Flexitallic UK – heavy duty pallet racking, mezzanine floor, and short span shelving

The challenge

There were several challenges throughout the whole of this project. To start with, engineering sealing solutions specialist, Flexitallic, already had a supplier that they’d used for their existing pallet racking and industrial shelving. Unfortunately, however, the existing supplier was unable to achieve the required pallet count through the current racking orientation. As a result, the client was using outside storage to store pallets and wanted to be able to store all pallets inside and within the same racking system.

Several companies were approached to quote on this new project and whilst the proposed racking layouts were very similar, Alternative Storage Systems won the project due to noticing a stream running under the warehouse. We raised this point as, with a mezzanine floor, the floor must be able to take the weight of the floor plus the loading on top. The company was then made aware of this and core samples of the floor were taking to assess suitability.

The solution

After taking the core samples, the client was made aware that, as it stood, the floor would be unable to take the proposed weight loading. It was made clear that the floor would have to be concrete piled exactly where each leg of the mezzanine would be positioned. Our attention to detail was the main reason we won the project, given that, had the client opted for another supplier and not realised about the stream running under the warehouse, the floor would almost inevitably have collapsed over the years.

Having won the project, we worked closely with the project manager and came together to decide on the require racking layout. We exchanged the client’s current racking and shelving and supplied brand new Sperrin Pallet Racking and short span shelving. We reconfigured their existing reach truck layout into a new flexi forklift orientation, achieving the client’s target of 1200 pallets. In order the maximise the customer’s stores area, we designed and installed a fully fire rated mezzanine floor 30m long by 20m deep, which incorporated 164 bays of short span shelving to go on top. Also, on top of the mezzanine, we built a new office for the warehouse manager.

The outcome

The project was sectioned into three phases…

1. The mezzanine floor
2. The short span shelving
3. The heavy-duty pallet racking

Each phase was delivered and completed within the target timescale. Once the project was underway the client expressed how happy he was to have chosen us due to the fact that we took the stress away and used our expertise the design, install, and project manage to the whole thing. This allowed the client to focus on his own work and not have to worry about the project.

Coming off the back of this successful delivery, we’ve worked together again providing additional shelving and pallet racking as well as creating a security cage to keep certain products away from the rest. We have always received the most amazing feedback from the client and he’s repaid us by having faith in us to complete all his future projects.