How To Maximize Storage In Your Warehouse with a Mezzanine System

How To Maximize Storage In Your Warehouse with a Mezzanine System


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The eCommerce boom and logistical challenges brought on by the COVID-19 pandemic have created an increased demand for warehousing. At the same time, the lack of adequate warehousing space is making it difficult to meet this demand. Warehouses are looking to maximize their storage capacity without having to increase their footprint. Adding a mezzanine system is a great way to increase your storage space and the efficiency of your existing warehouse.

What is a Warehouse Mezzanine System?

A warehouse mezzanine system is an elevated floor that can be added to your existing warehouse to increase its storage capacity. If you are running out of room at your warehouse but still have vertical room to spare, you may benefit from a mezzanine.

Mezzanine systems can be constructed from different materials. Steel is a common material used to support the mezzanine structure, while the flooring can be wood, steel, or even concrete. Industrial shelving and pallet rack can also be used to create the supporting base of a mezzanine.

Benefits of a Mezzanine System

  • Increased storage and distribution capacity

  • Additional space for work activities i.e. added office or breakroom space

  • Easier access to inventory when installed in between racking and shelving

  • The added visibility from a higher vantage point like a mezzanine can be used to improve security.

  • Allows you to stay in your current location longer.

Different Types of Mezzanines

There are different types of mezzanines to consider when deciding on a system. Here are the top 3 most common types:

Shelving-Supported Mezzanine

Shelving-supported mezzanine is an economical way to increase your storage density. In a shelving-supported mezzanine structure, the industrial shelving units are used as the support base. A deck can be added on top of the base to create an even floor and a larger workspace. Another option is to add additional units on top of the base to increase storage density while maintaining the same footprint. Catwalks can be built in between the shelving aisles to create access. 

Shelving-supported mezzanine system

Rack-Supported Mezzanine

Similar to a shelving-supported mezzanine, a rack-supported structure utilizes pallet rack as its base and creates additional storage space above or in between pallet rack. One of the benefits of a rack-supported mezzanine is that it creates additional areas for loading and unloading pallets.

Freestanding Mezzanine

A freestanding mezzanine, also called a structural mezzanine, is supported by columns. A floor is added on top of the supports, creating an additional level in the warehouse. One main advantage to this construction is that the space below remains open and can be used as needed without obstructive shelving or other structures in the way.

Mezzanine Add-Ons to Consider

Modular Offices

Modular offices can be added on top of a mezzanine or can be installed in the space underneath a freestanding mezzanine. 

Wire Mesh Cages

Cages can also be installed at the mezzanine level or underneath the structure to secure valuable items. Storing valuables at the higher mezzanine level creates another level of security.

Gravity Conveyors

Gravity conveyors can be installed to easily transport products from the mezzanine level to the main warehouse level. This will increase the efficiency of your picking operations as well as make it easier to move loose parts and palletized products.

Safety Equipment

Safety equipment like guard rails and handrails can play an important role in assuring the safety of employees utilizing the mezzanine space. A mezzanine also allows you to hang dome mirrors at a higher elevation and can increase the visibility for workers operating equipment such as forklifts.

Things to Consider When Building a Mezzanine System

If you are considering building a mezzanine, consider these factors:

  • Existing footprint measurements and building construction - Always make sure you have the proper clearances on the footprint that you plan on building your mezzanine on and make sure there are no building obstructions like columns or existing equipment that could interfere with the construction of your mezzanine.

  • Ceiling height - Pay attention to the height of your ceilings to ensure that you are accounting for things like lighting, support beams, fire suppression systems, and general code requirements.

  • Select the right materials - Have a plan in place to select the proper type of materials in your mezzanine construction.

  • Safety & code requirements - Make sure you understand the code requirements that need to be met when building a mezzanine, including local building codes and fire codes. Also, consider the purchase of additional safety equipment like guard rails to prevent accidental work injuries while working on the mezzanine.



We Can Help You Get Started with a Mezzanine System

A well-designed mezzanine system has many benefits and adds to the efficiency of your warehouse. American Storage & Logistics has been a trusted supplier of warehouse equipment for over 50 years. Our expert warehouse designers and consultants can help you at every stage from designing your warehouse layout to ordering your equipment to installation. Contact us today to get started!

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