WSL was approached by a leading liquid packaging manufacturer that specialise in items such as plastic wine boxes.

They were working from two different warehouses and wanted everything under one roof for simplicity and efficiency in order to streamline their operations.

The Challenge:
• Fitting everything from two existing buildings into one demanded a clever design for space maximisation.
• The client had a strict timescale, with a three-week lead time and only one month on site.
• The business would continue to operate as usual during the work, so the challenge to minimise disruption during the moving and installation was a big one.The logistics would be complex, as the racking couldn’t be moved across in bulk, because parts had to be used as storage while other racks were in transit.

The Solution:
Firstly, WSL designers had a look at the existing racking and at the space afforded by the already full existing warehouse. They designed an efficient layout which included installing racking above the access points.

Part of the design included a space saving walkway above the entrance doors in order to access the high-level racking without blocking the doors.

This was to be 10m long and manufactured in house at the WSL Leeds factory. This kind of structure involves even more precision engineering and structural design than standard pallet racking or narrow aisle racking.

Legally it required structural steelwork that is CE certified. When clients commission a storage solutions project with WSL, they can be assured that all structural steel projects are CE rated – from the procurement of the steelwork to its production and installation.

Engineers took into account the forces coming down the steel columns as well as the sway. Some sections had bracing designed along the back to guarantee there could be no buckling of the steel over time.

As with all WSL projects, a site foreman was on site at all times to oversee operations and verify that everything was running smoothly.

The project manager co-ordinated closely with the client’s warehouse manager throughout the job. The work was set out in nine phases so that everyone was clear on what areas of the buildings would be accessible during certain periods of time, allowing trade to continue as normal.

WSL is familiar with the safety legislation involved in installing racking while a building is continuing to operate.

The project manager and site foreman were responsible for ensuring that risk assessments and method statements in line with HSE guidance were planned and stringently followed.

They worked alongside other contractors that were taking down and moving heavy equipment and worked closely with the client to ensure that they were happy with the project throughout.

While the timescale was challenging, the WSL achieved installation within the allocated month.

The result is an efficient, streamlined warehouse, where all business operations can be completed on one site. The company was able to continue to trade as usual during the complex move, ensuring no loss of business for them.