1. What is 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. In saying that, we can also provide Mezzanine Floors with two raised floor levels.

Blue and silver Mezzanine Floor with guardrail and staircase

Mezzanine Flooring 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.

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.

2. Suggested Mezzanine Floor design considerations

You may find it helpful to review and consider the following questions …

a) Mezzanine Floor size

Note: We can build a Mezzanine to almost any size or shape.

  • What length would you like your proposed floor to be?
  • What depth (or width) would you like your floor to be?

b) Supports

Note: 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 ?

c) Mezzanine Floor Height

Note: We can build single level or multiple storeys

  • Top of Floor height ?
  • Clear underneath height ?

d) Access

Note: This consideration relates to provisions 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 ?

e) Load Rating

Note: you may request 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.

Example plan view and elevation of a Mezzanine Floor

4. What components are involved in a Mezzanine Floor?

a) Columns

Columns (or posts) support Mezzanine Floors. Posts are almost always square hollow steel tubes. At the upper end of the post are the main beams. The main beams sit directly on top of the columns.

b) Baseplates

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.

c) Floor Anchors

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.

d) Beams

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

e) 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.

f) Flooring

The flooring surface is fixed down directly on top of the joist level. Several different types of floor surface are available depending upon your application. These include tongue & groove floor board (commonly Industrial Particleboard or Structural Plywood) and open style steel grate.

g) 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.

h) 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.

i) 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 of a Mezzanine Floor

a) 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.

b) 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.

c) Partitioning

We can include partitioning if you have a need to create an office or separate working areas. This can be done both above and below the deck. Partitioning typically consists of stud walls and a combination of windows and doors.

6. Types of supporting Mezzanine Floor sub-structures

a) Structural Mezzanine Floor (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.

b) Rack Supported Mezzanine Floor (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. Mezzanine Floor design considerations

a) Free Standing Mezzanine Floor

As the name suggests, this style of Mezzanine Floor relies only on the columns for support.

b) Wall Supported Mezzanine Floor

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.

c) Deck Design

i) Standard Deck

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

ii) Low profile Deck

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. Mezzanine Floors Sydney accessories

a) 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.

b) Pallet Landing Skids

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

c) 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.

d) 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.

e) 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.

9. Related products to Mezzanine Flooring

Similar types of product include Pallet Racking and Longspan Shelving.

10. Availability

Space Rescue have Mezzanine Floor for sale in Australia only and on relatively short lead-times.. We have been designing, supplying and building Mezzanines for our customers in Sydney, Melbourne, Brisbane, Adelaide, Perth and surrounding regional areas for over 12 years.