Manufacturing: Production line expansion
A manufacturing client expanding production capacity needed proactive specialist flooring input from the outset.
Excelsa was brought in at the design stage to carry out a full design appraisal and review the proposed construction methodology. Working closely with the project team, we developed a bespoke floor specification tailored to the performance requirements of the expanded production line, and produced the inspection and test plan (ITP) and quality assurance documentation to sit alongside it.
During construction, we carried out as-built verification to confirm the floor had been built to specification. That included MEP positional accuracy checks and bespoke floor tolerance surveying, using methodology appropriate to the end-use demands of the environment.
Post-construction improvement works were identified, specified, and completed, bringing the floor fully into compliance before operational handover.
Service Provided:
Design appraisal
Construction methodology review
ITP and QA documentation
Bespoke specification development
As-built verification
MEP positional accuracy
Bespoke floor tolerance surveying
Post-construction improvement works
Automated Logistics: Robotics fulfilment centre
Robotics fulfilment centres make no allowances for floor variation. The tolerances required for automated systems to operate reliably are tighter than almost any other industrial environment, which means the floor has to be right before the equipment goes in.
Excelsa supported this project from the design stage, carrying out a design appraisal and reviewing the construction methodology to ensure the specification was appropriate for the robotic operation it needed to support. ITP and QA documentation were developed and managed throughout the build.
As-built verification confirmed that the installed floor met the required tolerances. That included MEP positional accuracy checks and bespoke floor tolerance surveying specific to the robotic system's operational requirements.
Where improvement works were needed following construction, Excelsa identified, specified and completed them, ensuring the floor was fully compliant before commissioning began.
Service Provided:
Design appraisal
Construction methodology review
ITP and QA documentation
Bespoke specification development
As-built verification
MEP positional accuracy
Bespoke floor tolerance surveying
Post-construction improvement works
High-bay Racking: Logistics centre
High-bay racking operations depend on floor flatness across long, narrow aisles. When the floor falls outside tolerance in a defined movement environment, the consequences range from equipment inefficiency to safety risk. Getting the floor right and being able to prove it, matters.
Excelsa developed a bespoke specification for this logistics centre, calibrated to the defined movement requirements of the racking system in use. Defined movement floor tolerance surveying was carried out along each aisle, producing data mapped directly against the operational requirements of the facility.
Where the surveying identified areas outside tolerance, Excelsa completed precision tolerance grinding to bring the floor into compliance. A final compliance verification confirmed that all surveyed aisles met the required standard before the racking installation proceeded.
Service Provided:
Bespoke specification development
Compliance verification
Defined movement floor tolerance surveying
Tolerance grinding
Renovation: Logistics hub
Not every flooring challenge starts at the design stage. Existing floors change hands, change use and accumulate wear. When that happens, the right approach starts with understanding exactly what you have before deciding what to do with it.
When this logistics hub came to the end of its tenancy, Excelsa carried out a dilapidation survey to establish the condition of the floor and provide an accurate record of its state at handover. That survey formed the basis for everything that followed.
With a change of use planned for the facility, Excelsa developed a specification tailored to the demands of the incoming operation. Rather than applying a generic renovation approach, the specification was built around what the floor needed to become, not just what it currently was.
Floor renovation works were then completed to bring the slab up to the required standard for its new use, with the work informed throughout by the survey data and specification developed in the earlier stages.
Service Provided:
End of tenancy dilapidation survey
Change of use specification
Floor renovation