As great as growth can be for businesses, it can also cause new problems, especially if you’re running operations in a busy warehouse. Many businesses find themselves in a sticky situation when available space begins to shrink, as moving to a new location or expanding the existing space is without a doubt going to cost a lot of time, money, and effort. One simple solution that many businesses overlook is adding a mezzanine. So, in this article, we’ll cover the different types of mezzanines that can be added to warehouses, the benefits of doing so, and more.
Types of Mezzanines for Warehouses
Believe it or not, not all mezzanines are the same. And this is important when figuring out how to choose the right application for your warehouse. Each type comes with its own set of advantages and disadvantages, which we’ve outlined below next to a brief description.
Freestanding (Structural) Mezzanines
“Freestanding” mezzanines are called as such because they do not depend on any other support, such as walls or storage racks. In other words, they can stand on their own. It is independent from the warehouse entirely, and they are supported by columns and beams attached to it. (You can even put other structures on top of them, such as modular offices.)
Pros:
- Highly flexible to your warehouse layout.
- Can be changed/moved at a later date easily (as they do not depend on anything else in the warehouse for support).
- Can be installed without changing existing structures.
- Can be used for just about anything, from storage to office space.
Cons:
- May be more expensive than other mezzanine types (because they support themselves).
- May take up slightly more floor space than some other mezzanine types (as the beams must support it from the warehouse floor).
Rack-Supported Mezzanines
Rack-supported mezzanines, on the other hand, are best used in warehouses where storage/racking systems are already in place. This type of mezzanine uses existing storage capacity as support and does not need to add too many structural changes.
Pros:
- Uses existing racking systems, which reduces costs (because there isn’t as great of a need for additional beams/columns).
- Makes great use of space above and between racks.
- Allows employees/personnel to access space that would otherwise be difficult to reach.
Cons:
- Less flexible because it relies on the current racking layout. Making future changes to the layout of your warehouse may also be difficult (though not impossible).
- Can only be placed in storage areas where racks are already installed.
Shelving-Supported Mezzanines
At first glance, this type looks similar to rack-supported mezzanines; however, they are not quite the same. Shelving-supported mezzanines rely on, well, shelves. Unlike rack-supported ones, which are built on heavy-duty pallet racks and can typically handle heavier loads, shelf-supported mezzanines are better for lighter storage/loads.
Pros:
- Uses lighter materials and therefore is typically lower cost.
- Easy to install and integrates easily with existing shelving.
- Takes advantage of vertical space within shelving units.
Cons:
- Less structural strength compared to freestanding and other mezzanine types.
- Limited to areas where shelving systems are used.
Catwalks
Catwalks are another great option for warehouses. These mezzanine-like structures are made for personnel movement rather than storage. You can think of a catwalk as special elevated walkways that enable access to hard-to-reach places. They can be used to access storage, equipment, or anything else that’s difficult to reach.
Pros:
- Grants access to hard-to-reach areas in warehouses, whether for maintenance, storage, inspections, or simply overseeing operations.
- Can be added without extensive structural changes (as they are generally narrow and lightweight).
- Great for warehouses with complex layouts.
Cons:
- Not necessarily suitable for heavy items/equipment.
- Limited to specific uses.
Custom Mezzanines
If none of the above options are suitable, you can always create a custom mezzanine. This type can accommodate things like unusual building dimensions, heavier load-bearing capacity, or integration with special systems, such as conveyors.
Pros:
- Can meet special warehouse requirements.
- Can maximize space based on specific needs, and therefore more efficiently.
- Can include special features like climate control or additional safety measures.
Cons:
- Typically much more expensive.
- May require more time for design and installation.
What are the Main Benefits of Adding Mezzanines to Warehouses?
Now that we’ve covered some of the main types of mezzanines used, let’s talk about the ways in which they can improve your operations. Here are a few of the top advantages of adding these structures to your warehouse.
Maximize Vertical Space
This one is the most obvious benefit. Warehouses can get crowded, but businesses don’t often use all the vertical space they have available. A mezzanine allows you to tap into this area, and can significantly increase your space (sometimes even double it) without breaking down walls or making expensive renovations to the warehouse itself.
Low Cost Expansion
As we hinted at in the last section, renovations to the warehouse itself can be expensive in time and money. Mezzanines are an affordable way to add space with minimal downtime to operations.
Better Workflow
When catwalks or other structures are correctly placed, you can reduce the distances that workers need to travel to perform their jobs. This speeds up the processes in general, and can lead to more efficient workflow.
(If you’re looking to section off parts of your operations into different zones/areas, you might also want to have a look at our warehouse separation walls.)
Flexibility
Furthermore, mezzanines are not permanent structures, which means they can be modified, expanded, or even relocated. This process is much easier with freestanding mezzanines than with shelving-supported and rack-supported ones, but all of them are much more flexible than building expansions.
Safety
Finally, mezzanines are created with safety in mind, and are also designed to comply with building codes and OSHA regulations. This includes proper guardrails, stairways, and load-bearing requirements. Following these standards can protect your employees and reduce work-related accidents.
What are Some of the Most Important Design Considerations When Adding Mezzanines?
Now that we’ve covered some of their main benefits, let’s consider some of the factors to consider when planning to install a mezzanine into a warehouse. Here are a few of the most important aspects to think about:
Load-Bearing Capacity
The design of a mezzanine must account for both live loads and dead loads. These include the weight of people, equipment, materials that will move across it, and the permanent weight of the structure itself. Engineering considerations such as load-bearing capacity are the most important when designing and implementing the structure.
Access Points and Staircases
Another important consideration is access points. Staircases and other entry points should be placed with both safety and workflow in mind. A poorly-implemented mezzanine can do more harm than good, so it’s important to plan how personnel will move around the structure.
Integration with Systems
This won’t apply to all applications, but in general, mezzanines should integrate well with existing warehouse systems, such as conveyor belts, racking/shelving, and HVAC. With the right planning, significant adjustments to your current setup won’t be necessary.
Customization
We touched on this earlier, but with custom mezzanines, you will need to work with engineers to make sure the structure you would like is feasible, which can add to the design time.
Compliance
Last but not least, it is important to ensure that your mezzanine meets all local and national building codes, as well as any additional regulations (which may vary by industry/location). Working with an experienced provider can help you comply with such regulations and avoid legal issues down the road.
Mezzanines in Warehouses: The Bottom Line
In short, mezzanines provide an excellent way to add vertical space to warehouses. Moving to a new location or expanding your current one can be outrageously expensive. So whether you need more storage, better workflow, or additional operational space, mezzanines are a flexible, low cost, and effective solution to crowded industrial locations.
Interested in adding vertical space to your warehouse? Contact the experts at Allied Modular today to get a free quote on a new mezzanine.
FAQs About Mezzanines in Warehouses
1. How long does it typically take to install a mezzanine?
Installation time will vary depending on how complex the structure is. With simple ones, it may be finished within a few days. If it is more complex, it may take up to 6 weeks. Most mezzanines, however, can be installed within a couple of weeks.
2. Can mezzanines be added to any type of warehouse?
Yes, they can. We can often work around unusual dimensions and can be designed to fit almost any warehouse layout.
3. What are the safety regulations for mezzanine installations in warehouses?
If you’re in the United States, each state will have its own specific rules; however, codes from IBC and OSHA are generally followed, and include guidelines on fall protection, guard rail requirements, falling object protection, and more.
4. How much weight can a warehouse mezzanine support?
The load-bearing capacity varies greatly with the design and materials used. Engineers will calculate loads early in the design phase. You can work with your provider to figure out your exact requirements.
5. Can mezzanines be relocated or reconfigured in the future?
Yes, they can. Mezzanines can be adjusted, expanded, or relocated as your needs change. As we mentioned before, this is much easier in the case of freestanding mezzanines, but it can also be done for the other types.
