Some warehouse projects are all about unlocking serious additional capacity without increasing the building footprint.
For this Project Spotlight, we’re looking at a completed two-tier mezzanine floor installation for Ziegler at London Gateway. The project created a large amount of additional storage space across two raised levels, helping the client make better use of the available height inside their existing warehouse facility.
Expanding Storage Capacity Over Two Tiers
The completed mezzanine floor was installed across two levels, with each tier providing approximately 1,086m² of additional usable floor space.
This created a substantial increase in storage capacity within the existing building, avoiding the need to extend the premises or relocate to a larger facility.
The mezzanine was designed and installed for storage use, with a loading capacity of 4.8kN/m² and finished floor heights of 5.6m and 8.83m. This made it suitable for a busy warehouse environment where the additional levels needed to support practical day-to-day use.
Built for an Industrial Warehouse Environment
A mezzanine floor of this scale needs to be robust, safe and suitable for the demands of an operational storage facility.
For Ziegler, the structure included 38mm P6 high-density particle board decking, selected for industrial use with racking, trucks and trolleys. The main steelwork was finished in Graphite Grey, while the joists were pre-hot dipped galvanised.
The project was not simply about adding extra floor area. It required a complete structural solution that considered loading, access, stability, safety and long-term warehouse use.
Safe Access Between Levels
With two raised storage levels, safe access was a key part of the completed installation.
The project included two full tower staircases, each with 1000mm clear width steel treads and risers for general access. The staircases were designed with handrails and knee rails to both sides, extended handrails beyond the top and bottom risers, and double mid-landings.
This gave staff clear and practical access between the warehouse floor and the mezzanine levels, supporting the day-to-day movement of people around the facility.
Looking to have a mezzanine designed & built?
Let’s get a free quote over to you as a start and we can go from there.
Loading Points for Stock Movement
For a storage mezzanine to work properly, goods need to be moved between levels safely and efficiently.
The Ziegler project included six safety pallet gates, designed for pallets up to 1.2m x 1.2m and a maximum height of 1.5m. Steel chequer plate loading areas were also included as part of the works.
These loading points helped turn the mezzanine into a usable storage system, rather than just an elevated platform. They allowed stock to be transferred between levels while maintaining safety at exposed edges.
Edge Protection Around the Mezzanine
The completed installation also included extensive edge protection around the exposed sides of the mezzanine.
A total of 303 linear metres of side-mounted edge protection was included, using SHS posts, tubular handrails, knee rails and kick angles. This helped create a safer working environment across both mezzanine tiers and supported the practical use of the raised storage areas.
60-Minute Fire Protection
Fire protection formed an important part of the completed works.
The mezzanine was fire protected to achieve 60-minute fire rating to both levels. This included fire-rated column casings, fire-rated fascia to exposed edges and stairwell areas, suspended ceiling protection and fire curtains within the ceiling voids.
The fire protection package helped ensure the mezzanine was delivered as a fully considered storage installation, with the structural elements, access routes and fire strategy all working together.
Fire-Rated Staircase Enclosures
The staircase areas were also enclosed using a 60-minute fire-rated partitioning system.
These enclosures included insulated plasterboard construction, decorated finishes, black laminate skirting and FD60 self-closing oak-style fire doors with vision panels, intumescent strips and smoke seals.
This was an important part of the overall project, helping to protect escape routes and support the safe use of the mezzanine levels.
Steel Partitioning to the Perimeter
The works also included Bastion single skin steel partitioning to the perimeter of the first and second floor levels.
This helped define the mezzanine areas and provided a practical perimeter solution suited to the industrial setting. Combined with the edge protection, pallet gates and stair access, it helped complete the mezzanine as a functional storage environment.
Coordinated Design, Management and Installation
A project of this size requires careful coordination from the early design stages through to installation and handover.
The works included construction design CAD drawings, site supervision, project management, health and safety documentation, hire equipment, waste removal and an operations and maintenance manual at completion.
A 16-week programme was allocated for the ACI works, reflecting the scale of the installation and the planning required to deliver a two-tier mezzanine floor in a live industrial setting.
Looking to have a mezzanine designed & built?
Let’s get a free quote over to you as a start and we can go from there.
A Large-Scale Mezzanine Storage Project
The completed Ziegler project is a strong example of how a mezzanine floor can transform the capacity of an existing warehouse.
By installing two storage levels, the project created significant additional floor space within the same building footprint. With stair access, pallet gates, fire protection, edge protection and perimeter partitioning all included, the finished mezzanine was built to support practical warehouse use from day one.
For businesses operating in warehouse, logistics or industrial environments, a two-tier mezzanine floor can be a highly effective way to increase capacity without moving premises.
Planning a Similar Mezzanine Floor Project?
If your warehouse or industrial unit has unused height, a mezzanine floor could help you create valuable additional storage or operational space inside your existing building.
The Mezzanine Company designs and installs mezzanine floors for warehouses, logistics facilities, storage areas, offices and industrial environments across the UK.
Get in touch with our team to discuss your project. Or simply fill in your details below and we’ll get back in touch! 🙂
