Client: TNT Retail Express
Type of works: manufactured a mezzanine storage solution.

An additional 12,400m2 of storage space has been created for TNT by handling and storage specialist AGF Maintenance, who have completed numerous projects for this client. Having worked in association with Mezzanine for many years, AGF were confident that Mezzanine could manufacture and deliver the 3-tier structure within the contracted tight time frame of just six weeks. This ensured that AGF would be able to install the floor and fit out the area, per their contract with TNT.

Dedicated to the distribution of products for one of Europe's fastest growing retailers, phase II of the distribution centre project increased the number of pallet positions from 35,000 to 57,000. Although the vast majority of storage space is devoted to boxed items that are picked as required, the client now also needed a storage area for up to one million hanging garments. It was this specific need that resulted in the decision to maximise the space available, by designing and installing the mezzanine structure. However, by keeping the fully adjustable garment storage racks completely independent of that structure, total flexibility for the future development or diversification of the centre could be achieved. Mezzanine also designed the structure to enable the floor area of each level to be extended when the need arises.

Accessed by 24 staircases, each mezzanine level is 47 metres wide and 88 metres long. The precise positioning of the columns, in the large 8m x 7m column grid, was critical as they had to fit exactly on to the special foundation plinths that had been built below the floor slab.

Fitted with almost 1000m of handrailing, the three mezzanine levels are designed to ensure their maximum use for high density storage. This has enabled the ground floor area to be kept free for the reception and marshalling of both palletised and hanging goods.

Clothing is received on hangers and sorted onto overhead trolleys before being taken to the point of storage along a series of overhead service rails which run throughout the structure. Movement upwards through the floors is achieved by six 'goods in' powered overhead conveyors. A series of racks provide 6,200 metres of storage rails on each of the three mezzanine levels. Garments are subsequently picked by store destination and moved through the floors by three 'goods out' conveyors to await despatch.

AGF's unique understanding of both the garment and storage equipment industry, together with its ability to provide a complete turnkey solution, has enabled it to become a renowned specialist in this market sector.