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Main advantages of mezzanines in the warehouse
Effectiveness: It is much easier, faster and cheaper to install mezzanines for the warehouse than to build a new warehouse complex. This storage method already pays for itself 100 % in three to four years.
Productivity: Maximizing spatial efficiency, a mezzanine floor for warehouse environments expands usable storage area by 2 to 4 times compared to conventional shelving. At the same time, the speed of the storage processes is not affected.
Easy installation: The warehouse mezzanine floor integrates into existing rack structures. If necessary, it can be easily moved to another location due to its dismountable design. Disassembly and reassembly of a mezzanine after maintenance and replacement of spare parts is quick and without major costs.
Flexibility: Mezzanines allow different types of storage to be arranged on each level. If required, different types of racking can be combined: Pallet racking, shelving, cantilever racking, gravity racking.
Adaptable: Flexible layout adjustments are seamless with an industrial mezzanine floor, enabling facilities to easily scale their usable footprint to match storage goals.
Practicability: Mezzanines allow the integration of different conveyor systems (spiral, vertical, powered and non-powered roller conveyors). In addition, mezzanines allow simultaneous handling of goods on different levels, all of which are easily accessible.
Multi-level constructions for efficient use of storage space: By utilising the entire storage height, you can accommodate more goods in the warehouse.
Mezzanine flooring types
A mezzanine racking system utilizes various industrial floorings across pick aisles and staging zones. These include: welded, perforated or non-perforated decking, fire-resistant and moisture-resistant chipboard. The choice depends on the needs of the particular warehouse and the maximum loads.
The best and safest option is lattice decking. With the right choice of grid profiles, noise from wheeled warehouse vehicles is reduced and warehouse staff can move around easily. In case of an emergency, e.g. a fire and its extinguishing, water will not accumulate due to the openings.
Mezzanine Types
Based on structural design, a mezzanine storage system is categorized into two types:
Platform type: This can have up to 5 levels. The usable area is a maximum of 50,000 m2 and the available height is up to 18 m.
The mezzanine is used to house goods and storage facilities as well as office space. The construction allows barrier-free passage of the storage equipment.
Shelving: The accessible height of the mezzanine is 15 m. Number of levels: up to 5. Number of shelves on each mezzanine level: from 2 to 11.
A mezzanine is therefore a simple, convenient and reliable type of storage that:
- can withstand a heavy load;
- allows quick access to the stored goods;
- does not require a great deal of time for assembly, disassembly or relocation.
Looking to buy a mezzanine platform? Contact KAPELOU today for a tailored engineering layout in the UK and worldwide. The price of a custom mezzanine is calculated based on floor area, total load capacity, number of tiers, and selected decking materials.
Mezzanine loading and unloading methods
Multi-tier storage solutions support adaptable loading workflows, enabling smooth stock transfer via lifts, hydraulic elevators, reach trucks, and forklifts. The pallets are lifted onto the platform from which the employee distributes the containers to the individual racking locations.
Mezzanine floor systems help to automate small-batch elevation by connecting floor-mounted conveyors to lifts, eliminating manual transport between levels. The container is then moved vertically by the lift and unloaded onto the conveyor at the desired height.
The spiral conveyor ensures a continuous and automated lifting and unloading of the goods onto the mezzanine levels and acts as a buffer.
See realized projects using mezzanines.
Expert planning: The engineers design in accordance with the European standards: Eurocode 0 (EN 1990), Eurocode 3 (EN 1993), Euronorm EN ISO 14122, EN ISO 12944, calculation of construction safety according to FEM 10.3.01 and 10.2.03 standards, consideration of the load caused by personnel and automation systems, elaboration of optimal variants of shelving placement, design of a mezzanine floor construction in CAD programmes.
We use certified systems: Mezzanines are certified in Ukraine according to DSTU B B.2.6-75:2008 and DSTU B.2.6-199:2014, comply with the strict European standards RAL-RG 614/2 and DIN EN ISO 9001:2008 and bear the voluntary GS mark. In addition, the DIN ISO 50001 energy management system is applied in the manufacture of components.
Precision and reliability of installation: Our engineers are highly qualified and capable of working at high risk and installing mezzanines strictly according to the technical drawings.
Experience: We have been designing, installing and maintaining mezzanines for warehouses for more than 13 years.
24/7 technical support: Under a service contract, each facility is supervised by a team to ensure rapid support and routine mezzanine inspections. Our customers always receive timely technical support.
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