Project brief
An online fashion and electronics retailer had outgrown a 1,600 m² footprint and could not move. We designed a two-tier rack-supported platform so the same floor area delivers three levels of hand-picking with longspan shelving and bin locations for 60,000 SKUs.
| System | Rack-supported mezzanine, 2 upper tiers |
|---|---|
| Floor area | 1,600 m² footprint → 3,200 m² added |
| Deck load | 500 kg/m² live load |
| Deck | 38 mm chipboard on steel grating walkways |
| Shelving | Longspan 2,000 × 600 mm bays, 400 kg/level, 5 levels |
| Access | 2 staircases, 2 pallet gates, 4 conveyor cut-outs |
| Fire | In-rack sprinkler brackets, 1.2 m handrail + kick plate |
| Standard | EN 15512 / EN 15620 tolerances, UAE civil-defence drawings |
| Delivery | 30 days production, 6 × 40′ HC |
What we delivered
- Structural calculations and stamped drawings for local authority approval
- Phased installation plan so order picking continued on ground level
- Colour-coded aisle and location labelling pre-applied in the factory
Result
Pick locations tripled without expanding the building; the platform was installed in 4 weeks with zero downtime on the ground floor.
