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Brunswick · 2024
Warehouse office mezzanine, Brunswick
A 190 square metre structural mezzanine and access stair inserted into an operating warehouse, installed in three night shifts to keep the tenant trading.
The brief
A fitout contractor needed to add first-floor office space inside a leased warehouse in Brunswick without interrupting the tenant's despatch operation. The existing slab had no recorded reinforcement details, the roof structure could not take additional load, and the only available crane access was a single roller door onto a shared laneway.
Our approach
We worked to the engineer's design for a free-standing mezzanine that transfers all load to new pad footings, so nothing hangs off the existing structure. Because the roller door limited member length to 6.4 metres, the primary beams were detailed as bolted splices at third points rather than single runs. Every member was modelled and shop drawings were issued for approval, then the frame was trial-assembled in the workshop to prove the splice geometry before it went to galvanising.
The outcome
The frame, decking support, stair and edge balustrade were installed across three consecutive night shifts. The tenant despatched as normal each morning. The trial assembly picked up two cleat positions that would have needed site drilling, which were corrected before galvanising rather than after.
Scope of works
- Structural mezzanine frame with bolted splice connections
- New pad footing base plates and holding-down bolt setout
- Steel access stair with grated treads and landing
- Perimeter edge protection and void balustrade
- Workshop trial assembly prior to galvanising
- Night-shift delivery and installation
Project details
- Client type
- Commercial fitout contractor
- Location
- Brunswick, Victoria
- Completed
- September 2024
- Floor area
- 190 m² mezzanine
- Primary sections
- 310UB and 200UC, bolted splices
- Finish
- Hot-dip galvanised to AS/NZS 4680
- Program
- 7 weeks from approval to handover
- Installation
- 3 night shifts, tenant trading throughout
We work throughout Brunswick
Warehouse conversions, terrace extensions and retail fitouts across Brunswick, fifteen minutes from our Campbellfield workshop.
Brunswick service areaGallery
Detail and installation
Trial assembly in the workshop confirmed the splice geometry before galvanising. Access stair with grated treads, landing and compliant handrail. Perimeter edge protection installed on the final night shift.
The trial assembly in their workshop is what sold me. They found two cleat positions that would have meant drilling on site at 2am, and fixed them before the frame went to galvanising. We despatched every morning of that install.
Dean Whitfield
Project Manager, Harrowgate Fitouts
See the project in BrunswickMore work
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- Workshop
- Unit 6, 42 Hume Reserve Court
Campbellfield VIC 3061 - Phone
- (03) 5550 0142