DHL Warehouse Mezzanine Case Study
Project overview
This case study showcases how Bradfields delivered a bespoke warehouse mezzanine floor installation for DHL, designed to maximise storage capacity and improve operational efficiency within a high-demand logistics environment. By creating additional floor space, the solution enabled DHL to optimise workflow and support continued business growth without relocating.
The Challenge
A Fully Bespoke Solution for DHL
Amid rapid growth in parcel volumes and a major £560m UK expansion, DHL required a fully bespoke mezzanine solution for its new automated hub at Segro Park, Coventry. The brief demanded a suspended, column-free design to optimise forklift access, built to exceptionally tight tolerances to support sensitive weighing equipment, and delivered at speed to keep the wider project on track. The project called for a fully bespoke mezzanine design – not an off-the-shelf solution.
Another key challenge was precision; DHL’s scales and tracking systems are highly sensitive, so the build needed to cater to that level of sensitivity. Finally, the build programme had to be delivered at speed. Every day of downtime had a direct impact on operations, so an accelerated turnaround was essential to maximise ROI.
The Solution
Our Solution for DHL
We designed and engineered a 20,350m² mezzanine floor:
- 3,100m² suspended to suit cross-dock forklift traffic.
- 15,844m² total floor area.
- 1,480 tons of steel, excluding open grid grating.
- 4,300 individual assemblies with 60,000 steel components delivered in total.
The standout feature was the large suspended mezzanine area, fixed directly to the underside of the building trusses. This eliminated the need for floor columns, giving DHL the wide-open operational space they needed for forklift access and free-flow pallet movement.
Throughout the project, high-precision manufacturing and installation methods were used to meet the strict tolerances required. Our experienced team also coordinated closely with DHL to deliver the project at pace, ensuring a smooth build within a very tight programme.
The Result
No Legs, No Problem
The completed warehouse mezzanine floor provided DHL with a fully tailored, column-free solution designed to maximise usable space and improve operational efficiency. By suspending the structure from the building’s trusses, the need for floor columns was eliminated, allowing for uninterrupted forklift access and free-flow pallet movement.
The high-precision construction ensured compatibility with sensitive weighing equipment, while the accelerated installation programme enabled DHL to achieve a rapid return on investment and support ongoing logistics operations without disruption.
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