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Types of Factory Mezzanines

In many factory plants, the need for greater amounts of floor space is often at odds with the desire for a compact plant and of cost constraints. When expansion is not an option there are several alternatives that may be worth pursuing that can help provide more floor space while preserving the existing structure of the facility. The inclusion of a mezzanine, an additional level, is one way to use vertical space to create additional floor space without expanding beyond the plant’s parameters. In warehouses, distribution centers, or manufacturing facilities, mezzanines can provide space for storage or house additional operations. Because mezzanines can be custom built, material choices range from steel to fiberglass providing numerous cost-effective options.

Aside from the range in materials, there are several basic mezzanine structural options including freestanding, shelving and rack supported, catwalk, full mat, and integrated or structural mezzanines. Depending on plant specifications and the intended mezzanine function, one of these structural variants may serve as a space-saving alternative to expansion.

A freestanding mezzanine is highly customizable and tends to be pre-manufactured into several standard sizes and models so it can be assembled into an array of configurations. The entire mezzanine level is open for use with an unobtrusive support system, which allows minimal interference in the level below. Steel beams support the underside of the mezzanine at key points, and attach directly to the factory floor. The supports should be long enough so that the mezzanine rests at a comfortable height and substantially clears any mechanical operations underneath.

For plants looking to increase storage space more than floor space, a shelving and rack supported mezzanine is a good option. Unlike a freestanding mezzanine where steel beams take up minimal floor space, a shelving and rack supported mezzanine depends on the integration of pallet racks, I-beams, or box columns to both support the structure and create more storage space. The mezzanine is actually configured so that the shelving continues above as well as below, creating very little extra floor space and taking up a portion of the original factory floor. This design is quite cost-effective but difficult to reconfigure.

A catwalk mezzanine is a kind of miniature mezzanine, only about thirty inches wide. It is used as a kind of elevated walkway, to provide access to equipment that isn’t otherwise accessible. Stairs can be added to allow easy access to the mezzanine.

A hybrid version of the freestanding and shelving and rack supported mezzanine, the full mat mezzanine combines key features of both structures. Depending on pallet racks, I-Beams, or box colums for support, a full mat mezzanine features added storage space on the factory floor level. The mezzanine itself, however, is open like a freestanding mezzanine, and can support additional manufacturing machines and operations or serve as an additional storage space.

Although the above mezzanines can support machinery, some machinery can be quite heavy and requires a thicker, more structurally sound mezzanine. In such cases, an integrated or structural mezzanine may be the solution. Usually, this kind of mezzanine is constructed of thick concrete so it provides optimal support for heavy machinery. Installation is usually done by the builder when the factory is built, so it is by no means a temporary or reconfigurable design. However, if planning is done in advance a factory that requires substantial machinery or equipment can benefit from an integrated mezzanine.

Because of the wide range of factories that may require a mezzanine, customized mezzanines can be designed to meet specific application needs. Consultation with a professional can lead to the correct selection of both material and structure for a given plant, and is a key step if considering adding a mezzanine to an existing plant.

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