What is a Mezzanine Floor?
Mezzanines are partial floors situated between other floors of a building. They are placed such that the floor above is enclosed. In Italian, “mezzo” implies half, and so a mezzanine sits half way (dependant on the height of the wall) up the wall.
It must be noted that a mezzanine is not counted as a floor in a building and is not considered with respect to maximum floorspace in a building.
The International Building Code does allow the increase of floor space by a third under the designated floor.
A building may have more than one mezzanine provided the total floor space is not above a third of the floor space directly underneath. However, differences in local building codes may apply.
Mezzanines are useful to fill under utilized ceiling heights. They help impose a more human feel to very spacious, high-ceilinged sections while creating more usable area.
It must be noted that due to their positioning, they may have lower-than-usual ceilings. Any specific function of “mezzanine” is referenced to its intended use – which can be almost endless in amount.
Mezzanines find application in modern-day architecture, which is characterized by an abundance of light and space.
Types Of Mezzanine Floors
Mezzanine flooring adds value to previously unused vertical space, transforming it into usable space. It can be easily tailored to fit any facility or structure due to its effortless adaptation and modernization.
Customizability in design, shape, and configuration for production or storage operations makes mezzanine flooring immensely beneficial.
The type of floor covering used has a significant impact on the effectiveness of a mezzanine, usually. To make the best use of the area and allow the structure to function as intended, the right floor covering should be chosen for the setup.
It is common for manufacturers of mezzanines to have suggestions on which floor coverings are most suitable given the conditions and surroundings where the mezzanine will be placed.
#1. Bar Grating.
Bar grating is primarily used for mezzanine flooring due to its strength and dependability. Such type of flooring permits the passage of air and light, and also allows for efficient water drainage from fire sprinklers.
Bar grating is made of aluminum or steel bars coil, carbon, or stainless that are edged, straightened, punched, and cut to size, a process which optimizes the reduction of waste during production. Moreover, bar grating does not require upkeep and does not easily wear out.
#2. Wood Mezzanine Flooring.
Wood mezzanine flooring is distinguished by straightforward setup, great aesthetic appeal, and sustaining a long lifespan. Its natural elegance enhances any building, making it a good fit for offices or additional retail space.
In addition, wood flooring is fairly inexpensive and can carry shelving or storage racks, making it a practical cosmetic improvement. Its ease of cleaning further increases its value for different applications.
#3. Steel Diamond Plate Mezzanine Flooring.
Mezzanine diamond plate of steel is constructed out of 12-gauge steel and installed onto a metal frame. Its robust construction makes it ideal for supporting large, heavy stored equipment.
The diamond pattern plates are designed to slip and skid resistant which with metals gives it great durability, strength, and safety for areas with constant foot traffic.
The tile or H beam, consisting of steel diamond plate flooring, is held in place using a top plate to the main bearer beam bolted to the concrete floor.
For added support, the walls of the structure can have their steel beams attached to them. This allows for the walls to serve as supports to the structural components of the building.
#4. Concrete Mezzanine Flooring.
Concrete walls provide the necessary strength and durability for a permanent structure such as a mezzanine placed in a wet or humid environment. This material can withstand extreme weight alongside forklift traffic.
It is ideal for dangerous environments as it eliminates the risk of combustion. The thermal mass concrete serves also reduce energy consumption as it helps in regulating the temperature.
The galvanized corrugated steel frame or deck supports the flooring, with the concrete poured to a four to five inch thickness for stability and strength.
#5. Particle Board Mezzanine Flooring
A construction composite, particle board is made from timber fragments bonded with resin onto a 38 mm thick board. This type of flooring easily resists moisture as well as slips while maintaining superior load strength.
It is appropriate for office mezzanines, retail stores, and warehouses due to its wood-like appearance. Moreover, particle board’s low cost makes it a much sought-after mezzanine flooring solution.
#6. Aminated Panel Mezzanine Flooring
The surface of laminated panel mezzanine flooring includes plywood that is covered with textured high density polyethylene (HDPE). The floor is designed for industrial applications since its abrasion-resistant poly laminate finish withstands strong wheeling and foot traffic.
The underlying structure also enhances impact resistance due to the layered design, making it ideal for industrial environments where floors undergo heavy use.
Laminated panel flooring’s moisture-resistant characteristics also make it impervious to chemicals, allowing for versatile installation both indoors and outdoors in diverse manufacturing environments.
#7. Resin Composite Mezzanine Flooring.
Resin composed flooring is a type of mezzanine flooring that can endure the impact from carts, dolly’s and pallet jacks. It is readily availble in 0.5-1 inch thicknesses. It performs better compared to imitatiing wooden floors in almost all atmospheric circumstances.
It is easy to work nad cut resin composed materials to the required fit of the mezzanine floor that needs to be installed. It adds flexibility alongside strength.
Mezzanine floor design definition
In any business that wants to increase their floor space amd has enough room height, they can consider installing a mezzanine floor. They ideal for warehouses, distribution centers, manufacturing facilities and repair operations, additing space for storage or work functions.
Mezzanine floors offer a world of endless possibilities. With no restrictions when it comes to style or design, they can be added into nearly any type of building and also do not need to be mounted onto walls or ceilings; they can be stand alone structures.
#1. Freestanding Mezzanine Flooring
A freestanding mezzanine floor is built with its own structural columns which allows for growth if additional space is required.
Serviced mezzanines of 40 feet height and above have extra space available underneath for lighting installation, electrical conduits, sprinkler system placement, and air conditioning ductwork.
Through the implementation of a mezzanine floor, the usable work area is increased approximately 100% since the space underneath is not required to serve a new purpose.
Mezzanine flooring’s adaptable characteristics allows it to be fitted around already existing structures and columns, thus enabling versality with a variety of building configurations.
#2. Rack Supported Mezzanine Flooring
Rack supported or shelving supported mezzanine floors are partially or completely supported by racks or shelving. These designs have shelves positioned close to one another and they also have high capacity load bearing strength.
Additional shelving or storage for parts, machinery, and other materials can easily be accessed with rack supported mezzanines. In some cases, the extra floor space can also accommodate conveyors.
Due to the high strength of rack supported mezzanines, integration of pallet racks and pallet storage is easily possible.
#3. Mezzanine Full Mat Flooring
Freestanding mezzanines and catwalks are incorporated into full mat mezzanines flooring systems, thereby offering flexibility and functionality.
Its floor structure has the features of a catwalk, a freestanding floor mezzanine, as well as a rack-supported mezzanine which makes it one of the most catwalks used geared towards flexibility.
The full mat mezzanine floor is left completely open to allow vertical space for bulk storage, office workstations, changing rooms for employees, vending devices as well as straightforward structures such as supermarket shelves. It is frequently employed in conjunction with shelving units to boost space efficiency.
#4. Catwalk Mezzanine Flooring
In addition to the shelving, if a new floor is added to the mezzanine, walkways may be required in order to create easy access to the newly added areas. Catwalks offer a solution to ease access while maintaining a reasonable cost.
Mezzanine flooring catwalk feeder constitute bridges or walkways suspended from lower level shelving units and from second level shelves.
Catwalk mezzanine flooring is a supplementary component of a mezzanine floor that is installed regardless of the construction method adopted for it.
#5. Multi-Level Mezzanine Flooring
Implementing multi-level mezzanine flooring can multiply the available floor space by 200-300 percent with the addition of one existing mezzanine.
This type of installation usually comes with multi-tiered staircases and a loading section for better access to the shelving on different levels.
It is possible to add other floors or grade level lifts which improve the distribution of materials. Also, conveyors, lifts, and chutes can streamline the distribution of materials.
#6. Modular Mezzanine Flooring
With modular mezzanine flooring, the buyer’s cost related to the purchase and installation of mezzanine systems decreases.
Defining the area to be installed first should be done to create a schematic design. It will be manufactured off-site and brought to the site to complete the assembly.
Like other permanent types of flooring, modular designs can be tailored and configured around certain specifications.
Once the need for a modular unit ceases, the unit can be quickly disassembled, packed for storage or relocated to different locations.
#7. Shelving Supported Mezzanines
More than any other type of mezzanine floor, shelving supported ones increase the height of the storage area. Shelving systems enable both the loading and the unloading of pallets at the same time.
These new kinds of mezzanines combine storage with extra floor space for other activities within your warehouse making them more flexible and usable.
Consider these mezzanines as elevated floors or platforms that ingeniously integrate into provided shelving units, augmenting the available storage levels.
These systems enhance vertical space usage and expand storage capabilities, all while increasing the efficiency of your warehouse.
How do these differ from other types of mezzanines such as rack-supported ones? As shelving-over structures, both shelving-supported and rack-supported mezzanines called deck over shelving, utilize existing shelvings and racks for support.
Shelving-supported mezzanines, however, have a second floor of decking that encompasses an entire lower level of shelving or pallet rack. This second level can incorporate racks, shelving, offices, or works, thus, enabling flexible space utilization.
In e-commerce and logistics industries that require precise delineation between storage and distribution facilities, these modular mezzanines are essential because they can be adjusted to meet different storage configurations and expanded upon as business needs evolve.
Application Of Mezzanine Floors
Business entities that are in a growth phase are best suited to mezzanine floors as they require additional space.
Mezzanine floors provide a cost-effective solution by increasing accessible space without the need to purchase or rent additional property while still eliminating additional footprint storage.
Mezzanines can be used for a variety of purposes such as setting up lock rooms for employees, storing idle machinery, increasing parts storage, or even for additional of office space.
The design features and specific functions of mezzanine floors can be designed to address the particular objectives and requirements of any organization.
Industrial
Industrial mezzanine floors are constructed of heavy duty articles such as stainless or carbon steel.
Depending on the use of the mezzanine, the type of flooring also changes, but is mostly steel plating or concrete. In addition to storage, Industrial mezzanines may include other multifunctional uses such as expanding production and assembly areas.
Warehousing
In a warehouse setting, mezzanine floors are highly effective in increasing space without the expansion of new facilities or reducing business operations because of space limitations. Businesses often outgrow their available storage space for inventory and racking.
A warehouse mezzanine enables the flexibility to increase storage containers by adding shelving, lengthening racks, and encouraging block stacking to optimize space usage.
Modular Offices
In the industrial type of modular offices, specific work areas are provided for each manager on the first intelligence level to facilitate their work.
These offices enable a manager to do his/her desk work, talk to subordinates, and sort out production problems without leaving the vicinity.
This type of modular office comes with an added benefit of being close enough to the production floor enabling the manager to multi-task with high efficiency.
Just like the case with mezzanines, modular offices are built out of ready-made parts. These parts are manufactured at a different location and brought to the building where they will need to be assembled.
As such, there is little to no delay in construction and modular offices can greatly lessen the impact on the environment compared to other types of building construction.
Modular offices may also be made to fit the design of the type of mezzanine and flooring that is used and can also be easily changed or expanded whenever needed.
Retail
Retail mezzanines are constructed into new buildings from the very beginning and are readily integrated into the architectural plan alongside product shelving considerations.
Outlet stores are some of the most popular users of retail mezzanines because there is a varying amount of spatial needs based on display needs.
Mezzanines are very useful to retailers because they can rolled away and kept when they are not needed enabling better space efficiency.
Workshop
Workshops are purpose-built to produce goods that can be sold. Changes in the volume of business in a workshop can create problems in which there is congestion with craftsmen or inventory and fighting space in the workshop.
The construction of offices in integrated storage facilities contributes significantly to the enhancement of productivity and communication at the company.
Automation
In modern manufacturing, Automation is one of the most important components of technology since it encourages the rapid relocation of items, materials, and supplies to different areas.
However, the use of these automation systems is often an additional spatial requirement. Automated systems do need space, and the use of steel mezzanines helps resolve this problem by providing support for the automations while keeping them out of the flow of operations below.
Observation Deck
Mezzanines are most commonly used as observation decks where they can view all aspects of the facility’s operations as well as view processes and measure performance and efficiency with minimal effort.
Ground level observation is a lengthy process and often does not capture everything that is happening as the entire process isn’t visible in real-time. Complete prompt adjustment is most likely to be achieved with observation mezzanines.
Catwalks
Catwalks have a number of advantages, the most prominent of them being the ease and safety with which personnel can move around a facility.
By providing raised walkways, catwalks alleviate ground traffic, clear areas for forklift movement, and guarantee unhindered, free access to all areas of the facility.
They make good use of vertical space by reducing congestion at ground level and improving efficiency and safety within the operation.
Advantages of mezzanine floors
A mezzanine floor refers to an auxiliary floor between the main floor and the ceiling in a building. It makes vertical space usable further improving the efficiency and productivity of work space.
Mezzanines provide a cheap and large solution to increasing working areas without heavy structural alterations.
As companies grow, they often run into problems with space and resources that can be utilized in their operations. Traditionally, the answer to this was leasing or constructing more adjoined facilities.
Mezzanine floors offer businesses the opportunity to expand floor area, alter the layout freely, and increase headcount without major investment required for traditional construction.
Companies can easily scale their floor space up or down as business needs dictate, which is not possible with permanent structures.
Space
The primary benefit of putting in a mezzanine floor is the substantial increase in the space that can be utilized.
Adding an extra level to a warehouse, office, manufacturing facility, or retail store enables businesses to improve inventory management and enhance operations with little impact to ongoing activities.
Installation
Installing mezzanine floors is simply effortless. They can be constructed within a week, as opposed to annexes or entirely new structures. The process is non-intrusive and does not impact existing walls, floors, or columns.
Mobil
Mezzanines offer outstanding convenience as they are not fixed structures. Relocation, removal, and reconfiguration to aid adapting to new business demands can be done easily.
This flexibility allows companies to optimize operations and spatial needs without complications. Removal and reassembly can be done with ease, similar to machinery or equipment.
Cost Effective
Straining budgets is something that every company is bound to face at some point. New building and infrastructural additions require thorough planning, and increase investments considerably.
Mezzanines serve these new spatial demands adequately while avoiding mobilization of funds. These structures expand available space significantly, and with little investment, a substantial increase in operational area can be achieved.
Customizable
Mezzanine floors can be added to any building with a website ceiling height. They have a high degree of flexibility for customization around existing columns, walls, and equipment.
Components or loaded requirements, however different they may be, can be designed to meet specific needs and integrate seamlessly into any space.
Decrease Clutter
As businesses grow, neglected areas often accumulate clutter and disorganization. Workspaces, filled with outdated projects or unused machinery, unoccupied areas can hinder efficiency.
Adding a measures helps address these areas, and organize them, enhancing overall workflow. A mezzanine provides an opportunity to tackle those organization challenges head on, they are key to success.
Life Cycle
How long a business retains a mezzanine floor relies on how well operational efficiency is maintained. While flexible and movable, a mezzanine is capable of providing long term stability. Supporting a business’s success for many years, remb structures are built to last.
Tax Advantages
Modular offices and mezzanines can be depreciated over a period of seven years, which is significantly better than the 39-year depreciation on permanent structures.
Because these modular units can be dismantled and relocated, they are classified as depreciable tangible assets under the Modified Accelerated Cost Recovery System as opposed to real property, influencing their depreciation timetable.
The cost of a modular office or mezzanine can be fully depreciated within seven years, which is a tax advantage.
In contrast to other forms of construction, this quick recovery of investment is strikingly different from the almost 40-year depreciation period for traditional construction.
Disadvantages of Mezzanine Floors
While the benefits of the different types of mezzanines are numerous, some potential downsides are worth discussing.
Structural mezzanines, which are often used to increase the capacity of a space in an industrial area, are expensive. Materials needed for large projects, such as steel beams and support columns, can be costly.
Additionally, the posts that are required to support the mezzanine floor may obstruct vertical workspace on the ground floor, potentially requiring a redesign of the lower floor workstation.
Apart from these practical considerations, there are also administrative challenges. Expanding the footprint of your warehouse with different types of mezzanines comes with some complications.
You, for example, will need building permits to comply with applicable regulations. This might seem trivial, but for those looking to expand rapidly, it can become a serious challenge.
Even considering these potential shortcomings, it is worth mentioning that every type of mezzanine has a particular set of benefits that can neutralize these challenges, which we will explore later. Here are the key drawbacks at a glance:
- Expansion threatens productivity of surrounding workspaces
- Require permits
- Distruptive permit work
- Significant material costs with structural multimaterials
How Much Does A Mezzanine Floor Cost?
In a commercial setting such as a warehouse or retail shop, the installation of a mezzanine would need to consider its prospective cost alongside the commercial benefit it can offer in to the business.
A mezzanine floor is viewed as a viable economic option to add space within a business, especially in comparison to taking up additional leasing space in a new premises.
However, the budget of a project is normally guided by multiple factors, including the specifics of the floor to be installed.
Areas of concern that could impact the cost of a mezzanine floor include:
- Required number of levels.
- Mezzanine level dimensions.
- Condition and configuration of the existing slab or base.
- Floor’s intended use and load bearing.
- Access e.g. staircases, lifts and their quantities.
- Location of the floor in the building.
- Fireproofing obstructions and utilities.
- Site requirements, constrictions and plant.
- Building control and CDM regulations.
As a result of the many factors that affect the cost of installing a mezzanine floor, a site survey and consultation must be done to provide accurate pricing.
Here at Avanta, we provide a complimentary site survey which allows our engineers and designers to develop a fully costed quote using exact information pertaining to your needs and your site.
Alongside our comprehensive turnkey service, you will rest assured the project will be executed to a high standard as all aspects of the required works are inclusive.