Mezzanine Floors


A Mezzanine Floor 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.

Mezzanine Floor

1. What is the meaning of 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.

2. What are the design considerations?

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. We take into account some of the following when helping you.

Mezzanine Floor Size
Length of floor ?
Depth of floor ?

Supports … 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 ?

Height … we can build single level or multiple storeys
Top of Floor height ?
Clear underneath height ?

Access … provision 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 ?

Load Rating … we can design to suit any floor loading application
Will it 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.

Plan and Elevation of a Mezzanine Floor

4. What components are involved?

Mezzanine Flooring typically conists of the following:

Columns ... are the posts that support the floor. They are anchored in to your concrete slab (or concrete footing) with floor anchors. The main beams sit directly on top of the columns.

Beams ... or main beams are the horizontal structural steel members (typically I-beams and a.k.a. RSJ's) that sit on top of the columns

Joists... these are the cold-rolled steel purlins that are fixed on/to and run perpendicular to the main beams. Flooring sheets are afixed directly on top of them.

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

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.

Staircases... their design may consist of straight sections, landings and returns. They may be positioned to suit your operation, platform size and shape plus your warehouse layout.

Pallet Gates (or Gates) ... may be either sliding, swing or roll-over access and their selection is dependent on budget and operation. Their use makes it possible to transfer palletised loads or cages up on to your platform.

CONTACT US ... for a Mezzanine Floor design, availability or more information!

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5. Elements and Sizes

1. Sub-Structure that is generally either assembled from structural steel components (columns and main beams) as described in Type A below or pallet rack (end frames and rack beams) as described in Type B below.

2. Deck that is typically made using tongue & groove Board (or Grid Mesh). Floor Boards are placed over joists which are supported by the main beams within the sub-structure. The top of the finished floor of a single tiered floor is generally between 2.4m and 4.5m in height.

3. Partitioning is sometimes included if you need to create separate working areas, mezzanine rooms or storage areas either on top of or beneath your mezzanine level. They typically consist of typically consist of stud walls and a combination of windows and doors.

6. Types of Supporting Structures

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.

Rack Supported Mezzanine Floors ... typically consist of Pallet Racking components supporting the deck. Typically pallet rack frames under a floor are used for pallet storage or shelving though they need not be. One advantage of using frames is that they may be continued through the new floor level to provide a ready made means for including shelving above the floor. Longspan Shelving is a another sub-structure material that is typically used in lieu of Pallet Racking. Less common is RUT Shelving.

7. Two other special design considerations

Wall Support ... There is often the option in modern warehouses to use adjacent concrete slab walls for supporting your floor. This saves cost and removes the need for some columns thus improving the open area under your floor. This can be achieved by bolting brackets to your walls.

Deck Design ... typically consists of joists laying on top of main beams. 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. Do you supply Mezzanine Floor Kits for sale?

Yes, Space Rescue can supply your new Mezzanine Floor structure in kit form if you like. This is an option we provide as some of our customers are qualified builders. Space Rescue are able to deliver these kits to anywhere within Australia including regional areas.

9. Accessories and other Components

Access Ladders
Ladders are sometimes used in lieu of staircases when access space or budget is limited.  In comparison to a staircase, they are not as safe and a more awkward means of access.
Pallet Landing Skids
These are steel plates that are placed to protect the floor in the area where you deposit and retrieve pallets from.
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.
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.
These are raised horizontal walkways used for connecting platforms or an existing stair landing to a platform.

Space Rescue have Mezzanine Floors for sale in Sydney, Melbourne, Brisbane, Perth and Adelaide!

CONTACT US ... for a Mezzanine Flooring cost, availability or more information!

   ... by email  sales©

   ... by online  contact form

   ... by phone  1300 309 320