Workshop Mezzanine

Context

A growing manufacturer needs storage above its assembly area without moving to a bigger unit. The main contractor has the mezzanine designed by an engineer and needs a workshop to fabricate it while their own team prepares the floor and services.

Constraints

The unit stays in production throughout, so deliveries have to arrive on agreed mornings and in erection order. The existing floor slab sets the base plate sizes. Everything is galvanized, so there can be no site welding and no drilling after finishing.

Scope

Columns, primary and secondary beams, open steel flooring, a straight access stair and edge guarding with a loading gate. Supply only: fabrication, galvanizing, marking and delivery to the contractor’s programme.

Process

We reviewed the drawings within a week and returned a short list of queries, including two connections that would have trapped zinc during galvanizing. Once those were resolved, every piece was fabricated with bolted connections, vent and drain holes in the right places, and a clear mark that matches the erection drawing. Pieces were bundled by bay and delivered on two mornings so the contractor could lift straight from the trailer.

The stair and guarding were trial-assembled before galvanizing to check that the loading gate cleared the handrail in both positions. Small items such as kick plates and gate hinges were bagged and labelled by bay, which spared the erection team a morning of sorting. Because the deck is open steel flooring, the sprinkler and lighting layouts below were coordinated with the electrical contractor at drawing stage.

Handover

The contractor receives erection drawings, a marked-up piece list, galvanizing certificates from the coating plant and torque values for the bolted connections. The client receives the floor loading notice for the mezzanine edge.