mezzanine storage system

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.