fully operational facility. These works / Services included: • Full Principal Contractor Role – Including site set up and the running of the site for a set period. Please see Principal Contractor - Avanta UK for further details. • Sprinklers – Design, Supply & Installation with tanks, pump house • Concrete Pads for Services and further civil works. • Full External Perimeter Security Fencing • High Specification ANPR barrier for access and egress to main car park • Mechanical & Electrical Works throughout including the Jet2 IT department’s data requirements. • All CCTV, Fire Alarm, Intruder Alarm, and Wireless Access Points • Feature Reception desk • Gunnebo Access Gates • Access Control Systems – In line with current airport security specification. • Additional Access and Roller Doors to suit the operation. • Cut Out and Glaze Viewing Area from Office to Warehouse • Full Ground Floor Facilities Fit Out, including. o Break Out Areas o Canteen Facility o Toilets o Locker Rooms & Shower Facilities o Reception o Multiple Meeting / Training Rooms – Subdivided by Operable Walls o Glass Partitioned areas – double and single glazed. o Hygiene Wall for Locker Room Facilities o Flooring – hard wearing durable vinyl in ground floor facilities area and carpeting within ops office and first floor. o Furniture – in Bespoke Jet2 colours o Ceilings • Full Fit Out of First Floor Office Suite – taking a typical class A fitout to class B to personalise the facility for Jet2. o Created Multiple Meeting Rooms, Offices & Open Plan Area o Office Furniture o 2x Supply and installation of acoustic meeting POD’s o Created Viewing Area from Office to Warehouse with 54mm thick fire rated glazed screen. • Created additional large storage area with vertical personnel access ladder and safety handrails. • Carton Live Storage Area – Bespoke solution designed in conjunction with Hatmill. 50x Pack stations (3x distinct types) Constructed using carton live storage bays (Shelving bays with angled roller beds). Stock is pre-loaded to the rear of the unit on FIFO basis and the operator picks from the front of the unit and uses a fixed workbench to consolidate and pack into totes and carts. • Circa 100 Linear metres of Single Skin Steel Partition to subdivide the warehouse • Created a Two-Tier Control Room Suite with a fire rated Mezzanine Floor and Steel Partitioning including toilet pods and full fit out with bespoke furniture. • Secure Bunded Warehouse Area with two security X Ray scanners and laser alarm ceiling • High Bay Pallet Racking Area for circa two thousand pallets with bespoke smoke baffles to meet insurance requirements. • Safety Barriers & Protections including the industry leading polymer barrier system – ASAFE supplied and installed to protect personnel and property. • Function as Principal Contractor for PHASE 2 – Automation. Utilisation of Vanderlande Adapto Shuttle System - Intelligent shuttle-based automated storage and retrieval system (AS/RS) with built-in sorting and sequencing capabilities. • Responsibility for delivery of all Health & Safety objectives throughout both phases.
sales@avantauk.com 42 150,000m2 Full fit out Internal and external works Distribution of retail goods Principal contractor role
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www.avantauk.com 55 Avanta Create 40,000 Pallet Locations for Global Retailer of Apparel and Home Fashions Avanta UK successfully tendered for and completed a large-scale pallet racking project for one of the World’s leading “off price” retailers of fashion and homewares. The client acquired a newly built 450,000 circa square foot warehouse in the North West, specifically to store palletised goods to service a growing network of stores and resellers. Avanta UK were invited to take part in an extremely competitive tender process and successfully satisfied the strict criteria set out against large European manufacturers of racking systems. The project size and length of programme meant that Avanta functioned as Principal Contractor. This means, there is a single point of contact coordinating multiple contractors on site. This saves time, effort, and money in managing multiple teams on behalf of the client. Avanta Undertook the sitemanagement of all other trades, from sprinkler works to M&E contractors. This approach not only allows for better communication between trades and therefore a smoother, economic, and quicker installation. It also allowed for design adjustments to were made quickly and efficiently as works progressed. Avanta looked after all the Health & Safety and having all the relevant accreditations and levels of insurance gave the client ultimate peace of mind. The pallet racking, designed in a narrow aisle configuration giving the client 40,000 UK sized pallets. With heights up to 15m high, there is circa 2400 heavy-duty frames stood and circa 35,000 2700mm pallet racking beams in this project. Anti-collapse mesh is secured to all single runs of racking within the scheme. With the racking & mesh extending above the highest pallet, to ensure maximum protection. In addition to the pallet racking, Avanta designed and supplied steel decks with smoke baffles, sprinkler brackets and rack protection products. Prior to the contract award, Sample bays were supplied and set up on site with various deck options. This allowed the client and associated parties to choose which option they felt was best for the application. Avanta Comment – “A really satisfying project for Avanta. We ran an efficient installation in a clean and clear site. This contributed towards finishing the project on time and on budget. This was a hard-fought contract win against a selection of the world’s largest pallet racking manufacturers who were quoting directly.”
sales@avantauk.com 56 40,000 Pallet locations 2,400 Heavy duty frames 35,000 2700mm beams Wide aisle racking
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www.avantauk.com 61 VNA Pallet Racking with Low-Level Pallet Racking Scope: High-density pallet racking installation across multiple warehouse zones Avanta UK Ltd has partnered with a prominent UK multichannel retailer for over 25 years, delivering a wide range of warehouse improvement projects — from mezzanine installations to office conversions and staff shop fit-outs. This particular project focused on increasing storage density in two distinct areas of the warehouse using a combination of Very Narrow Aisle (VNA) pallet racking and lowlevel pallet racking. The solution was designed to accommodate pallets, boxes, and rolls of fabric efficiently. VNA Adjustable Pallet Racking • Height: 17m to 18.5m • Frame: Galvanised • Beams: Painted orange, 2.7m long, 2000kg capacity • Adjustable pitch: 50mm, allowing reconfiguration for different pallet heights • Current beam levels: 1850mm, 3700mm, 5500mm, 7400mm, 9250mm, 11000mm, 12950mm, 14800mm, 16650mm Configuration: • 1 single run (30 bays) • 2 double runs (30 bays each) • Capacity: 3,000 pallets • Sprinkler brackets: Installed throughout Low-Level Adjustable Pallet Racking • Height: 2m and 2.5m • Bay size: 2.7m clear entry width x 1m depth Configuration: • 46 runs @ 20 bays long • 5 runs @ 21 bays long Capacity: • 4,310 pallets • 1,235 pick locations Features: • Mesh decks fitted to all levels • End barriers and upright protection throughout • Designed for storing pallets, boxes, and fabric rolls used in furniture production Conclusion Pallet racking is a vital component of modern warehouse operations. It supports efficient inventory management, optimises space, and ensures safe and organised storage. This project highlights how tailored racking systems can meet both high-density and flexible storage needs.
sales@avantauk.com 62 Height: 17 to 18.5m Galvanised Beams: 2.7m Long 2000kg Capacity APR Racking Height: 2 to 2.5m End Barriers & Upright Protection
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www.avantauk.com 69 Over 30,000 Box Locations Created for Top Retailer As part of a wider project, Avanta UK has been awarded and fulfilled a contract to supply, deliver and install a large quantity of Longspan Shelving for one of the UK’s leading multi-channel retailers. The top floor of a recent multi-level mezzanine floor project undertaken by Avanta was to be specifically used for box storage and associated picking. The Longspan Shelving system proposed is designed to store the popular box size 400mm high x 300mm wide x 600mm depth known as a BDC (Bulk Distribution Carton) and this project gave the client 32,688 full height BDC locations. The total of 454no bays measured 3300mm (H) x 1200mm (W) x 1850mm (W) with each bay storing 72 boxes. The beams are a ‘Z’ shaped profile to accept an inset mesh deck that has an integral divider to prevent boxes being pushed out. The snug fit of the mesh also helps prevent accidental lifting of the deck level when picking a full box or from the box. Another advantage of the ‘Z’ Shaped beam is for the labels to be inserted. The frames are of an extended height to accept the 5 levels but to also self-support the PIR aisle lighting and additional services as required. The shelving was sourced from long term Avanta supply partner AR Racking of Spain who are a leading manufacturer of shelving and pallet racking systems. Avanta UK Ltd acted as principal contractor on this project taking full responsibility for CDM of the work areas. The shelving element of the project took 4 weeks to install.
sales@avantauk.com 70 32,600 BDC Locations 454 Bays Storing 72 Boxes Extended Height To Accept 5 Levels 4 Weeks To Install
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www.avantauk.com 77 Collaboration Creates Efficient Storage Picking Solution The client, Next plc had a requirement for a manual storage solution for boxes that enabled them to locate, store, empty and fill the racking in the most ergonomic, efficient and effective way possible. Space for this project was allocated on an existing level of an Avanta mezzanine floor with an existing conveyor layout and column grid to integrate into the designed solution. Working closely with the client, Next tasked AVANTA with supplying a FILO (First In Last Out) flow racking system (Also known as carton live storage) that could store up to 12,000 BDC1 Boxes. In the early design stages, the client supplied AVANTA with the size of the boxes and the details of our conveyor layouts in order for a proposal to be put together. Avanta engaged with 2x prominent manufacturing partners on this project: AR Racking – A leading European manufacturer of racking systems. Interroll Group – A world leading provider of material handling solutions and in this instance – Roller beds. Avanta UK designed, supplied and installed 151 bays of carton live storage with 3x levels giving 453 roller beds measuring circa 2700mm length x 2500mm depth. The client commented: “The solution supplied does exactly what we need, we are now able to use the flow racks to load and unload boxes with ease, the roller system allows us to stand in one spot and load boxes without overreaching or twisting and allows us to be close up to the conveyor system as we do it, saving time and keeping our operators safe. The installation of the flow racks could not have been better, the modular style of the racking system allowed the installers to put them together quickly and allowed them to create a production line of installation. All nuances to the install were consulted with by ourselves, such as column clashes, walkway gaps and flow rack heights, this ensured speed and certainty of correct installation.” Avanta commented: “Next plc and Avanta UK collaborated effectively yet again to create a highly efficient and ergonomic storage solution. The use of a FILO flow racking system, along with the integration of AR Racking and Interroll Group’s roller beds, seems to have met all their needs perfectly. The modular design and the attention to detail during the project, such as addressing column clashes and walkway gaps, contributed to the project’s success. It’s great to hear the feedback from Next that the system allows operators to work safely and efficiently.”
sales@avantauk.com 78 151 Bays of Carton Live Storage FILO Racking (First in Last Out) Length Circa 2700mm Store up to 12,000 BDC1 Boxes
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www.avantauk.com 85 Multi Tier Fire Rated Retail Mezzanine Floor Project Leeds-based storage equipment specialist, Avanta UK Ltd successfully tendered for and delivered a turnkey warehouse improvement project for a leading multi-channel fashion retailer. The client is long established in the fashion arena selling garments and footwear through mail order, ecommerce, franchises, concessions and its own stores. Having completed a significant warehouse extension, the next stage for the client was to engage with a specialist storage equipment provider to optimize the storage capacity of the cubic space within the extension, improve pick rates and lock into the warehouse management system to service the afore mentioned channels. Warehouse Storage Solutions All items are picked from the BDCM1 Retail box / carton, and the system was designed around the box and the available space. The solution included: Two Tier Mezzanine Floor The mezzanine floor came in at a healthy 4,271m2 (46,083ft2) and is fire rated to 1 hour with suspended ceilings, fire enclosed staircases with fire escape doors. There are 120 linear metres of handrail and temporary handrail, and safety netting was employed during the build of the mezzanine floor. Ground and level 1 are to be used for the main storage and picking operation with the smaller level 2 to be used for bulk and overstock. Lighting and Smoke Detection PIR lighting was installed throughout the structure with power and data for the sortation and packing area benches also supplied and installed. Electrical supply was installed for the mezzanine floor goods lifts and conveyor system. Smoke / Fire detection system was a pre-requisite of the Building Regulations organised by Avanta UK. Mezzanine Floor Goods Lifts Floor slab preparation works took place for 2x mezzanine floor goods lifts to service all levels of the mezzanine floor took place. The lifts enabled the safe movement of products in totes between levels. Avanta oversaw the installation and the commissioning of the goods lifts to all relevant standards. Warehouse Shelving Systems Longspan Warehouse Shelving Avanta UK designed, supplied, delivered and installed 1057 bays of BDC box storage shelving. Each shelf level is complete with a mesh shelf with integral divider for back-to-back storage of the picking boxes. This gave the client the capacity to store circa 58,000 BDCM1 boxes to pick directly from. The shelving system is designed to have no wasted space with the bay sizes designed around the box size. Returns Shelving No Internet retail warehouse is complete without a dedicated area or facility to store individual returned items. Avanta UK have designed and developed a returns shelving system that in this instance the 96 bays supplied gave the client circa 3168 return locations to pick from and re-work. Sort / Pick / Pack Area Workbenches With power and data to a specific area of the mezzanine floor, Avanta UK supplied 40x bespoke packing 2.1m length workbenches complete with louvre panels, base and upper shelves. Conveyor System Complete with bar code reading, warehouse management interface and service package, the conveyor package offers the client a quick, cost-effective method of moving products in plastic totes around the 3 levels. With powered rollers, decline belts and lift up transfers, this conveyor system is an efficient mode of transporting product around the warehouse to the pick pack area workbenches. There is circa 150m of conveyor on this project. Picking Totes 2000 stack and nest containers 600 (L) x 400 (W) x 325 (H) mmwith 15KG capacity in 4 colour ways were supplied for multiple picks in the trolleys and conveyor systems. Trolleys 20 off bespoke picking trolleys designed and supplied. Each trolley is designed to accommodate and transport 12 totes. Principal Contractor Role With a project of this size / duration to conform with Construction (Design and Management) Regulations 2015 (CDM) Avanta UK Ltd acted as Principal Contractor (PC). This included full site set up with welfare facilities for all trades, full site supervision with suitably qualified site management throughout. Avanta was responsible for full health and safety in the CDM area throughout the project. The Project This turnkey project was a 2-phase programme with 60% of the fire rated mezzanine complete with shelving could accommodate stock that was originally bulk stacked in the warehouse extension. This then freed up the space tomove to phase 2 and this included the remaining 40% of the mezzanine, conveyors, goods lifts and ancillary items.
sales@avantauk.com 86 4,271m2 Two tier mezzanine 58,000 BDCM1 box locations 3,168 Returns locations 150m of conveyor employed
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www.avantauk.com 91 Mezzanine & Shelving Project Phase 1 The project took place in the North of the UK and it was for a fire rated multi-tier mezzanine floor measuring approximately 14,500 Square Metres. This project is a two tier platform with each platform measuring 7210.57 metres square and the finished floor levels are set at 3900mm and 7500mm. The existing warehouse floor slab was piled to accommodate the additional load and this gave Avanta the opportunity to increase the span between the columns and set the footplates into the floor slab and thus reducing obstructions and creating a neat finish. The floor loading is rated at 5Kn/m2 and load access is via a goods lift and 4 up and over pallet gates. There are 6 staircases with mid landings and over 800 linear metres of handrail and kickplate. In addition to the hand rail extra protection is achieved using 1200mm high mesh panel to prevent boxes falling. Both floor levels were finished in a two pack epoxy floor seal providing an anti-slip waterproof finish to the mezzanine deck. Avanta also supplied wrap around column protection for the ground floor and full barrier protection to the perimiter. On the middle floor Avanta supplied and built longspan shelving with mesh decks to create 40,000 BDC box locations. On the top floor Avanta designed and supplied various workbenches and trolleys creating a new QC Area and garment hanging section. Outcomes With the addition of this mezzanine, apart from the obvious space creation this project has enabled- • The creation of 200+ new jobs. • Increased storage capacity. • Improved picking rates. • The floor can be extended upwards and outwards if required to suit the needs of the business. • The use of the floor could be changed or adapted if required. Mezzanine & Shelving Project Phase 2 The original floor measured 14,500m² and the extension would offer a further 7,500m² for the client to utilise. An additional 300 linear metres of handrail were required to levels 1 and 2 and an additional 3 staircases. Floor was fire rated to 1 hour and deck levels finished in an anti-slip resin. Selected Statistics Mezzanine Floor Phase 1________________________________ 14,500m² Phase 2_ ______________________________ 7,500m² Total_ _________________________22,000m² Handrail Phase 1__________________800 linear metres Phase 2_ ________________ 300 linear metres Total_ __________________1100 linear metres Staircases Phase 1_______________________________6 Phase 2_ _____________________________ 3 Total_ _______________________________ 9 In addition to the existing Longspan Shelving supplied and installed by Avanta that gave 50,000 BDC box locations, Avanta supplied and built new Longspan shelving that offered an additional 60,000 BDC locations. Mezzanine Floor Uses Include… Running concurrently with the mezzanine project were multiple projects centred around the uses of the floor. In addition to the BDC storage these include: • Secure partitioned area formed from solid steel and mesh panels with garment hanging system for high value stock. • Creation of specific self-contained workspaces for concessions including partitions, suspended ceilings, benches and more. • Covid secure packing areas with 2mx1m workbenches and 2m high covid screens.
sales@avantauk.com 92 Multi tier mezzanine floor Floor approx: 14,500m2 6 Staircases with mid landings 4 Up and over pallet gates
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www.avantauk.com 97 END to End Storage Solution Leeds based Storage Equipment Specialists Avanta UK Ltd have completed one of the largest multi-tier shelving systems projects in the UK for an influential multi-channel menswear retailer. Theonlinedemandforcuttingedgesportswear, trainers and the best in contemporary menswear has driven the requirement for this large-scale expansion programme. Alongside UK based flagship stores the client has a growing online presence servicing the UK and to over 80 Countries Worldwide fuelling the requirement undertake this project. Having worked with the client before, Avanta UK already had an insight into what the best solution for the client would be in order to increase storage capacity of a warehouse extension for box storage utilising the full height, widthand lengthavailable. This resulted in refining a design for a multi-tier shelving system incorporating a mezzanine floor. Avanta UK Ltd successfully tendered for the project against a very competitive field and were awarded the contract. It could not be anticipated that this project would be undertaken during the Covid-19 National Lockdown. The multiple trades teams had to complete the installs whilst following Government advice in all aspects. This also could have impacted the supply of raw materials with various factories closing or operating on a reduced staff number. However, despite this situation the project was successfully completed in the 20 week programme required working along side the Sprinkler company, Electrical Contractor and other Trades. The contract worth circa £1.8 million is for one of the largest multi-tier shelving systems in the UK giving the client: - • 3 Levels plus ground – (Ground, Level 1 & Level 2 for shelving and Level 3 for storage and potential growth. • Each level measures 145m in length x 35m width giving 5075m square per level x 3 in the structure = 15,225m square. • If you include the ground level, there is over 20,000 square metres of storage. • 15,000 Shelves within the structure. • A capacity of 550,000 shoe boxes can be stored. Access to each level for product included 3x goods lifts. One of which had capacity for 4 pallets and the other 2 lifts could accommodate 2 pallets each. Pedestrian access is via 4 staircases of which 2 were enclosed. Avanta UK also built a galvanised staircase for outside with access to all areas as well as various fire exits as required. Avanta Commented – “This was a great contract win for myself and Avanta after many weeks of refining the design to create an impressive storage solution for the client that will help them satisfy their growing demand now but also in the future. This project displays the capability of the Avanta team, and it is a solution that other large Internet Retailers could adopt going forward.”
sales@avantauk.com 98 Multi tier shelving system 3 Levels plus ground Each level 145m in length 20,000m2 of storage
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www.avantauk.com 103 Storage Equipment Fit Out Project For New Lockwood Group Distribution Centre Lockwood Group have had a new 110,000sq ft warehouse purpose built in Denby to add to their existing 7 UK Sites. The Group is a family run business and currently has over 280 employees and activities include UK haulage and storage, frozen food production and commercial vehicle maintenance. Leeds based Storage Equipment Specialist Avanta UK Ltd worked closely with the Lockwood team and Handling Equipment Specialists to optimise the pallet storage of the new Grade A Warehousing Facility. The project included: - • Pallet Racking - Arranged in a very narrow aisle configuration to 13 metres high giving a storage capacity of circa 24,000 pallets to store a combination of Euro and UK pallets. • Mezzanine Floor - Two tier fire rated mezzanine floor giving circa 1000 square metres of additional storage space. Access is via a utility and general access staircases. Pallet access is via 4 pallet gates. • Protective Barriers and Upright Protectors. • Pallet Location Labels. Lockwood Haulage are one of the UK’s leading logistics providers. They have a large diverse fleet, with cost effective, quality, sustainable logistics solutions. Lockwood sites are in excellent locations to serve the whole of the UK and beyond on a same-day or next day basis. With the addition of this excellent new facility Lockwood are in the perfect position to deliver on their client promise. AvantaUKLtdoffersa full officeandwarehouse interior design and installation service. We offer a free Site Survey and CAD Design and Consultancy Service, responding promptly to your enquiries.
sales@avantauk.com 104 Very narrow aisle racking 24,000 (Circa) pallet spaces Two tier mezzanine floor 4 Up and over pallet gates
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www.avantauk.com 109 Avanta Create Safe, Secure Enclosed Environments for Meggitt Plc The new 440,000 square foot Headquarters for Meggitt Plc located in Ansty Park in Coventry is a state of the art UK engineering and advanced manufacturing centre of excellence and global. The site is one of the biggest investments in UK manufacturing capability in a decade as well as being Meggitt’s largest infrastructure investment in history, one of a number of recent global infrastructure investments. As one of the largest industrial projects in the Midlands, this hub for next-generation UK aerospace innovation is the European Operational Centre for braking systems, thermal solutions, aftermarket. Built in 2020 and now internally equipped and fitted out, this specialist manufacturing and testing unit is now operational. Meggitt Plc is a global leader in aerospace, defence, and energy with 1000 staff to be based at the site creating a centralised UK operation. Working inpartnershipwithCleggConstruction & Meggitt Plc – Avanta UK Ltd designed and supplied a multiple enclosure solution that could be used for various applications across the factory. The project evolved over a 12-month period and resulted in some 65 enclosures supplied and installed over 12 zones within the factory. Various applications for the enclosures included multiples of: • Machine Housing. • Offices. • Canteens and Break Out areas. • Workshops. • Control Rooms. • Test Units. • Paint Roomwith 2x Speed Doors. • Stores. Working closely with manufacturing partner Troax it was felt that a combination of double and single skin steel partitions would be the perfect solution and provides many advantages over a traditional plasterboard or timber product. Steel Partitions are formed from a panel system to divide and subdivide the workplace and are commonly used in a warehouse and factory environment. Panels are fully demountable and can be re-configured to be used in other areas of the factory if required. Utilising the standard Sigma single skin steel and Elan double skin steel partitioning panels offered the client flexibility to have a variety of solid and solid with glazing and / or mesh enclosures to suit the application. A small number of enclosures utilised a bespoke panel arrangement. Sound proofing to achieve the required dB rating and fire rated panels for specific enclosures and housings ensured compliance. Specialist enclosures for strict temperature control and air purification applications were also supplied and installed as part of the project. Mezzanine floors with high-level bracing to utilise floor space, walk-on ceilings were also part of the Avanta contract. All doors were supplied to specified locking arrangements – from access control to simple euro cell lock or thumb turn locks etc / door closers. A bespoke large steel double sliding door was installed in zone 1 and 2x speed doors to the paint shop. Quote from Meggitt: “Ansty Park is a major advance in the development of our global manufacturing footprint and we have been pleased to work with Avanta to build these important enclosures which can be used for various applications as and when we require.” Quote from Troax: ‘’We are very proud to have supported Avanta with this project. It is not often we get the opportunity to showcase our wide range of solutions and products, all under one roof. This project included single skin, double skin, fire and acoustic systems, pressed panels, mesh panels, glazed panels and ceiling systems. Working in close partnership with Avanta, we were able to navigate all of the challenges of the pandemic and ensure work was completed safely and on time. Our whole ethos is ‘Protecting People, Property and Processes’ and we are delighted that we have been able to install that fully into this unique project.’’ Quote from Avanta UK: “We were delighted to be awarded this project for such a large blue chip aerospace company. The results of everyone’s hard work have contributed to a modern state of the art facility one which Meggitt can be proud of. These enclosures will help Meggitt employees work safely and securely in a modern factory environment. Working with our supply partner Troax enabled a quick build time of a top-quality steel partitioned product. Under the CDM of Clegg Construction we worked safely and diligently to complete this project on time and to budget”
sales@avantauk.com 110 65 Enclosures over 12 zones Single & double skin partitions Canteens and Break Out areas 65 Enclosures & 12 zones
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www.avantauk.com 117 Staff Benefit from Avanta Shop Creation Avanta UK recently completed a comprehensive and multifaceted project for Next Plc, transforming a section of the Dearne Valley Pallet Warehouse into a 9,000 square foot retail staff shop. This involved collaboration with various teams and contractors to ensure the design met Next’s retail style and included essential features like an office, changing room, back of house secure storage area and staff break-out space. Working with Next’s in-house teams and contractors to create a compliant and attractive layout involved working closely with the following: • The Next in-house retail team • Warehouse engineering project team • Loss prevention department • Multiple Next contractors Avanta collated this information and formulated a layout with the architect and liaised with Building Control to ensure design and build compliance. Acting as Principal Contractor, Avanta was responsible for all the health and safety for the project and managing all subcontractors. Key aspects of the project included: • Strip out of existing site equipment • Supply and install 1hr jumbo stud walls with full internal ply lining for mounting shelving and wall furniture • Supply and install column casings, suspended and MF ceilings in offices and lobby • Firestopping • Back of house caging • Barrier protection • Full joinery package including high-spec door sets, skirtings, architraves and fascia. • Decorative spray painting of the soffit and some existing services to give retail specification • Building works included. o Modifications to existing fire stairwell o Cladding and steelwork modifications to form entrance o Automated shop door sets with supporting steelwork o Forming new entrance corridor o Concrete plinths for M&E equipment Other fit-out items on the project included stripping out the existing Mechanical & Electrical equipment and installing full new M&E (exposed) set at 3mhigh tomatch into the retail stores specification. Part of the electrical brief included till set up, power, lighting, data and CCTV. A specialist hard wearing epoxy floor system with decorative flake finish was also installed. The project required meticulous planning and coordination to integrate a new retail space within an operational warehouse, showcasing Avanta’s ability to manage diverse construction disciplines effectively. This project included • Design and Compliance • Construction and Installation The project duration was 14 weeks.
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