Large Warehouse Interior Storage Systems Project

Client: Leading British mobility retailer

Location: UK

Duration: 20 weeks

Scope: Full turnkey warehouse interior fit-out

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 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

Flex Guard Barriers & Column Protection

35m of protective barrier installed along ground floor walkways and forklift charging areas

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

Signage & Labelling

- All pallet and box locations barcoded and compliant signage installed at aisle ends

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

Partitioned Work Areas

Two workshop areas were created beneath the mezzanine using single-skin steel partitions and mesh panels.

Custom Workbenches

40 bespoke workbenches were supplied, split into two types tailored to specific tasks.

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

To learn more about mezzanine floors, visit: Mezzanine Floors - Avanta UK