Warehouse mezzanine floor
Karndean Designflooring

Warehouse mezzanine floor project

New warehouse mezzanine floor solution totalling 4,100 sq/ft in size increases overall pallet capacity without impacting charging area and warehouse materials handling operation...


Client Background

Karndean DesignFlooring specialises as a global leader in flooring design with operations in the USA, UK, Australia and New Zealand. Exceptional sales growth for Karndean Designflooring has seen the need to rapidly increase pallet storage capacity and thanks to a new mezzanine floor solution from SEC Storage this has been achieved at their Evesham warehouse facility.


Karndean Designflooring


Evesham, Worcestershire

Project Summary:

A new warehouse mezzanine floor solution totalling 4,100 sq/ft in size increases overall pallet capacity without impacting the charging area or warehouse materials handling operation...

Mezzanine floor design and installation
Forklift charging area underneath a newly installed mezzanine floor

“The exceptional sales growth Karndean has experienced is excellent for the business but has put strain on the warehouse operation.


It seemed like an impossible task to increase pallet capacity without having a detrimental effect on the warehouse operation, however, thanks to SEC Storage we have been able to do so with a relatively cost effective and time efficient solution.”

Richard Payne 

Head of UK & European Logistics

Pallet gate loading system
Wire mesh pallet rack netting

An intelligent solution which maximises space and storage capacity


Significant sales growth in the last twelve months meant that Karndean was receiving an unprecedented number of inbound deliveries. The need to increase pallet capacity was evidenced by congestion in the existing marshalling and despatch areas.


A detailed design process led by SEC Storage sales manager Gary Kirk found that a mezzanine floor with uniquely designed column grid would ensure the space above the charging area could be utilised, with no impact on any of the warehouse storage or materials handling operations.


The new mezzanine floor is over 4,100 sq/ft in size and now accommodates the entire samples department. The forklift charging area also remains unaffected in terms of its capacity and access, whilst the subsequent area made available by relocating this operational function has provided Karndean Designflooring with an additional 1,140 pallet positions, boosting total warehouse capacity to nearly 11,000 pallets overall.



Interested to see how we've optimised other warehouse operations? View our case studies...

Before you go...take a look at some of our other storage projects