Case studies

College floor space

Yale College, Wrexham

Requirements: To provide extra floor space to create new trainee welding bays.

The project team for Yale College approached Doity Engineering for a solution to their floor space problem, requiring space to provide them with a new specialised training area for welding techniques at Yale College in Wrexham.

Doity Engineering Ltd provided a fully fire-rated RevlokTM mezzanine floor with an installed size of 18m x 11m to include external and internal staircases. The RevlokTM Mezzanine Floor was installed with Infill Safety Handrail to all open edges and staircases, and finish painted to the customer's specification in Orange. Both above and below the mezzanines was then sectioned into individual bays for their training purposes.

Warehouse Expansion

Al Murad DIY Limited, Warrington

Requirements: To expand available space for Tiling and Decorating Products.

Two adjacent new build retail units were occupied by Al Murad DIY to expand their retail sales on their DIY Decorating and Tiling Ranges.

Both units had Revlok™ mezzanine flooring installed, each sized at 19m x 12m, expanding their storage floor area by over 400m2.

Workshop Extension

F T Finley & Co. Limited, Stockport

Requirements: To provide extra floor space utilising their existing office building

F T Finley & Co. Ltd. acquired new premises in Stockport to expand their electrical installation business.

A RevlokTM mezzanine floor sized at 11m x 5m was installed to match up with the existing load bearing roof of their office block, Creating an additional 100m² of easily accessible storage space.

Warehouse Project

Bob Elliot & Co. Limited, Chorley

Requirements: Maximise Storage Space

Over 5 years, Bob Elliot had four RevlokTM mezzanine floors fitted in their Wigan warehouse to cater for their rapid expansion of bicycle imports and sales.

The company finally outgrew the premises and relocated to a new warehouse unit in Chorley where they installed a new RevlokTM mezzanine flooring sized 12m x 17m, giving an additional 200m² storage capacity for their parts stock.

Bakery Project

Warburtons Bakery Cold Store, Wakefield, Yorkshire

Requirements: Provide Extra Space within Existing Cold Room

With 15 depots across the UK and producing over two million bakery products each day, Warburtons is now the UK's second biggest grocery brand. The need to create extra space within the self-contained cold room bread store at the company's depot in Wakefield, Yorkshire led to the installation of a Revlok mezzanine floor.

Given the harsh conditions within the cold room area - an internal temperature of minus 25 degrees centigrade - the specification for the Revlok mezzanine included open steel mesh decking that was fully hot-dipped. It also featured a further mesh overlay with no protruding fixings which ensured that trolleys could be rolled easily along the surface.

The other key benefit of the open mesh decking was to allow cold air to flow under the three-metre-high mezzanine to maintain low temperatures for the bakery products stored below.

Overall dimensions of the Revlok mezzanine were 22m x 16m which included a small cut-out for a goods lift and caging supplied by Techmach Ltd. Internal and external access staircases were also part of the Revlok mezzanine design.

Warehouse Project

The Colours Group, Knaresborough

Requirements: Expand Warehouse Space for Additional Racking and Shelving

The Colours Group's new warehouse capacity was increased with the installation of a 12m x 4.8m Revlok Mezzanine. This allowed for small items to be stored on racking and shelving on the top of the mezzanine platform, leaving the ground floor free for garments on hangers.

Nutritionals' mixing facility

Glanbia Nutritionals', Middlesbrough

Requirements: Assist in the construction of a new weighing facility

Following the successful installation at Warburtons Bakery Doity Engineering was again chosen by a principal contractor, Demeva Refrigeration to assist in the construction of a new weighing facility at Glanbia Nutritionals' (UK) mixing facility based in Middlesbrough.

The project brief was to provide a mixing room to turn the by-product of cheese manufacture, Whey into the many health supplements seen on the high street. Doity Engineering Ltd was presented with the task of providing an 8-metre clear span frame to support an explosion proof room without any centrally supporting steelwork. In conjunction with Demeva Doity Engineering delivered and installed the framework as designed and ahead of schedule.

Mezzanine floor Installation

Mardix, Kendal

Requirements: Provide extra space and a viewpoint for potential clients

Further to a successful installation of a RevlokTM mezzanine floor in their parts store, Mardix of Kendal approached Doity Engineering Ltd and requested they install a high-quality facility in their main manufacturing facility to provide extra space and a viewpoint for potential clients.

The fully fire-rated Revlok platform provided by Doity Engineering Ltd gave the client approximately 200 square metres of space which was finished to a high specification in white plastisol.

Production facility

Myprotein, Cheshire

Requirements: specify a clean area for the goods

After moving production to a new facility in Cheshire, Myprotein found they had a need to feed product from above into various mixing vessels and Doity Engineering Ltd were asked to specify a clean area for the goods.

The installation features a fully powder coated handrail and staircase system along with aluminium decking laid over the traditional 38mm chipboard to give a durable and clean surface.

Warehouse Expansion

Rainbow Cosmetics

Requirements: Provide additional pallet storage in an already bulging warehouse

With warehouse expansion in mind, Doity Engineering Ltd was approached by the operations manager of Rainbow Cosmetics with the idea of providing additional pallet storage in an already bulging warehouse.

After several client consultations regarding potential locations, a Revlok platform 4.8 metres high and over 50 metres long was installed in dead space over the packing area providing the client with an additional 450 square metres of valuable floor space. The fully fire-rated platform was delivered with minimal fuss to the existing operation and completed on time.

Warehouse floor space

Bauer Kompressoren Limited

Requirements: Construction of a Revlok mezzanine floor with one hour fire protection - Provide approximately 125 square meters of additional floor space to allow separation of customers stock holding.

Supply and install a 25m x 5m RevlokTM mezzanine floor with one part K compliant staircase, handrail and pallet load gates. Span over existing ground floor welfare facilities and provide the required one-hour fire protection to the structure. Undertake all electrical works, standard and emergency lighting and smoke detection to the underside.

Bauer Kompressoren are one of the world's premier compressor manufacturers and are a worldwide group, we fitted the mezzanine floor at their Haydock facility to give separation of different clients product within the building.

The brief specification was a 22m x 5m mezzanine floor with one access stair and two up and over pallet gates spanning the existing ground floor facilities. We fitted Full one hour fire protection - suspended ceiling and column casings and we also took control of the electrical installation and Building Regulations application meaning only one main contractor on site.

The final floor finish is a vinyl covering.

"We are very happy with the newly installed mezzanine which provides us additional floor space at a realistic price. From initial order through to completion Doity have made the process easy. The installation was carried out with no disruption to our production area. The work was carried out to a high standard and completed on schedule"


Additional warehouse floor space

3P Logistics Ltd

Requirements: Mezzanine Floor Construction - Provide approximately 312 square meters of additional floor space to cope with increasing stock levels

Supply and install a 20m x 15.6m Revlok Mezzanine floor with two-part K compliant staircases, handrail and pallet load gates to clients fulfilment centre based in Wigan.

"Hats off to the Doity Engineering Ltd team following the recent installation of a sizeable Revlok mezzanine floor at our Wigan based order fulfilment centre. From the point of initial quote right through to completion of installation, the process was seamless. With a busy operating floor to contend with, undertaking installation without disrupting the operation was no mean feat and I'm glad to say that everything passed off without a hitch.

The additional storage capacity has already been put to good use and we are now considering extending further to accommodate increased demand. The flexibility of the Revlok product ensures a natural extension to the existing installation.

A highly professional outfit - well done Doity Engineering Ltd."

Kind regards

Ian Walker
Managing Director.

Fire protection

Rexquote Limited

Requirements: RevlokTM mezzanine floor, fire protection and a fire rated staircase enclosure

During the refurbishment of one of their units, Rexquote contacted Doity Engineering Ltd with the view to installing a RevlokTM mezzanine floor to form additional workshop space.

Although the original specification did not include one, Doity Engineering identified the need for a fire rated staircase enclosure as part of the project in addition to the one-hour fire protection of the structure. This was installed by Doity Engineering Ltd's own installation team and commissioned by the Approved Inspectors.

mezzanine flooring Installation

Wessex Resins and Adhesives

Requirements: Providing around 100 square metres of mezzanine flooring complete with loading facilities and access stairs

Wessex Resins and Adhesives quickly found that with a large number of packaging materials the space available to them was rapidly shrinking.

Works Manager Darren Lebbern approached Doity Engineering Ltd with a view to providing around 100 square metres of mezzanine flooring complete with loading facilities and access stairs.

Within four weeks the installation was complete and following phase one an additional 200 square metres of flooring has been added with minimal disruption due to the modular design of the RevlokTM system.


DBN Audile

Requirements: RevlokTM mezzanine floor installation

Having secured a large industrial unit in Trafford Park, Manchester DBN Audile found themselves needing more space than expected. Their managing director, Stephen Page contacted Doity Engineering Ltd with a view to installing around 300 square metres of fully fire-rated Revlok mezzanine flooring but with an exceptionally short lead time.

From initial survey to delivery of materials on site, the process was completed within the three-week time frame set out by the customer.