NEXT

Project Overview:

Overview
NEXT, one of the UK’s largest fashion and homeware retailers, required additional space for robotic operations at their distribution centre in South Yorkshire.

With heavy racking and constant robot movement, the project demanded speed, precision, and minimal disruption to ongoing operations.Robot Floor, a collaboration of four trusted partners, was selected to deliver a complete flooring solution to support NEXT’s pick and sort hybrid robot system.

The Challenge
The project involved constructing a new mezzanine level above an existing two-tier structure, requiring significant reinforcement and structural bracing.

With over 1,500 tonnes of steelwork and timber decking used, the scale was substantial — delivering a floor area equivalent to three Premier League football pitches.

All works had to be carried out within a live warehouse environment, operating with over 500 staff, making programme, safety, and coordination critical.

The Solution
Robot Floor delivered a fully integrated solution, combining structure, flooring, and robotic compatibility.

• Robotic floor preparation tailored to the Geek+ AMR system
• Installation of a 3mm heavy-duty resin floor with anti-static properties
• Screed and floor finish installation by ATS
• Bespoke mezzanine structure by Davicon
• Full turnkey warehouse fit-out by Avanta UK

The resin system, developed with Flowcrete, incorporated a specialist aggregate to prevent static build-up and protect sensitive robotic equipment.

Additional upgrades included a temperature-controlled air handling system and five new fire-rated staircases integrated into the existing structure.

The Results

• 22,000 sqm of new operational space
• Delivered within a live warehouse environment
• Supporting over 100 AMRs (P800 & S20 robots)
• 14 weeks ahead of schedule
• Fully robot-ready environment

The completed system now enables NEXT to process up to 26,000 units per day, with improved efficiency and next-day delivery capability for late orders.