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Some warehouse projects we have worked on:


TBS Distribution Centre, Frating Green, Colchester, Essex


The 30 acre site was developed to provide  24,000 sq. m. (260,000 sq. ft.) of distribution warehouse and  4,000 sq. m. (43,000 sq. ft.) of offices.  9,000 sq. m of the warehouse was highbay with a height to haunch of 16.5m. The slab in the highbay area was suspended on approximately 1,000 piles to accommodate racking leg loads of 16 tonnes, whilst 4,000 stone columns were used to improve the ground under the low bay slab.


In order to avoid the usual problems and maintenance associated with joints in industrial floor slabs, a new design concept was used whereby the suspended slab in the high bay warehouse was reinforced only with short steel fibres instead of continuous loose bar reinforcement (steel fibres are used regularly in ground bearing slabs instead of mesh). The slab was cast in only four pours with no joints other than the two day joints.


This was the first slab of its kind in the UK

Frating Distribution Centre 

Frating Distribution CentreFrating Distribution Centre

The 15,000 sq. m of low bay slab was non suspended supported on ground improved by 4,000 stone columns and was cast in 6 pours in 5 days. The only joints in the slab were the day joints formed with specially designed steel couplings.


Development works included a balancing lake, extensive car parking, service yard and access roads.




Thurrock Distribution Centre 

Thurrock Distribution Centre


23,000 sq. m. (250,000 sq. ft.) multi-bay portal framed building with connecting office block, all  supported on piled foundations with a ground bearing slab.

Development included car parking and service yard.


Westlands Nippon


We have recently completed the design of a 9,400 sq. m distribution warehouse in Hayes, Middlesex.  The steel portal framed warehouse is comprised of 2 spans each of 45.60 metres x 11 bays of 9.30 metres.  The height to haunch is 11.0 metres.  The project also includes an adjacent two storey steel framed office block. 

Westlands Nippon 


Mezzanine Floor Construction 

Mezzanine Floors Erected Inside Existing Warehouses


Melliss have planned and managed the provision of several single and two storey mezzanines supporting imposed loading of 5 kN/m2 per level, including investigating the capacity of the existing slab to safely support the mezzanine leg loads.


These photographs show piling to install fifty piles to support 1300 sq. m of mezzanine on two levels each with an imposed load of 5kN/m2.

The floor area represented only 6% of the total floor of the existing warehouse.

Mezzanine Floor Construction