Initial Assessment

The first step in a mezzanine project of any size is understanding whether your space is suitable. This typically involves a site survey to assess the building’s dimensions, layout, restrictions, and existing infrastructure. A site assessment helps define the scope of your project and identify any constraints early on.

Key factors considered at this stage include:

• Available floor space and ceiling height
• Existing structural capacity and restrictions
• Access points and workflow requirements
• Fire safety considerations and building regulations

Defining Requirements

Alongside the site assessment, it’s important to clearly outline how you want the mezzanine floor and space to be used. Different applications, such as shelving, racking, or office spaces, will influence the design, load capacity, and access points.

At this stage, you should consider:

• Intended use of mezzanine (current and future use)
• Load-bearing requirements (people, products and machinery)
• Access solutions (stairs, lifts and pallet gates)
• Integration with existing storage and processing systems

Mezzanine Design and Planning

Only when all measurements and requirements are confirmed should the design phase begin. This is where concepts are translated into detailed plans that consider functionality, compliance, and future-proofing. A well-executed space design helps clients visualise their mezzanine in situ and highlights any concerns early on, reducing the risk of costly changes later.

During this phase, we provide:

• Detailed blueprint drawings and structural calculations
• CAD design and 3D modelling to replicate a real-life installation
• Positioning of lighting, ventilation, utilities and access points
• Fire protection measures and safety barrier positioning
• Collaboration with building control and regulations

Quotation and Project Scope

An accurate design helps provide a detailed and realistic quotation. This should provide a clear outline of all aspects involved, as well as providing transparency around costs and timelines. It’s important to review the quote and scope carefully to ensure everything is as expected and accounted for.

Project scopes and quotes tend to include:

• Materials and manufacturing prices
• Installation timeline and labour costs
• Compliance measures and safety features
• Project timelines and key milestones

Fabrication and Preparation

Once the design and quote are agreed and signed off, manufacturing can begin. Each piece of your mezzanine structure, from stairs and flooring to racking, chutes, and even interior design, is fabricated with precision and attention to detail, ensuring full compliance and quality for a smooth installation

Site preparation will also begin, which covers:

• Clearing and organising installation area
• Coordinating with contractors and departments
• Confirming access and delivery logistics
• Final approvals from building control and landlords
• Communications with key personnel to ensure minimal disruption

Mezzanine Installation

A professional mezzanine installation team will be on hand to efficiently assemble your bespoke mezzanine structure. Fully aware of the design and layout, they will deliver a smooth, swift installation, maintaining safety and compliance while causing minimal disturbance to your site. The length of this phase is dependent on the size and complexity of your project, but often includes:

• Delivery of materials and components
• Structured build sequence to minimise disruption
• Ongoing communications and progress updates
• Adherence to health and safety standards

Final Inspection and Handover

Once built, the project moves into its final stage. This involves multiple inspections of the structure to ensure its integrity, functionality, safety and compliance. Once all standards are met, the mezzanine can be signed off and prepared for operational use.

• Final quality checks and safety inspections
• Thorough testing of electrics or machinery
• Certification and compliance documentation
• Client walkthrough and handover

Site Size & Structural Restrictions

Every mezzanine project begins with an initial conversation and fact-finding meeting. A site visit allows us to assess the premises footprint, ceiling height, column spacing, structural material, floor load capacity, fire and safety, and access routes – all of which influence the final design.

Existing structural constraints may dictate column placement, beam depth, or overall layout. It may also indicate that additional structural work is required, which will increase costs. Our experienced design and fabrication teams assess these factors early in the process, helping us to ensure all mezzanines are engineered to maximise usable space without limitations and mitigate issues later.

Load Weights & Structural Integrity

Load requirements are among the most critical cost drivers in the design and manufacturing of a mezzanine floor. Whether the structure supports inventory, shelves, pallet racking, machinery, AMRs, offices, or high-density storage, the load rating must be accurately engineered.

Naturally, higher load capacities require stronger steel partitions and structural calculations. In contrast, unusual-shaped loads will require bespoke, complex fabrication to accommodate your inventory. Every mezzanine project requires a tailored engineering and fabrication approach.

Space Capacity & Use Cases

We don’t believe in off-the-shelf mezzanine solutions. Every industry is different, with varying purposes and storage expansion requirements. For example, a car dealership may require a single-storey mezzanine for its customer service department. This setup may benefit from a minimalist, open-plan design to accommodate additional desks and personnel. Whereas a large retailer may require multi-tier racking solutions to accommodate both human and robotic workflows. Each use case needs to be assessed and addressed individually.

At Bradfields, our quotations factor in structural specifications, flooring types, safety requirements and access solutions to meet your specific storage solution.

Accessibility & Safety Requirements

Mezzanine floors are designed and built around human needs as much as they are around products and machinery. The footprint of your premises will influence the selection of safe access points and routes to support efficient workflows. Staircases, goods lifts, pallet gates, chutes, and conveyor belts should all be considered when configuring your mezzanine floor.

With each of these access points and walkways, safety must be considered. We conduct a thorough risk assessment to ensure every eventuality is covered. This involves incorporating handrails, bollards, and other fire-rated safety measures to protect your people, products, and structure.

Supporting Future Needs & Scalability

It’s important to remember that a mezzanine is not just a solution for today; it’s an investment for future growth. As part of our fact-finding, we establish your business goals and design a mezzanine floor that supports your mission, all of which is factored into your quotation.

Whether you’re planning to expand product lines and require additional storage, implement AMR operations, or bring more departments in-house for a complete turnkey service, bespoke mezzanines can adapt to your evolving needs. This provides long-term flexibility while supporting future business growth and operational decisions.

Labour, Consultancy, & Project Management

Beyond physical materials and high-quality steelwork that come with a price tag, a mezzanine quotation also reflects the expertise behind the structure. To achieve a first-class, functional, customised, and fully compliant mezzanine, you need a range of skills to deliver these complex projects successfully.

Essential behind-the-scenes costs may include:

• Structural engineering and calculations
• Detailed design and real-time configuration
• Skilled fabrication and finishing
• Experienced installation teams
• On-site, dedicated project management
• Continuous communication and support

With Bradfields’ complete turnkey service, we factor each of these costs into your final quote. Clients receive a clear breakdown, operational timelines, a single point of contact, and no surprise invoices upon completion. We have found that this approach streamlines the process, improves efficiency, and reduces costs for mezzanine installation.

Where They Add Value

• They run fixed pallet routes between goods-in, storage, and despatch without disruption
• Respond to pick completion signals, automatically moving orders to packing stations
• Increase productivity and daily throughput in high-volume e-commerce fulfilment centres
• Improve safety by securely lifting, lowering, and handling heavy loads
• Keep stock levels updated and replenished, allowing operations to scale capacity

Heavier Load & Tow Capacity

• AMRs are suited to totes, cartons, and light-to-medium pallets, carrying and transferring loads up to 3,300lbs
• There are light-duty and heavy-duty towing AMR models that can tow between 1,000 and 10,000lbs
• AGVs are capable of moving extremely heavy loads and high volumes, carrying and transferring loads up to 11,000lbs
• Heavy-duty AGV towing capacity can exceed 100,000lbs, making them ideal for high-demand operations

Instant Data Sharing

• They connect to live order systems for picking and packing automation
• Scanners and sensors report stock levels and update inventory in real-time
• Integrated AI systems help AGVs learn, evolve and scale with business needs
• Provide instant and accurate reporting on productivity, KPIs, and potential issues

Enabling 24/7 Operations

• More resources to meet customer expectations, modern demands, and tighter KPIs
• Extend operational times without an increase in labour costs
• Replenish stock levels outside of peak operational times for minimal disruption
• Increase processing times and help reduce pressure during peak seasons
• Allows businesses to stay ahead of competitors in delivery and service levels

Increased Safety Levels

• Reduce forklift traffic and accidents
• Minimise manual handling accidents
• Lower collision risks with sensors and speed restrictions
• Set routes for robots and clear, safe pathways for humans
• 360° obstacle detection for real-time reactions and automatic stop functions

Human-Robot Collaboration

• Assists with good-to-person workflows
• Reducing human handling errors
• More accurate and faster stocktaking
• Supports teams during peak seasonal pressures
• Reduces the strain on labour shortages