mezzanine racking system

  Shelving-Supported Mezzanine design to expand warehouse storage and operation platform in vertical space, allowing you picking and store inventory by manual. In this guide, we’ll explore what Shelving-Supported Mezzanine is, layout of shelving-supported mezzanine systems available, how to install it, and best practices for labelling/numbering. What Is Shelving-Supported Mezzanine? As a compact storage platform, shelving-supported mezzanine consist of mezzanine floors and warehouse shelving system. The main benefit of shelving-supported mezzanine is that it maximize vertical space, reducing the aisles of shelving system and offer extra crosswalk to store product quickly and safely.    Types of Mezzanine Racking System Fits to different storage needs, Mezzanine Racking System come in various types, ranging from heavy duty storage solutions to Multi-layer storage solution accessibility. Here’s an overview of some of the most common options:   Shelf Supported Mezzanine: The most widely used racking type, offering direct access to each pallet. Ideal for warehouses with diverse stock-keeping units (SKUs) where accessibility is essential. Best For: Light-duty to medium-duty storage of smaller items and goods that don’t require heavy racking systems.   Rack-Supported Mezzanine: This type of mezzanine is supported by a racking system(also called clad-rack),  racks serve as the structural support for the mezzanine floor. Widely use for Multi-layer warehouse with heavy duty storage for multi-SKU. Best For: High-density storage and businesses that need additional pallet racking along with a platform for staff or equipment.   Mezzanine Storage Rack (Deck Supported): This mezzanine platform is supported by a steel framework that is mounted directly onto the rack structure. The platform is typically built with decking material (steel, wood, or other) that forms the floor of the mezzanine. Best For: Businesses that need multi-tier storage for smaller items, such as parts, tools, or lightweight products.   Cantilevered Mezzanine: Cantilevered mezzanine uses an extended framework to support the mezzanine floor without the need for vertical columns. This allows for more open floor space below the mezzanine. Best For: Irregular inventory storage like pipes,timbers,tubes , such as assembly lines or workshops.   Benefit of Shelving-Supported Mezzanine Investing a shelving-supported mezzanine system is a great solution for warehouses and distribution centers that need both additional storage space and a platform for workspaces or equipment. Here are the main benefits of making a valuable addition to any storage operation:   Expanded Footprint Moving operations to a new location can be expensive and disruptive for both the business and employees. Instead, adding a shelving mezzanine system to medium or e-commerce warehouse allows increase storage efficiency , saving costs on relocation and employee commute adjustments. For larger distribution centers, you can even install multiple levels of mezzanines to make the most of your vertical space, further enhancing your storage capacity.   Flexible storage & Safety Shelving mezzanine provides a opening warehouse operations connect floor and layer storage operation. Managers can monitor workflow with WMS, you can setting a operation area wherever floor or mezzanine floor. This helps improve to picking and labeling for each cartons and reduces the chance of errors or accidents.   Scalable and CustomizableShelving systems are typically modular, which means they can be adapted or expanded as your storage needs change. Whether you're storing small parts, boxes, or bulk items, the shelves can be adjusted to accommodate various product sizes. This flexibility makes it easy to scale the mezzanine as your business grows.   Employee-Friendly Space Beyond storage, shelving-supported mezzanines can be used to create dedicated areas for employees. Whether for office space, break areas, or workstations, you can design the mezzanine to cater to the needs of your workforce while keeping them within the main warehouse.   Increased Product Distribution Capabilities The extra levels in a shelving-supported mezzanine improve your warehouse’s ability to handle higher volumes of products. More storage means better organization, quicker access to goods, and the ability to manage a more complex inventory system with ease.   How to Install Shelving-Supported Mezzanine   Planning and Preparation Before installation, thorough planning is essential to ensure safety, compliance, and functionality.     Assess Your Space and Needs: Measure the area, ceiling height (ensure at least 7 feet clearance above and below), and existing layout. Determine the purpose (e.g., storage for small parts or tools) and load capacity (typically 500 kg/m² or 125 PSF for floors). Check for obstructions and verify the foundation can support the added weight—consult a structural engineer if needed.   Design the Layout: Create a drawing including dimensions, number of shelving levels, column/beam placements, access points (stairs or lifts), and safety features like guardrails. For shelving-supported designs, integrate with existing industrial steel or rivet-style shelving uprights to act as supports. Factor in entry points, fire safety, and compliance with local codes (e.g., mezzanine area ≤1/3 of the room, open design).   Obtain Permits and Approvals: Check local building regulations for zoning, safety standards (e.g., fire exits, sprinklers), and load restrictions. Submit plans and get approvals to avoid delays.   Choose Materials: Use steel for high durability and load capacity in industrial settings; wood for lighter, aesthetic applications. Flooring options include plywood, grated steel, or concrete. For shelving supports, select heavy-duty racks or shelves. Include braces (cross or knee) for stability.   6 Step to Install Shelving-Supported Mezzanine Site Preparation: Clear the area of obstacles and debris. Mark the floor with chalk for shelving supports, columns, and framework based on your design. Verify the foundation's strength (e.g., ≥6-inch thick slab). Install Shelving Supports and Columns: Anchor shelving uprights or columns to the floor using bolts or base plates. Ensure they are level, plumb, and aligned. For shelving-supported designs, use existing or new shelf units as the primary vertical supports. Assemble Beams and Framework: Attach horizontal beams to the shelving uprights or columns using brackets or welding. Add cross-bracing for stability and even load distribution. Cut components to size if needed. Install Flooring: Position and secure the decking (e.g., plywood or steel panels) over the beams using screws or bolts. Ensure full coverage, alignment, and stability against vibrations. Add Stairs, Access Points, and Safety Features: Install stairs with handrails, attaching them to the ground and platform. Add guardrails around edges, kick plates to prevent falls, and any lifts if required Final Inspection and Testing: Check all connections, alignments, and load capacity by applying expected weight. Verify compliance with codes and conduct a professional inspection.   How to Label Shelving-Supported Mezzanine Labeling a shelving-supported mezzanine is crucial for optimizing inventory management, enhancing operational efficiency, and ensuring safety in warehouse environments. Below is a clear, step-by-step guide outlining best practices for effective labeling.   Implement Clear Identification: Assign intuitive alphanumeric codes to each section of the shelving (e.g., Row A, Bay 1, Level 2). This system simplifies navigation and reduces the time required to locate items. Apply Color Coding: Designate unique colors for different zones or product categories. This visual strategy enables quick identification and minimizes errors during inventory handling. Select Durable Labels: Choose high-quality, adhesive labels designed to endure harsh warehouse conditions, such as dust, moisture, and frequent handling. For reliable options, consider solutions from providers like Whittan, which offer labels engineered for long-term durability and performance. Incorporate Barcode or QR Codes: Integrate barcodes or QR codes on labels to support advanced inventory tracking. These technologies facilitate seamless scanning, real-time data updates, and integration with warehouse management systems. Add Safety Signage: Prominently display weight limits, load capacities, and other essential safety information on each rack or shelf. This reinforces safe handling practices and helps prevent accidents or structural overloads.   By following these steps, you can create a well-organized, user-friendly labeling system that improves productivity and compliance. If your facility has specific requirements, consult with a storage solutions expert for customized recommendations.   Why Choose HEDA SHELVES for Your Mezzanine Floor Supplier? At HEDA SHELVES, we provide ONE-STOP Solution for pallet racking & mezzanine floor, from design to installation.  Our experts ensure that your system is safe, efficient and built to last. Our goal is offer cost-efficiency solution in mezzanine racking to help you load more and save money.   Ready to invest a shelving-supported mezzanine or mezzanine racking system? Contact HEDA SHELVES today to discuss your needs.

A mezzanine racking system offer extra storage platform and high density racking storage in warehouse. For warehousing and factory, selecting a mezzanine racking system is a cost-efficient storage solution. But How to Choose Factory Mezzanine Rack or Warehouse Mezzanine Rack?  In this guide, we offer the common factors to consider of buying mezzanine rack in factory or warehouse.    Defining the Mezzanine Racking System   A Mezzanine Racking System is a modular, semi-permanent, elevated platform structure erected within a building to create an intermediate level. Unlike traditional construction, this system utilizes existing vertical space, or the "cube," to dramatically increase storage or work area without incurring the high costs and lead times associated with physical facility expansion.   Structurally, a mezzanine can be categorized by its support mechanism: Structural/Column-Supported Mezzanines (Freestanding): These are independent platforms supported by heavy-duty steel columns anchored to the floor slab. They are the most versatile option, designed for heavy loads and adaptable to any use, from offices to manufacturing. Rack-Supported Mezzanines: These systems integrate directly with existing pallet racking or industrial shelving as the main support structure. While highly cost-effective, their flexibility is limited by the underlying rack layout and load capacity.   Factors to choose mezzanine racking system for warehouse The selection of an appropriate mezzanine system demands a rigorous, data-driven approach, prioritizing safety and operational longevity over initial cost savings. The decision hinges on a careful analysis of the intended function, structural demands, and regulatory compliance.   How much weight can Mezzanine Racking System hold? Load capacity is the most critical engineering variable, dictating the design, material selection, and column spacing of the system. Capacity is measured by the live load—the weight of goods, equipment, and people—in terms of pounds per square foot (PSF) or kilograms per square meter (kg/m 2).   Industry standards, such as those promulgated by the International Building Code (IBC) in the U.S., stipulate minimum design requirements. For most industrial applications, the live load must be specified to exceed the maximum possible usage scenario.     Intended Mezzanine Use Typical Live Load Rating Structural Design Notes Light Storage / Catwalk 50 PSF (approx. 244kg/m2) Suitable for maintenance access or very light, manually handled goods. Office / Personnel 75 – 100 PSF (approx. 366−488kg/m2) Required for office furniture, equipment, and high foot traffic. Must meet deflection limits for comfort. Standard Palletized Storage 125 PSF (IBC Minimum) The baseline for medium-density storage and picking modules. Heavy Industrial / Bulk 150 – 200+ PSF (approx. 732−976kg/m2) Engineered for heavy pallet loads, industrial machinery, or high-density shelving arrays. Requires heavier structural steel members.   A common psychological error is underestimating future load growth; therefore, professional engineers recommend selecting a capacity with a sufficient buffer above immediate needs to future-proof the investment.   Flooring material  for a Mezzanine Racking System   The best flooring material for a Mezzanine Racking System is determined by the platform's intended use, required load capacity, and crucial fire safety regulations, particularly regarding sprinkler penetration. There is no single "best" material; rather, the choice is an engineering compromise between cost, durability, and compliance. The three most common types of mezzanine decking are:   1. High-Density Chipboard (Wood Composite)   This is typically a heavy-duty, industrial-grade chipboard or particleboard finished with a durable, anti-slip resin coating. Best For: Offices, break rooms, light assembly areas, and very light manual storage where a solid, comfortable, and quiet surface is desired. Pros: Most cost-effective, easy to install, comfortable underfoot, and aesthetically suitable for non-industrial areas. Cons: Not suitable for heavy point loads, machinery, or wet environments. It is the least compliant option for fire safety, as it blocks sprinkler water from reaching the area below.   2. Steel Decking (Punched or Solid)   This category includes cold-rolled steel panels, often referred to as diamond plate, checkered plate, or perforated/punched steel. Best For: Areas with heavy wheeled traffic (pallet jacks), high point loads, or industrial environments needing chemical resistance. Punched versions are used for standard storage. Pros: Extremely durable, high load capacity, and long-lasting. Punched steel offers better light and air flow than solid plate and allows some sprinkler water to pass through. Cons: Higher material cost than chipboard. Solid steel is heavy, can be slippery when wet, and significantly blocks fire sprinkler water.   3. Bar Grating   This consists of heavy-duty, open-mesh steel bars, often galvanized or powder-coated. Best For: Industrial utility, maintenance platforms, and all areas where maximum fire safety compliance is paramount. Pros: Excellent Fire Safety: The open structure allows maximum penetration of light, air, and, most importantly, water from overhead fire sprinklers to the area below. This can often eliminate the need for costly in-rack sprinklers beneath the deck. Cons: High material and installation cost, uncomfortable for workers to stand on for extended periods, and small items can fall through the gaps.   Planning Permission of Mezzanine Racking System   The installation of a mezzanine structure requires strict adherence to regulatory standards, which generally fall under two categories: Building Regulation Approval (Mandatory): This is always required to certify that the structure is engineered for Structural Safety (load capacity, foundation anchorage) and Occupant Safety (fire protection, means of escape, access). Key requirements include: Fire Rating: Often requires a 60-minute fire resistance for the underside structure (suspended ceilings, column casings) if the mezzanine exceeds a certain size (e.g., 400m2), length (e.g., 20m edge), or if permanent staff will occupy the area. Egress: Mandates the number and specification of staircases based on the mezzanine size and the number of people served. Headroom: The IBC specifies a minimum clear height of 7 feet (2.13 meters) both underneath and on top of the deck. Planning Permission (Conditional): Planning permission is not usually required for internal, non-structural alterations to existing facilities. However, permission must be secured if the installation: Involves any external structural changes (e.g., adding doors or windows). Constitutes a change of use (e.g., converting a raw storage floor into a permanent office, which changes the building's classification). Exceeds specific local floor area percentages relative to the building's ground floor. A crucial point is that a mezzanine designed solely for storage is treated differently under fire codes than one designed for permanent human occupancy (office or production).   Conclusion   While this guide provides a comprehensive overview of mezzanine racking system, bringing your vision to high efficiency warehouse storage. At HEDA Shelves, we specialize in industrial storage solution and mezzanine floor for business of any sectors. Our team of experts can help you navigate every step of the process, from initial concept development to fixture manufacturing and installation. Whether you need a complete warehouse racking solution or specific mezzanine storage solution, we’re here to help you save money, more capacity. Contact us today at to discuss your project and discover how our customized solutions can transform your warehouse.   Frequently Asked Questions (FAQs)  Q: What are the main benefits of a rack-supported mezzanine over a structural mezzanine? A: Rack-supported mezzanines are generally more cost-effective and space-efficient because they integrate the storage racking as the primary support structure. This design eliminates the need for numerous independent columns, maximizing the floor space utilized for actual storage and minimizing the initial investment.   Q: How wide do mezzanine aisles need to be? A: Aisle widths are dictated by the intended use and material handling equipment. For manual picking and hand pallet trucks, aisles can be as narrow as 3 to 4 feet. If the mezzanine serves as a pick module integrated with conveyors, widths will be determined by personnel flow and emergency egress routes, which must adhere to local fire codes.   Q: Can a mezzanine be relocated? A: Yes, one of the principal advantages of a modular, bolt-together steel mezzanine (especially those using roll-formed steel) is its semi-permanent nature. The system can be disassembled, moved to a new facility, and reconfigured, protecting the initial capital investment.   Q: What are the fire safety clearance rules for storage below the ceiling? A: According to standards like NFPA 13, a minimum vertical clearance of 18 inches (45 cm) must be maintained between the top of the stored material and the sprinkler heads to ensure effective water distribution in the event of a fire. This constraint is critical when determining the final deck height of the mezzanine.   Q: How does a mezzanine system compare to a two-tier shelving system? A: A two-tier shelving system uses shelving uprights as the primary support for a second-level catwalk, suitable only for light, carton-level storage and manual picking. A full mezzanine system provides a heavy-duty, open floor platform capable of supporting offices, heavy pallet racking, or machinery, offering far greater structural flexibility and load capacity.