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Case Study: Custom Mezzanine Floor System

Oddies Warehouse

Purpose-built mezzanine combining fabric racks and pallet storage with enhanced durability and safety

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PROJECT OVERVIEW

Palletower designed a purpose-built replacement mezzanine for Oddies Warehouse, increasing upper-level storage capacity while improving fabric handling, safety and long-term durability.

Project Type:

Custom Mezzanine Floor System

Industry:

Warehouse & Storage

Requirement:

Integrated Fabric Storage Solution

The brief

Oddies needed to replace an existing mezzanine floor with a heavy-duty, high-density storage solution capable of supporting fabric storage at upper level. The new installation also had to be fitted over and around existing ground-floor fabric racks that remained in continuous use. 

The brief was not only to increase storage space, but also to reduce lifecycle maintenance and repair costs. The finished system needed to protect stored fabric, support high loads and maintain safe working aisles below the mezzanine.  

The challenge 

The main challenge was to combine fabric racks, pallet racks and mezzanine flooring into one integrated structure without disrupting the working area below. Load distribution, fire protection and fabric protection all had to be considered from the outset.

The design also needed to avoid point loading and protect fabric from snagging or tearing during handling and storage.

PROJECT DETAILS

Palletower’s solution

Palletower specified integrated fabric racks using Galvatite steel decks. These created a strong, smooth storage surface designed to protect fabric during day-to-day use.

The fabric racks were inserted into purpose-built steel channels, helping to spread the load evenly along the rack runs rather than concentrating it on individual baseplate points. This improved strength, durability and long-term performance.

The mezzanine was designed to achieve a minimum of one-hour fire protection in line with UK building standards. Support columns were positioned inside the existing ground-floor racks so that aisles below remained clear and safe to use. An Up and Over pallet gate was also installed to support safe movement of materials between levels. 

The result

The completed installation gave Oddies a significantly larger and more practical storage area. By combining mezzanine flooring with integrated fabric and pallet racking, Palletower delivered a durable storage system that improved capacity while reducing the risk of future maintenance issues. 

Key outcomes 

  • Increased upper-level warehouse storage capacity 
  • Smooth steel decking to protect stored fabric 
  • Even load distribution across the racking structure 
  • Safe access and transfer between mezzanine and ground level 
  • Reduced lifecycle maintenance and repair risk

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