Global mezzanine solutions supplier, MiTek® specialises in the implementation of large-scale steel platforms to tight schedules.
Vast new warehouse for UK retailer
Earlier this year, MiTek successfully handed over its biggest mezzanine project to date. The multi-tier solution, which totals over 100,000 sq m and reaches 24m in height, forms part of an automated e-commerce distribution facility for a leading UK retailer. The mezzanine system was installed in a brand-new building located in the north of England, with MiTek working in partnership with one of the UK’s leading construction groups and one of Europe’s largest system integrators.
The distribution centre features five floors plus a further level of steelwork above the top floor for fixing automated handling systems to. With a build time of around seven months, the mezzanine solution required integration with various intralogistics automation technologies, including standard tote conveyors, spiral conveyors, elevators and overhead garment-conveying systems. A mezzanine section with less deflection was also installed for a canteen area, using stiffer steel parts to ensure a more rigid floor.
To facilitate the installation of the spiral chutes into voids between the floors, the MiTek team designed and built support steelwork to help lift in and position the chutes. Additional support steelwork was used to build a lift in one of the staircase towers. Due to the multi-level nature of the project, MiTek also incorporated special connections between columns and beams into the mezzanine design, in order to minimise installation time.
“The challenge of this project was in its scale,” explains Dan Humphreys, Project Manager for MiTek’s mezzanine operation. “To give an idea, the solution we provided features columns up to 21m in length, as well as four staircase towers to all levels and over 17,000m of handrail. Thanks to meticulous planning and the team’s vast experience in large-scale projects, on-site installation went smoothly, despite the complexity of the solution.”
Rapid retrofit for US automotive aftermarket distributor
A recent project for MiTek in the US has been the retrofitting of a mezzanine system in the distribution centre of a leading automotive aftermarket parts distributor. This is part of the solution provided by Siggins, a system integrator and MiTek customer for over 20 years. Servicing several thousand orders per day, the distributor stocks products from over 100 manufacturers. The warehouse previously had a small amount of conveyor, but the company wanted to introduce more automation and create more workspace.
MiTek installed two single-level mezzanines. Both are cold-formed platforms, which improve carbon footprint through their reduced weight, as well as saving costs for customers due to needing less material and enabling faster lead times. All component parts for the mezzanines, staircases and pallet gates were manufactured at MiTek’s factory in Wisconsin. The steel platforms support conveyor lines, leaving the areas below free.
“In this project, the challenge was to keep the DC running while installation took place,” explains Tom Surges, Midwest Regional Manager for MiTek’s mezzanine operation in the US. “The mezzanine floors were built in phases and the customer moved operations from area to area to facilitate installation.”
“MiTek supported our implementation plan perfectly,” notes Siggins’ Project Manager, James Powers. “With excellent communication, well-planned deliveries and superior on-site support, MiTek and their project management team answered the bell every time during a challenging installation.”
Again, integration with automated intralogistics systems was required – an area that MiTek has amassed considerable expertise in. In addition to new conveyors, the Siggins solution features multiple OPEX Perfect Pick HD aisles (a shuttle-based ASRS), which required cut-outs in the mezzanine profile to enable tote retrieval. The mezzanine solution also interfaces with rack-supported pick modules and spiral conveyors.
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