Client
First Floors completed a mezzanine floor installation in Poole for Flexicovers. The client is a leading UK boat cover manufacturer with more than 50 years of trading history. The project was delivered in just four weeks. It created a new manufacturing space with three staircases, fire-rated casings, and a jumbo stud wall. This ensured the facility gained additional capacity while meeting building control requirements.
Mezzanine floors are classed as intermediate structures and must comply with Building Regulations. This covers fire safety, access, and load-bearing capacity. By working with First Floors, Flexicovers secured a regulation-approved solution. Working together has improved their production efficiency and backed their long-term growth. For further examples of recent projects, visit our Case Studies page.
Project Brief
Based in Poole, Dorset, Flexicovers supply marine covers for brands such as Sunseeker, Princess, and Fairline. With increasing demand, their facility required greater production capacity without relocating. A mezzanine floor was identified as the most effective way to achieve this within the existing site footprint.
The client’s specification was clear, and the project required:
A structural mezzanine floor to support a new manufacturing area.
- Three staircases positioned for safe circulation across work zones.
- Fire-rated floor and column casings in line with regulatory standards.
- Enclosed staircases to strengthen fire safety measures.
- A jumbo stud wall to divide production areas and improve workflow.
By meeting these requirements, First Floors ensured the installation aligned with British Standards. Guidance on mezzanine compliance can also be found in our Mezzanine FAQs page.
Project Implementation
We began with a complete site survey to assess structural capacity, workflow requirements, and fire safety provisions. From this, a bespoke CAD design was produced to meet the client’s exact specifications. It also provided precise drawings for building control approval. This approach ensured compliance was integrated from the start.
The installation was delivered in five coordinated phases:
- Construction of the structural mezzanine framework.
- Installation of three staircases for safe and efficient access.
- Application of fire-rated floor and column casings to meet regulatory standards.
- Addition of enclosed staircases to strengthen fire protection.
- Completion of a jumbo stud wall to separate manufacturing zones.
All mezzanine floors must follow the Building Regulations 2010. This includes Part B for fire safety and Part K for protection against falling, collision, and impact. These requirements cover structural stability, safe access routes, and minimum fire resistance standards. We achieved full compliance by using fire-rated casings and enclosed staircases in the project.
The project was completed in four weeks with minimal disruption to ongoing operations. For custom mezzanine projects, Hand Railing and Pallet Gates are available as complementary products.
Challenges Faced
The main challenge was installing the mezzanine floor while Flexicovers’ factory stayed open. To avoid disruption, the project was phased and coordinated closely with the client’s production schedule. This ensured that manufacturing activity could continue safely alongside installation work.
By working together and using phased handovers, our team completed the project on time. We delivered a safe mezzanine floor that met all regulations. Thanks to collaborative efforts, daily operations continued smoothly.
The Results
The mezzanine floor created a new manufacturing area for Flexicovers. This expansion increased capacity at their facility in Poole. The business expanded upwards, creating more usable space. This way, it avoided the hassle and expense of relocating.
The client mentioned that the workflow had gotten better. The staircases and stud wall made processes safer and more organised. They noted the quality of the finish, particularly the enclosed staircases and fire-rated casings. These features helped staff feel more confident about the safety of the new environment.
Key outcomes included:
- Expanded production space within the existing facility.
- Improved workflow and safer circulation routes.
- A compliant installation delivered on schedule.
- A cost-effective expansion that supported long-term growth.
- Enhanced confidence among staff using the new space.
The client received a scalable, regulation-approved solution fit for businesses of all sizes. To explore how these solutions can apply to your site, visit our Mezzanine Floor Services page.
Mezzanine Floor Installation Specialists
The project shows how a well-planned mezzanine floor can safely create space for business growth. Completed in just four weeks, the new area increased capacity while daily operations continued.
First Floors has more than 30 years of experience. We design, manufacture, and install bespoke mezzanine floors throughout the UK. For more insights into recent projects and industry developments, head over to our News section.
Call 01789 764172 or arrange a free, no-obligation quotation to find out how a mezzanine floor could optimise your existing space.
