Engineering Excellence: 2,060m² Mezzanine Transforms Primeline DC

 

CUSTOMER

The client for this project was the **Primeline Group**, recognized as Ireland’s largest independent provider of integrated supply chain, logistics, sales, and marketing solutions for major international brands and retailers across the Irish and UK markets. The installation took place at **Unit 12F, Ashbourne Business Park, Meath, Ireland**.

Core Business Context:

  • Delivers 1.6 million cases weekly to over 7,500 retailers.
  • Requires best-in-class warehousing for high-speed, accurate fulfillment.
  • Unit 12F is a **LEED Silver** certified facility, prioritizing sustainability.

 

PROJECT

The project involved the design, supply, and installation of a significant capacity expansion to support modern logistics operations.

Scope Highlights

  • Two-Tier Mezzanine Floor
  • 60-Minute Fire Protection System
  • 607 bays of HI-280 Shelving

Key Specifications

  • Structural Steel: S355 Grade (Eurocode 3 compliant).
  • Future-Proofed for a 3rd tier expansion.

 

CHALLENGE

Primeline required a high-capacity storage foundation that could handle intense operational loads and safely integrate specialized MHE (Material Handling Equipment) within a demanding regulatory environment.

  • Meeting Extreme Load Requirements: The structural design required robust certification (Eurocode 3) to support a heavy load, necessary for integrating high-density Conveyor systems.
  • Mandatory Fire Safety: Achieving certified. This required precision installation of specialized components for ceiling, columns, and perimeter integrity.
  • High-Volume Access Integration: Designing and safely installing access points, including two Tower Staircases and eight total Up & Over Pallet Gates, without compromising the structural or fire envelope.
  • Sustainability Compliance: The construction had to respect the environmental profile of the **LEED Silver** certified facility, ensuring materials and installation techniques aligned with stringent building standards.

 

SOLUTION

Storage Systems Ltd engineered and delivered a fully certified, heavy-duty, two-tier mezzanine solution designed for operational longevity and seamless integration with Primeline’s logistics technology.

Structural and Capacity Engineering
  • Utilized high-yield  grade steel in primary and secondary beams to manage the high
  • Design validated against **Eurocode 3** and officially certified with **CE/UKCA Declarations of Performance.
  • Future-proofed the columns and main support structure to accommodate a planned **3rd tier** expansion.
Specialist Fire & Safety Integration
  • A **60-minute fire integrity** was achieved across the floor system using:
    • **OWA Mezz Pro 60fr** suspended ceilings.
    • **Galvanised Column Casings** (incorporating Rocksilk FireTech Slab technology).
  • Provided **two Tower Staircases** and **eight Up & Over Pallet Gates** (4 per floor) for secure, high-throughput access.
  • All electrical works within the mezzanine structure were certified via a **SAFE ELECTRIC Completion Certificate**.

 

 

BENEFITS

  • Sustainable & Compliant Infrastructure

    The installation supports Primeline’s ESG goals by operating within a **LEED Silver** certified facility. The comprehensive **60-minute fire rating** (certified by HCL) ensures total safety compliance, protecting personnel and inventory.

  • Triple-Fold Capacity & Future-Proofing

    The creation of two additional floor levels instantly triples the usable warehouse area (2,060m²), while the structural design is pre-engineered for a cost-effective, seamless future expansion to a third tier.

  • High-Performance Logistics Platform

  • Operational Safety and Throughput

    Eight dedicated pallet gates and two Tower Staircases ensure efficient, continuous material flow and safe access for personnel, directly supporting Primeline’s high-volume delivery model.