Building a Warehouse Mezzanine

What information do I need to know if I want to build an industrial warehouse mezzanine?

Usually when a business runs out of space in their facility, it’s a good problem to have. It means that the business has grown to a point that a decision needs to be made about how to keep up with future storage requirements. The work that has been put into sales and marketing has paid off. But now, in order to keep up with demand and to continue moving forward, they need to make a decision that will give them more storage space 

When the decision has been made to equip your facility with an industrial warehouse mezzanine, you will need to be able to provide – or talk with an industrial warehouse mezzanine professional – a few key points of information in order to obtain a quote.

Dimensions (width x length)

Most mezzanines are simple rectangles or squares and the dimensions can be easily written down. For other more intricate designs, a sketch is the best way to show what you are looking for. A picture is worth a thousand words.

Mezzanine Height

Mezzanine height is determined one of two ways. You can either specify a clear height that you would prefer or a Top of Deck height. A clear height indicates the height that you would like underneath your mezzanine – from the ground floor to the bottom of the lowest joist. Top of Deck height refers to the distance from the ground floor to the top of the deck of your mezzanine. Usually, the difference between the two numbers is about 14” to 18”. This accounts for the height of the beams/joists and any flooring above that. By code, a mezzanine must have 7’ clear height below and on top plus the profile of the mezzanine

Column Spacing

Column spacing refers to the distance between each vertical column of the mezzanine. Most companies will be fine with the most economical column spacing which is different for each mezzanine and is determined by the mezzanine manufacturer at time of quoting. For those with stricter requirements of where these columns can be, the best thing to do is talk to your industrial warehouse mezzanine professional about the specific locations.

Load Capacity

Load capacity is very important for mezzanines. Too low of a load capacity and you put yourself at risk of the structure failing. Too high of a load capacity and you are wasting dollars on extra steel that you don’t need. If you are just storing extra pallets, all that needs to be known is the size of the pallets and the maximum weight of a pallet and the load capacity is easily determined. For those that will utilize their mezzanines for extra racking or shelving storage, point loads of these systems will determine the load capacity. For other pieces of equipment that need to be stored, three pieces of information need to be known. How much does the equipment weigh? What is the footprint of the equipment? Does the equipment sit flat on the ground or is it on legs (3, 4, etc.)? Load capacity is indicated by pounds per square foot (PSF). 125 PSF is standard for a storage mezzanine.

Required Building Codes

The most common building codes that need to be complied with are IBC and OSHA. Other codes, such as specific local codes, can bet met. Speak with your industrial warehouse mezzanine professional if you have specific needs regarding codes. Most mezzanine manufacturers provide products that comply with both OSHA and IBC codes. Mezzanines can only fill up 1/3 of a room. Platforms can fill 2/3 but needs city approval.

Usage

Mezzanines can be used for many different purposes. It is very important to discuss the specific use for the mezzanine with your mezzanine professional. Mezzanines can be used for purposes such as adding a modular office while maintaining floor space, extra pallet storage, extra racking or shelving storage, small parts, reserve stock area, packaging storage, and many more. The usage will affect size, load capacity, and flooring type.

Handrail

Since mezzanines are raised platforms, it is important to incorporate handrail to prevent people or product from falling over the edge. Handrail is sold by the linear foot. So if you have a 50’ x 50’ mezzanine that needs handrail on all 4 sides, you would need 200 linear feet of handrail. Generally, sides of mezzanines that are against walls do not need handrail.

Mezzanine Gates

Mezzanine gates are used primarily for pallet access to the mezzanine. Location and quantity of mezzanine gates will be determined by the size of your mezzanine as well as your operation – both on your warehouse floor and the mezzanine floor.

Staircases

Staircases – and ladders – are utilized for personnel to access the mezzanine. Many different styles of staircases are available including straight, U-shaped, and L-shaped. Your local code office will be able to tell you how many staircases you need for your mezzanine, since it is a fire safety issue. Another important thing to make clear is whether you want your staircase within the profile of your mezzanine or on the outside. So, for example, if you want your staircase on the outside of a 50’ x 50’ mezzanine, your overall footprint would be 2,500 square feet of usable mezzanine space plus the staircase. If you want your staircase on the inside of a 50’ x 50’ mezzanine, the total profile of your mezzanine including the staircase would be 2,500 square feet. You would not have 2,500 square feet of usable mezzanine space because the staircase would take up some of that space. For code purposes, you must be standing no more than 100 linear feet to a staircase wherever you are on the mezzanine.

Flooring

Many different flooring types are available for many different mezzanine applications. Do you want to avoid having to add a fire sprinkler system underneath your mezzanine? An open flooring option, such as bar grating, would be your best option. Are you looking for a smooth surface that will be suitable for personnel foot traffic and pallet jacks? A wood option such as ResinDek would work. Other flooring types include concrete, stainless steel diamond plate and fiberglass.

Finish

Generally, standard powder coat paint is sufficient. Many different colors are available if the company would like to customize their mezzanine. Mezzanines can also be hot-dip galvanized for specific applications such as washdown environments or pharmaceutical companies.

Once you have these pieces of information determined, you are ready to get your pre-fabricated industrial warehouse mezzanine quoted!