When it comes to optimising the space of your industrial warehouse, there’s no better way to maximise efficiency than with a mezzanine floor. Mezzanine flooring is a custom-made, economical and space-saving solution that adds an extra storage level to your existing warehouse, boosting your storage capacity while saving floor space below.
Whether you’re looking for additional storage space, safer loading and unloading areas or another level of office or retail area, mezzanine flooring is an ideal choice. In this article, we’ll walk you through the installation process so you understand exactly what’s involved in bringing this innovative and flexible solution to your business. We’ll also discuss the design requirements for an effective and efficient mezzanine floor, as well as the multitude of benefits it provides.
What Is Industrial Mezzanine Flooring?
Industrial mezzanine flooring is a great way to increase the storage capacity of your industrial warehouse. It essentially functions as an additional floor between the main floor and the roof of your warehouse. This extra space can be used for additional storage, production, office space, or even a canteen area.
Mezzanine floors are usually made from steel support beams with a chipboard or metal decking system supported on them. It is typically designed to fit your specific warehouse size and load-bearing requirements. We always recommend that mezzanine floors are entirely freestanding, so as not to rely on the walls for support.
When it comes to installation, industrial mezzanine flooring requires an experienced team of professionals in order to ensure that it’s safely and correctly installed according to local building regulations. This includes consultation with building control, fire safety professionals and structural engineers before signing off on the installation process.
Benefits of Mezzanine Flooring for Warehouse Storage
Looking to expand your warehouse storage options? Mezzanine flooring offers a great way to maximise your existing square footage without the huge price tag of a major construction project. This cost-effective solution can help you get the extra space you need without having to purchase additional square footage. Here are some key benefits of installing a mezzanine floor in your industrial warehouse:
- Create Additional Floor Space: You can add up to three levels of additional storage space above your existing warehouse with mezzanine flooring, increasing the capacity of your facility significantly.
- Cost-Effective: Building out a new warehouse is typically expensive and time-consuming, making a mezzanine floor a cost-effective alternative that can often be installed much more quickly than traditional construction solutions.
- Versatility: Mezzanine flooring systems offer a high degree of flexibility in terms of design, materials and structural elements, which allows for easy customisation for any specific application.
- Flexibility: With the ability to easily move and rearrange components, you can quickly adapt your mezzanine system as needed to meet changing demands in your facility.
Mezzanine Floor Design Considerations
Before installing a mezzanine floor, there are a few important design considerations to think about.
Durability
It’s essential to make sure that your industrial mezzanine is strong and durable for the type of use and the overall environment. The materials used should be able to withstand high traffic from people and products. The use of a 38mm thick P5 moisture-resistant chipboard is a good upgrade choice over standard P6. A steel chequered landing plate where the product is loaded and offloaded onto the floor is also a sensible option. Consider choosing heavy-duty steel or concrete flooring if you need something with superior strength.
Capacity
Think carefully about the capacity of the industrial mezzanine – it needs to be able to handle whatever weight you plan to place on it. That includes not only the weight of your people, materials and equipment but also the weight of any containers or pallets that you may use when storing items on the mezzanine.
Safety Requirements
Safety is a priority when installing an industrial mezzanine floor, so make sure that you follow all safety protocols and local building codes before beginning installation. This includes making sure that you have adequate edge protection around the exposed edges of the mezzanine, and along open stairways, as well as other features like fire protection and an adequate means of escape in an emergency situation
Structural Steel Mezzanines
Structural steel mezzanines are supported by steel columns and utilise standard structural beams for the main components of the floor. This is an ideal choice for people who have a lot of weight to support since it can be engineered to meet load capacity requirements ranging from to 500Kgs to 1000Kgs per m2. On top of that, it looks great since these are welded structures that can be painted any colour you need, for example, to match your brand colours or existing colour features. Installation of a mezzanine floor requires extra coordination with other trades for safety reasons, so it should be noted that you need to adhere to relevant legislations such as CDM
Mezzanine Floor Installation Process
The installation process for mezzanine flooring is quite straightforward for an experienced contractor, below are the steps required before installation can take place:
- Site preparation – we will inspect the area to make sure it’s suitable for the work and prepare it properly.
- Foundation and columns installation – we will set the foundation and install steel columns to support the mezzanine structure.
- Framework installation – we will build a lightweight framework using metal components like beams and slotted c-sections joists.
- Floor installation – we will install 38mm chipboard or in some cases open-top grating to form the top of the mezzanine flooring platform.
- Handrail installation – we will construct additional elements such as guardrails, stairs, ladders, etc., for safety purposes.
All work is carried out and adheres to building regulations.
Cost of Mezzanine Flooring and ROI
It’s not a surprise that adding mezzanine flooring to your industrial warehouse is not the cheapest option, but the return on investment (ROI) makes it worth considering.
To start, the cost of mezzanine flooring can depend on its size, design, and other components like staircases and lifts. These structures may have an upfront cost, but the savings that come from increased storage and productivity in a shorter construction time will make up for it in the long run. For example, a mezzanine floor can double or even triple your space for about one-third of what a traditional building extension would cost.
If you need more motivation to invest in a mezzanine flooring system, consider its easy installation process as well. It requires minimal disruption and no additional foundations or utilities as it’s built above existing workspace. With this flexibility in mind, you can reconfigure and expand quickly without having to do major renovations — allowing you to easily adjust to changes in inventory demands.
Overall, mezzanine flooring is an economical option that can really pay off in terms of efficiency and productivity across your industrial warehouse. Plus, you don’t have to worry so much about construction costs since installing it is relatively quick and easy!
In conclusion, mezzanine flooring is a great way to increase the storage capacity of any industrial warehouse. By utilising the space more efficiently, you can make a warehouse more organised and efficient. Furthermore, mezzanine flooring is relatively quick to install, it’s relatively cost-effective, and requires minimal upkeep.
If you’re looking to expand your warehouse, mezzanine flooring is a great option to consider. If you have a project in mind that you would like to discuss, we’d love to hear from you.