Mezzanine Floors

16 May MDA Completed

Group Effort for MDA

When award winning fulfilment and procurement specialist MDA handed WSL the keys to their brand new empty warehouse ahead of anticipating the busiest period in their 25 year history it took all the skills of the WS Group of companies to hand it back just seven weeks later ready to operate.

The first job of Warehouse Systems was to understand MDA’s business model and logistics patterns; only then can we design a system that will work now and into an expanding future.

The scheme includes eight thousand pallet locations operated by articulated fork lifts in 2 metre aisles, and a multi-tier long span shelving system with 8,000 SKUs.  In addition to marketing materials and consumable goods, MDA also house high value items so we constructed a secure cage for them in the multi-tier shelving system.  We took care of all the lighting requirements too; making sure lighting is in the most beneficial place for the storage is sometimes overlooked.  Knowing where and when to install essentials like lighting and sprinklers is just one of the advantages of having a total project under the auspices of one main contractor.

The WS groups manufacturing arm made a mezzanine loading platform to all tiers with pallet safety gates and staircases. The whole system was protected with our own access barriers and end of run protection.

Group interior specialist company Nexus Workspace constructed offices within the building.  This was a turnkey approach and included partitions, floor coverings, external windows, air-conditioning and electrics.  We also painted 120,000 sq ft of warehouse flooring with a two part epoxy finish in zone colours.

MDA Head of Fulfilment, Carl Lee, said of the project, “From start to finish we were delighted with the performance of WS Group. The opening of our brand new Fulfilment Centre marks both a significant investment and milestone in the growth of MDA as we continue our rapid expansion in the UK fulfilment industry. As the first choice to many of Britain’s and the world’s biggest brands we need to get it right first time and the support provided by WS Group throughout this process has been invaluable in ensuring our customers receive the highest quality of service from MDA at all times.”

Read More


Client – Superdrug PLC

Superdrug put out its brief for this £150K project in an open forum to seven contractors. WSL was chosen because of our ability to truly understand a client’s requirements and tailor our work accordingly.

Client Background

Superdrug is a well-known value chemist with a staggering 900 stores across the UK and Ireland. It also has a retail website from which products are sent direct to customers.


The Challenge

Due to its online expansion programme, Superdrug wanted to maximise storage space in its South Elmsall warehouse to accommodate picking fulfilment. The work to create this extra space would have to be done within a busy warehouse employing expert health and safety techniques.

The Solution

WSL installed a 5m-high, 1000m2 mezzanine floor. We erected short-span shelving for picking on the new first floor, and designed the layout around workbench areas to ensure picking and packing can be done as efficiently as possible. The mezzanine was fitted with a fire-rated suspended ceiling, column casings and fascias to comply with current building regulations.

In addition, as the mezzanine was built over a storage area, we dismantled the existing racking and reinstalled reduced-height racking under the mezzanine. We also installed end-of-run barriers, mezzanine guards and pallet racking post protection.

WSL was also contracted to install low-energy lighting, smoke detection and sprinkler system too. The mezzanine floor, part K staircases, rack barriers and pallet gates used on this project were manufactured in-house by WSL.

Added Value

The site was run under CDM regulations, with WSL being the principal contractor. We completed the project in just 16 weeks from start to finish.



Read More




Warehouse Systems Limited has worked with Poundworld since 2008 to design manufacturer and install mezzanine floors for housing stock in its stores.

Client Background

Poundworld was originally founded as Bargain Centre in 1974. Its aim was to transfer the exciting hustle and bustle of a market place into a high street store environment. In 1997, the company opened its first store to be branded Everything’s £1. This single price point concept was so successful all stores re-branded to Poundworld in 2004. There are now more than 120 Poundworld stores in Britain and the company employs more than 2500 people.

The Challenge

Poundworld has a product range of more than 3000 lines across multiple departments. With so many lines, the company needs to maximise the floor space in its stores.

 The Solution

Installing a mezzanine level boosts in-store floor space significantly, providing room for either more product display or more storage. The latest mezzanine that we installed for Poundworld was in Kettering and was around 400m2, although we have built mezzanines from 120m2 in smaller Poundworld stores. Staircases are either part K or part M and have standard twin rail handrails. The floor decking is 38mm, high-density tongue and groove chipboard and is laid in brickwork fashion to give the floor strength and tie everything together.

Added Value

This store, like most of the Poundworld stores we’ve worked on, only had double door access, so we provided specialist, low-level forklift trucks to move the steel during the build. A clear, bright working area enabled our team to work even faster than usual and the build was completed in just four days. We were first on site and left everything tidy so the shop fitter could quickly get to work installing ceilings and store fixtures.




To see a time lapse video of the mezzanine floor installation at Poundworld’s Kettering store, please click here

Read More


Cintas Document Management

Products utilised:
Archive box storage system


Cintas Document Management is part of one of the world’s largest business-to-business service providers, specialising in document storage and management. As a large and complex storage operation, their ability to utilise and maximise available space is key to attracting new clients and building on their success. A solution from WSL helped them do just that.


Our Solution

Our solution for Cintas was complex at both design and install points, yet simple in its objective: to make better use of the available space than competitor designs. We incorporated High-Density Multi-Tier Longspan Racking, with stairwells, handrails and pallet gates that were manufactured in-house.

The solution was implemented across three sites: Manchester, Charlton and Stroud, at a cost of around £1 million.

The UK Business was purchased by the American company prior to the implementation of these three projects. Our teams had cultivated such a strong reputation for quality and client service with the original business that the new owners recognised that WSL was the company to carry out the work without changes to budget, schedule or design.


Added value

Our project teams work very closely with clients to ensure that we support the overall needs of their business. In this case, Cintas continued to trade while our teams delivered the new storage solution. We found ways to ensure that the work could be completed without interfering with the client’s ongoing operations.

Read More


Existing client Reelvision Print who specialize in small bespoke printed packaging solutions contacted WSL regarding installing further pallet spaces in their Factory and Warehouse in Haslingden, Lancashire , at the same time they were looking to install a mezzanine floor. Steve Moore (Quality Manager) had only associated WSL with Pallet Racking (if we had a pound for every time this happened !!) and did not think of us for the mezzanine. “It was only after I had seen several other mezzanine companies, of which none impressed me that I looked closer and realised Warehouse Systems designed and installed them” said Steve. After a lengthy site meeting at which we discussed several design options the solution was an extended staircase with large mid landing. “We needed to overcome a number of space issues and access problems” said Steve. “Warehouse Systems took their time to understand our concerns, and came up with a cost effective solution that suited all parties, we are looking forward to commencement of installation later this month”. For further information on the client visit their website at

Read More