Industrial mezzanines help manufacturers, warehouses and distribution facilities make better use of vertical space by creating additional usable floor area inside an existing building.
Rather than immediately expanding or relocating a facility, a properly designed mezzanine can create space for storage, production, equipment, work areas or access platforms above existing operations.
Fredon Handling provides structural steel mezzanine and industrial platform solutions for facilities looking to increase usable capacity, improve space utilization and support changing operational needs.
What Is an Industrial Mezzanine?
An industrial mezzanine is an elevated structural platform installed within a building to create additional usable space above the existing floor.
Unlike conventional shelving or pallet racking, a mezzanine can create a new working or storage level within the facility.
Industrial mezzanines may be used for:
- Warehouse storage
- Parts storage
- Manufacturing areas
- Production support
- Equipment platforms
- Maintenance access
- Work platforms
- Catwalks
- Office support areas
- Process equipment
The best configuration depends on the building, intended use, load requirements and how people and materials need to move between levels.
Warehouse Mezzanines
Warehouse mezzanines can help facilities increase storage capacity without immediately increasing the building footprint.
If a warehouse has available clear height, an elevated platform may create space for:
- Small parts storage
- Carton storage
- Picking operations
- Reserve inventory
- Packaging supplies
- Maintenance materials
- Seasonal inventory
A mezzanine can be particularly useful in facilities where floor space is limited but substantial vertical space remains unused.
Manufacturing Mezzanines
Manufacturing facilities may use mezzanines to create additional space for production, storage or support functions.
Potential applications include:
- Assembly areas
- Parts storage
- Maintenance platforms
- Production support
- Quality inspection
- Equipment access
- Material staging
- Light manufacturing operations
The mezzanine should be planned around the production process so it does not interfere with material flow, machinery, overhead handling equipment or employee movement.
Equipment Platforms
Industrial equipment platforms provide elevated structural space for machinery, utilities or process equipment.
Applications may include:
- Mechanical equipment
- Process systems
- Conveyors
- Facility equipment
- Production machinery
- Maintenance access
Equipment platforms should be designed around the weight, dimensions and operating requirements of the equipment being supported.
Industrial Work Platforms
Work platforms create elevated areas for employees to perform tasks above the main facility floor.
They may be useful for:
- Assembly
- Inspection
- Maintenance
- Production support
- Equipment access
- Process monitoring
Access, guardrails, stairs and material movement should all be considered as part of the complete platform design.
Mezzanines and Vertical Space Utilization
Many industrial facilities have unused space above storage racks, production equipment or work areas.
This unused height represents potential capacity.
Before expanding the building footprint, facilities may benefit from evaluating:
- Clear ceiling height
- Existing structural conditions
- Floor loading
- Storage requirements
- Production needs
- Material flow
- Equipment placement
- Future growth
A mezzanine can sometimes convert underused cubic space into valuable operational space.
Mezzanine vs. Building Expansion
A mezzanine can provide an alternative to expanding the building or relocating operations.
It may be appropriate when:
- The facility has significant unused vertical space
- Additional floor space is needed
- Building expansion would be costly or disruptive
- Operations need to remain in the existing location
- Storage or production requirements are growing
However, a mezzanine is not always the right solution.
In some facilities, better pallet racking, industrial shelving or layout changes may provide enough additional capacity without adding a second level.
The decision should begin with the actual space problem.
How to Plan an Industrial Mezzanine
Planning should begin with a clear understanding of how the additional space will be used.
Intended Use
Determine whether the mezzanine will support:
- Storage
- Employees
- Machinery
- Workstations
- Production
- Maintenance
- Material handling
The intended use affects nearly every other design decision.
Available Floor Area
Measure the area where the mezzanine may be installed.
Account for:
- Columns
- Machinery
- Aisles
- Dock areas
- Doors
- Utilities
- Existing storage
- Traffic routes
Clear Height
Measure the available vertical space.
Enough clearance must exist both above and below the proposed platform for the intended activities.
Load Requirements
Determine the expected loads on the mezzanine.
These may include:
- Stored products
- Shelving
- Machinery
- Workstations
- Employees
- Carts
- Material handling equipment
Structural requirements should be evaluated by qualified professionals for the specific project.
Material Flow
Consider how products will move onto, across and off the mezzanine.
Possible movement methods may include:
- Stairs
- Pallet gates
- Conveyors
- Vertical lifts
- Cranes
- Other material handling equipment
Material flow should be planned from the beginning rather than added after the platform is installed.
Mezzanine Stairs and Access
Access is a critical part of mezzanine planning.
Depending on the application, the design may include:
- Industrial stairs
- Handrails
- Guardrails
- Landings
- Access gates
- Material transfer points
The number, location and design of access points should support both employees and facility operations.
Mezzanine Safety Gates
Where pallets or materials are transferred to an elevated platform, safety gates can help manage openings in guardrail systems.
The appropriate gate depends on:
- Opening size
- Pallet dimensions
- Material transfer method
- Platform layout
- Frequency of use
These features should be considered during the initial design process.
Mezzanine Decking
The deck surface should be selected for the intended application.
Factors may include:
- Load requirements
- Foot traffic
- Equipment use
- Storage requirements
- Environmental conditions
- Maintenance needs
The deck is part of the structural system and should be selected appropriately for the application.
Mezzanines and Pallet Racking
Pallet racking and mezzanines can sometimes be used together as part of a broader storage strategy.
For example, a facility may use:
- Pallet rack for reserve inventory
- Shelving on a mezzanine for small parts
- Ground-floor picking below the platform
- Elevated storage above production areas
The right combination depends on inventory, product size, picking frequency and available space.
Mezzanines and Industrial Shelving
Industrial shelving is commonly used on or below mezzanine systems for small parts and hand-picked inventory.
This can create a highly organized multi-level storage system where different products are stored according to size and access requirements.
When shelving is incorporated into the mezzanine area, load requirements should be accounted for in the structural design.
Mezzanines for Parts Storage
Parts departments and maintenance operations often require large amounts of shelving and bin storage.
A mezzanine can create additional space for:
- Spare parts
- MRO inventory
- Tools
- Maintenance supplies
- Replacement components
This can be useful when the existing parts room is overcrowded but vertical space is available.
Mezzanines for Production Support
Not every mezzanine needs to be used primarily for storage.
Industrial platforms can also create space for:
- Production support functions
- Quality control
- Assembly
- Inspection
- Maintenance
- Equipment access
Separating some support operations from the main production floor can free valuable ground-level space for machinery and material movement.
Structural and Facility Considerations
Mezzanine projects should account for the complete building environment.
Important considerations may include:
- Existing floor conditions
- Building structure
- Ceiling height
- Column locations
- Fire protection systems
- Sprinkler coverage
- Lighting
- Electrical systems
- HVAC
- Egress
- Material handling equipment
- Building and fire code requirements
Applicable structural, building, fire and workplace requirements should be verified for the specific project with qualified professionals and the appropriate authorities.
How Much Space Can a Mezzanine Add?
The amount of usable space depends on the available footprint and building conditions.
For example, a mezzanine installed over a 3,000-square-foot area could potentially create a substantial additional usable level, subject to structural, code and operational requirements.
The key question is not simply how much floor area can be added, but whether that space can be used effectively.
Signs Your Facility May Benefit From a Mezzanine
A mezzanine may be worth evaluating when:
- Storage areas are consistently full
- Production space is becoming constrained
- Employees are using temporary storage areas
- Inventory is spreading into aisles
- Expansion is difficult
- Relocation would be disruptive
- Significant vertical space is unused
- Parts storage is overcrowded
- Equipment is consuming valuable floor space
These conditions do not automatically mean a mezzanine is required, but they indicate that a space-utilization study may be worthwhile.
Information to Gather Before Requesting a Mezzanine Quote
Before contacting Fredon Handling, gather as much information as possible about the facility and intended application.
Useful information includes:
- Building dimensions
- Available floor area
- Clear height
- Intended use
- Desired mezzanine dimensions
- Expected loads
- Existing floor conditions
- Column locations
- Nearby machinery
- Existing storage equipment
- Required stairs
- Material transfer requirements
- Photos
- Building drawings if available
The more information available, the easier it is to evaluate the application.
Frequently Asked Questions About Industrial Mezzanines
What is an industrial mezzanine used for?
Industrial mezzanines create additional usable space within an existing facility for storage, production, equipment, work areas or maintenance access.
Can a mezzanine increase warehouse capacity?
Yes. Where sufficient vertical space exists, a mezzanine can create an additional level for storage or other operations without immediately expanding the building footprint.
What is the difference between a mezzanine and an equipment platform?
A mezzanine generally creates additional usable floor space, while an equipment platform is typically designed primarily to support machinery or facility equipment.
Can shelving be installed on a mezzanine?
Yes, depending on the design and load requirements. Shelving is commonly used on mezzanines for small parts and hand-picked inventory.
How do materials get onto a mezzanine?
Material transfer methods may include pallet gates, conveyors, lifts, cranes or other material handling equipment depending on the application.
Does a mezzanine require engineering and code review?
Industrial mezzanine projects should be evaluated for applicable structural, building, fire and workplace requirements by qualified professionals and the appropriate authorities.
Make Better Use of Your Facility Space
Before adding square footage to a building, it can be worthwhile to evaluate the space already available above your operation.
Fredon Handling can help determine whether an industrial mezzanine, work platform or other space-utilization solution may be appropriate for your facility.
Tell us about your building, available dimensions, intended use and capacity requirements.