The mezzanine to pick
June 1st 2006

A dual solution of mezzanine floor and chiller roof support from Mezzanine International has proved central to the success of Roche Diagnostics' new South of England Distribution centre

When the international healthcare company Roche Diagnostics needed a new South of England distribution centre Mezzanine International was chosen to design and install the main ambient temperature order picking mezzanine, the 23.4 metre long chiller roof support structure and a rack supported mezzanine within the chiller. Also involved in the project were logistics consultants, Alan Wilson Associates

The design allowed for orders to be picked into tote boxes from shelving and flow racks on the main 3.5m high 32m x 23m mezzanine and then to be moved on conveyors designed and installed by Knapp Logistics & Automation and, via a Knapp tote lift, to and from the ground level. A maintenance platform to allow access to the tote lift was to be built out from the main mezzanine level and a conveyor run to the ground level needed to be supported from the side of the mezzanine to maximise the useable space on the mezzanine. This was achieved by extending a number of the mezzanine beam lines beyond the mezzanine's perimeter.

The main mezzanine columns adjacent to the chiller were extended to a height of 6.75 metres and portal frames were constructed, spanning the 12 metre wide chiller, to support its roof structure. Within the chiller itself a rack supported mezzanine structure, complete with access staircase, was constructed to allow optimum use of the available storage height.

A 15m x 8.5m extension to the main mezzanine was designed to be built over the goods inward area and partitioned from the ground to the mezzanine level. Both the partitioning and the mezzanine structure were designed to incorporate a full height quick-action loading bay door. The object was almost to create an 'air lock' environment so that during loading/unloading, when the external roller shutter doors are open, the inner quick action door remains shut and more or less hermetically seals the warehouse area.

Suitable access to and from the mezzanine level was achieved by way of a standard 'Part K' staircase and by positioning an 'ambulant access' staircase, in accordance with Part M of Building Regulations, in a confined area alongside the chiller. A bridge from the mezzanine also allowed access/egress directly through a new fire exit into an existing office area.

Once all parties were committed to the final design, a build programme agreed with AWA and the client ensured that the construction of the mezzanine areas was integrated expediently with the conveyor and shelving suppliers and other site trades to provide Roche Diagnostics with a satisfactory and timely project conclusion.

Roche Diagnostics' logistics manager commented "The Alan Wilson Associates/Mezzanine solution for a difficult site proved that the location could be viable and in practice the distribution centre certainly meets all our requirements."

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