Install two-tier mezzanine floor, Bodiam

To design, supply, and install a two-tier mezzanine floor alongside a high-capacity pallet racking system to maximise storage and operational efficiency within an existing warehouse.

Client: Manufacturer of Commercial Washroom Solutions

Location: Bodiam, East Sussex

Objective:Create a multi-level warehouse storage solution that increases usable floor space, supports both storage and office functions, and integrates a high-density pallet racking system suitable for fast-moving operations.

Warehouse Storage Solution Overview
Linear Storage Solutions were approached by Dolphin Solutions to develop a comprehensive warehouse upgrade that would significantly increase storage capacity while also introducing additional operational and office space within their existing facility.

Following detailed consultation and design development, we proposed a two-tier mezzanine floor combined with a tailored pallet racking system, enabling the client to maximise vertical space and improve overall workflow efficiency.

The mezzanine structure was designed to provide:

• Two additional floor levels at 3.6m and 7.2m finished floor heights
• 360m² of additional floor space across both levels
• Dedicated areas for storage, operational use, and office space
• Floor loadings of 4.0kN (storage level) and 3.5kN (office level) to suit varying usage requirements

The project also included the installation of a high-capacity adjustable pallet racking system, designed to support a wide range of pallet sizes and weights while maintaining efficient access and safe operation.

The installation was carefully planned to align with the client’s operational needs, with an estimated 2–3 week mezzanine construction period, followed by a structured fit-out phase coordinated alongside other contractors.

Equipment & Specification

Mezzanine Floor System
The mezzanine floor was engineered to maximise usable space while meeting all relevant building regulations and safety requirements. Key features included:

• Steel structure with 6m clear spans to minimise internal columns
• 38mm high-density P6 particleboard decking for durability
• Two compliant staircases designed to Building Regulations standards
• One-hour fire-rated suspended ceiling between levels
• Integrated design to accommodate partitioning, lighting, and services

The structure was finished with a combination of primed and galvanised steelwork, ensuring long-term durability and performance within an industrial environment.

Pallet Racking System

The pallet racking solution was designed to deliver flexibility, strength, and efficient storage for both Euro and GKN pallet types.

Key specifications included:

• Frame heights of up to 9.5 metres
• Beam load capacity of 3,000kg per level (UDL)
• Bay load capacity of up to 12,000kg
• Multiple beam levels configured to suit varying pallet heights
• Timber decking installed across all levels for enhanced picking capability
• Full system supplied with load notices and SEMA-compliant installation

The layout was optimised to ensure safe operation, efficient picking, and maximum use of available warehouse space.

Project Outcome

This integrated mezzanine and pallet racking solution delivered a significant increase in storage capacity and operational flexibility, allowing Dolphin Solutions to scale their operations without the need for relocation.

By combining vertical expansion with a high-performance racking system, the project successfully transformed the warehouse into a multi-functional, high-efficiency storage environment aligned with the client’s long-term growth plans.