While an exact number is difficult to predict due to factors such as facility size, building materials and labor, the total cost of building a new warehouse can easily creep into the millions. Facility owners can reduce the costs of expanding operations and optimize their existing space by building vertically rather than laterally.
A commercial mezzanine floor is one such solution for your warehouse. This guide includes everything warehouse owners and employees need to know about designing and installing a mezzanine in their facilities.
What Is a Mezzanine in a Warehouse?
A warehouse mezzanine is a free-standing modular platform with one or more stories that is installed between your warehouse’s ground floor and ceiling. It’s typically made from either steel or wood and custom-designed to your facility’s unique layout and needs.
Some common applications of warehouse mezzanine systems include:
- Creating space for staff amenities like kitchens and break rooms
- Providing an optimal space for offices and other administrative requirements
- Expanding floor space in your existing facility
- Increasing storage density by utilizing previously unavailable vertical space
- Opening new transportation routes for equipment operators
- Improving floor management with employee catwalks
The Benefits of Warehouse Mezzanine Systems
The main advantages of hiring a team of professionals to install a warehouse mezzanine system include:
- Custom designs: Experts in warehouse design and optimization can help you develop a mezzanine system that fits perfectly into your facility so you can begin generating a robust ROI right away.
- Flexibility and scalability: The flexible construction of a warehouse mezzanine makes them easy to set up and tear down for relocation. You can also expand your mezzanine to meet changes in demand as your organization’s needs evolve.
- Seamless integration with your existing layout: Warehouse mezzanines are designed to fit above your existing floor space, enabling you to place them wherever needed in your facility.
- Increased storage space: By installing a mezzanine, you can use your entire warehouse floor for storage and operations. You could also move some storage to the mezzanine’s floors, allowing you to open up a cramped ground level.
- Cost savings: Because a mezzanine opens up more usable space in your facility, it can help your organization reduce or avoid costs associated with new construction and relocation.
If you find the right application for your mezzanine, these advantages can quickly add up to generate a fast, robust return on investment (ROI).
Are There Drawbacks to Installing Mezzanine Warehouse Storage?
While installing a mezzanine floor will ultimately benefit your warehouse, there are some potential drawbacks to be aware of:
- Upfront investment: The upfront cost will vary depending on factors such as the mezzanine’s size and the type of floor you choose. These costs should be considered when evaluating your potential ROI, as they can have a serious impact.
- Workflow disruptions: Installation takes time, which can disrupt your facility’s normal operations and reduce productivity. You can mitigate this risk by planning workarounds for your employees to use during the installation.
- Building codes and permits: Before you can install a mezzanine, you’ll need to obtain the proper building permits to ensure adherence to your area’s fire safety and building codes. A reliable design and installation company can take on this task for you so your organization can focus on business continuity.
Because regulations and cost requirements tend to vary between regions, it’s important to discuss your needs with suppliers in your direct area. Allow Burns Industrial Equipment to help in designing and engineering a floor that meets regional requirements, as well as obtain the appropriate permissions you need to install your mezzanine.
What Are the Requirements for a Mezzanine Floor?
Here is a brief overview of the materials, costs and regulations your facility will need to consider before beginning construction on a warehouse mezzanine.
Material Requirements for a Mezzanine Floor
The key components of a storage mezzanine system include:
- The structural framework: Columns, beams, baseplates and other structural supports provide stability and strength to the mezzanine structure.
- Flooring options: Mezzanine flooring surfaces, known as decking, are available in various materials such as steel, fire-retardant plywood, concrete and more.
- Safety features: Required safety precautions like guardrail systems, safety nets and personal fall arrest devices are critical for compliance with Occupational Safety and Health Administration (OSHA) standards and other industry regulations.
- Loading and unloading options: Whether you need lifts and conveyors or a simple elevator system, you should consider how employees will move materials between the mezzanine and ground floors.
Costs will vary depending on the specific materials and company you use for your mezzanine, so providing an exact number is difficult.
OSHA Safety Regulations for Mezzanines
OSHA standard 1910.28, Duty to Have Fall Protection and Falling Object Protection, states that employers must provide protection for all employees who work on or under the mezzanine if it is at least four feet from the warehouse floor.
To reduce the risk of falls from the mezzanine floor and adhere to OSHA regulations, employers must install the following fall protection measures:
- Guardrail systems
- Safety net systems
- Travel restraint systems
- Personal fall arrest systems
Working with a professional warehouse design team can help you ensure your mezzanine adheres to critical regulations for greater security and compliance management.
Calculating Costs and ROI of Commercial Mezzanine Floors
Assessing the effectiveness of your investment or ROI is critical for maintaining high profitability and maximizing stakeholder value.
The ROI formula is ROI = (Total Benefits – Total Costs)/Total Costs x 100. Here’s how it breaks down:
- Determine the total initial and ongoing expenses, including building materials, design services, installation and permits.
- Quantify the financial benefits, such as enhanced productivity, increased storage capacity and enhanced efficiency.
- Subtract the total costs from the total benefits and divide that outcome by the total costs.
- Multiply that outcome by 100 to get the final result.
One way to save costs and improve your ROI is to work with professional warehouse design services. Experienced professionals can help you create and install a mezzanine tailored to your unique requirements and goals, so your team can start generating more revenue.
Work With Burns Industrial Equipment to Design a Mezzanine Tailored to Your Warehouse’s Specific Needs
A professionally installed mezzanine can help you upgrade your warehouse and operations in so many ways, whether it creates new office and break room amenities for your employees or you shift extra storage to it.
At Burns Industrial Equipment, we’re proud to serve warehousing and industrial clients throughout Western Pennsylvania, Ohio and West Virginia. Our expert warehouse design team has extensive experience developing and installing custom racking and storage solutions for facilities across a wide variety of sectors, including metal fabrication, 3PLs and general manufacturing.
Make the most of your existing space with a custom warehouse mezzanine from Burns Industrial Equipment. Contact us today to request a free quote.
