Due to an increase in demand created by the securing of new business, a major North West manufacturing client of Active Supply & Design needed to increase storage space within their manufacturing facility. The most cost effective method of achieving what was required was deemed to be the installation of a mezzanine floor to an area of the factory floor. Three companies were asked to quote for the project, whilst also defining how any obstacles were to be overcome. Active Supply & Design were awarded the contract due to their competitive pricing, pro-active approach, innovative thinking and flexible attitude.

An operational manufacturing site with no production time to be sacrificed whilst a mezzanine floor is installed provides the kind of challenge that the team at Active Supply & Design thrive on. Expensive machinery could not be relocated, so extra care and detailed risk assessments specific to the task in hand were vital. Active’s 20 years’ experience of installing mezzanine floors helped tremendously in providing the solutions to this demanding remit. By utilising two teams, materials could be moved to where required during the evening without any disruption to operational aspects for the client. The build of the floor then continued around the clock so as to minimise disruption as much as possible.

Due to the nature of the underlying substrate, the concrete slab on which the floor was to be located required piling before installation commenced. This aspect of the works was also completed during the evening hours so as not to hinder the on-going manufacturing operation, the piling process also being fully managed by Active Supply & Design.

Building control regulations is an area where this client recognised one of the many benefits of using Active Supply & Design. During the design phase of all mezzanine floors, Active include means of achieving compliance with Building Regulations. Active regularly deal with local authorities and the fire brigade to ascertain the correct level of protection for both your mezzanine and building as a whole. This gives clients the peace of mind that their project will satisfy building control requirements.

This particular mezzanine floor is of single tier construction and of approximately 650m2 with a finished floor level of 4.5m, and is accessed by two steel staircases. One hour’s fire protection is provided by means of a suspended ceiling, fascia and the cladding of all support columns with intumescent materials. The installation of the floor being completed in less than two challenging weeks helped ensure the complete satisfaction of their client.

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