Mezzanine Floor

Blue coloured Mezzanine Floor supported by both walls and posts with staircase at right hand end.
Mezzanine Floor

1. What is the meaning of a Mezzanine Floor?

By definition, a Mezzanine Floor refers to “a low storey (level or floor) between two others”. In a warehouse, factory or shed, the two other stories referred to here are the ground floor level and the roof.

It is a simple yet highly effective means of increasing the floor area within the confines of an existing warehouse by simply adding in an additional level.

2. What are the Mezzanine Floor design considerations?

Space Rescue are Mezzanine Floor builders with the ability to design cost effective solutions of any floor size and shape to save you the expense of having to move.

To help you, we take the following considerations in to account.

Mezzanine Floor size

Mezzanine Floor Size
Length of floor ?
Depth of floor ?

Supports

We can place columns and supports almost anywhere
Do you require a certain spacing between columns?
Would you like us to create a clear area under the floor?
In lieu of some columns, we may be able to create more clear area by supporting the floor using brackets affixed to concrete tilt slab walls ?

Height

We can build single level or multiple storeys
Top of Floor height ?
Clear underneath height ?

Access

Provision for people and product to gain access
Where would you like your staircase ?
Would you like a gate for loading materials on to your floor ?
Is there a need for a stair ladder ?

Load Rating

Space Rescue can incorporate a a floor load rating to suit almost any floor loading application
Will your Mezzanine Floor be used for storage or additional working space?
Will there be high point loads on the floor ?

3. Mezzanine Floor plan

Below is a Mezzanine Floor plan and elevation drawing with labels showing the main components.

Examples of plan and elevation Mezzanine Floor drawings.
Mezzanine Floor Plan & Elevation

4. Which components are involved?

Columns

Columns (or posts) support Mezzanine Floors. Posts are almost always square hollow steel tubes.

The welding of a baseplate at the bottom of a post is common. A baseplate helps to spread the load over the concrete slab.

Mezzanine floors are anchored to the slab via the baseplate.

Anchoring is achieved with the use of floor anchors.

They are anchored in to your concrete slab (or concrete footing) with floor anchors via a baseplate welded at the bottom of the post.

At the upper end of the post are the main beams. The main beams sit directly on top of the columns.

Beams

Main beams are the horizontal structural steel members (typically I-beams and a.k.a. RSJ’s) that sit on top of the columns.

Joists

Joists are the cold-rolled steel purlins. They sit on top of or within the depth of the main beams. Joist orientation is perpendicular to the main beams. Flooring sheets sit directly on top of the joists.

Flooring

Several different types of floor surface are available including tongue & groove floor board (commonly Industrial Particleboard or Structural Plywood) and open style steel grate depending upon your application.

Flooring is fixed down directly on top of the joist level.

Guardrail

Guardrail typically consists of a top handrail, mid rail (a.k.a. knee rail) and kick-plate (a.k.a. toe plate) is our standard guardrail design on floor edges to provide safety for personnel on and under the mezzanine level.

Staircases

Staircase design may consist of straight sections, landings and returns. Positioning is based on the operation, platform size and shape plus your warehouse layout.

Pallet Gates

Pallet Gates consist of sliding, swing or roll-over access. Interestingly, their selection is dependent on budget and operation. Their use makes it possible to transfer palletised loads or cages up on to your platform.

5. Elements and sizes

Sub-Structure

The Sub-Structure is typically assembled from structural steel components (columns and main beams) as described in Type A below or Pallet Racking (End Frames and Beams) as described in Type B below.

Deck

The deck surface is often made out of tongue & groove flooring boards or mesh decks. Floor Boards are placed over joists which are supported by the main beams within the sub-structure.

Deck height, or the top of the finished floor is generally between 2.4m and 4.5m.

Partitioning

We can include partitioning if you have a need to create separate working areas.

This can be done both above and below the deck.

They typically consist of typically consist of stud walls and a combination of windows and doors.

6. Types of supporting Mezzanine Floor structures

Structural Mezzanine Floors (Type A)

Structural Mezzanine Floors are supported by a structural steel sub-structure and has the advantage of typically being able to offer greater clear spans under your floor and hence greater flexibility with the placement of support columns. This creates opportunity for larger clear areas (more space!) and accommodating specific work areas, machinery and stock movement.

Rack Supported Mezzanine Floors (Type B)

Rack Supported Mezzanine Floors typically consist of Pallet Racking components supporting the deck such as frames and beams.

These frames and beams may also be used for pallet storage or shelving.

Extending these frames above the floor level has its advantages. For example, it provides a ready made means for including shelving above the floor.

Use of Longspan Shelving as another sub-structure material is also common. Less common is RUT Shelving.

7. Two special Mezzanine Floor design considerations

Wall Supported Mezzzanine Floors

There is often the option in modern warehouses to use adjacent concrete slab walls for supporting your floor.

As a result, this saves cost and removes the need for some columns thus improving the open area under your floor.

A bracket is bolted to the wall to achieve this.

Deck Design

A typical Mezzanine Floor deck design consists of joists laying on top of main beams.

In some instances, particularly when warehouse roof heights are low, we can make savings on the deck thickness by placing joist cleats on the main beams and running the joists within the profile height of the main beams. This design technique is often the difference in making the addition of a mezzanine area viable.

8. Do you supply Mezzanine Floor kits for sale?

Yes, Space Rescue can supply your new Mezzanine Floor structure in kit form if you like. This is an option we provide as some of our customers are qualified builders. Space Rescue are able to deliver these kits to anywhere within Australia including regional areas. We have these kits for sale in Sydney, Melbourne, Brisbane, Adelaide and Perth.

9. Mezzanine Floor Accessories and other components

Access Ladders

An alternative to a staircase is an access ladder. Some of the reasons you would choose an access ladder over a staircase is that they are cheaper and take-up less space.

Access ladders are not as safe and are a more awkward means of access.

Pallet Landing Skids

Steel plates protect the floor in the area where you deposit and retrieve pallets from.

Partitioning

Should you wish to enclose your platform by creating rooms for additional office, assembly, service, manufacturing or storage space, we can help with the design and fitting of partitioning. Our designs typically consist of stud walls and a combination of windows and doors.

Column / Post Protectors

As in Pallet Racking, column or post protection is available for protecting structural steel columns or uprights within pallet rack supported floor levels.

Catwalks

A raised horizontal walkway is the definition of a catwalk. A catwalk connects two platforms together or joins an existing stair landing to a platform.


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