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Mezzanines or work platforms are an excellent way to take advantage of often underutilized warehouse “cube” space. By cube we mean the 3rd dimension… not just square footage but vertical space too. You’re paying for the whole inside of your facility, so why not maximize every bit of it, right?
Mezzanines can support office space, additional manufacturing or storage operations. Planning out the best use of this space should include choosing the best method for building your platform to ensure a safe, efficient work space. There are two primary construction options, both far less expensive than new construction. So if your business is growing or processes are changing and you need more space it is wise to consider these value-adding options.
The two main construction options are:
The IWP is a freestanding heavy-duty structure that can be configured to accommodate almost any aspect of business growth. From small standard designs to multi-level custom structures these bolt-together systems are built to handle the workload of a busy operation. Heavy-duty rails, stairs, ladders, lifts and gates can be designed into your structure where needed. Several decking choices provide the appropriate coverage for your needs such as moisture-resistant, open grating or heavy-traffic surfacing.
A few pros inherent in IWP construction:
While an IWP is clearly a solid choice for many applications, there are a few things to consider before settling on this option. They include:
Now, let’s take a look rack supported mezzanines as a comparison. This mezzanine can be designed within the pallet racking and over the aisle space, or over the top of the racking uprights. To secure the mezzanine frame, it is bolted to the uprights and then the decking is fitted to the frame. Pallet storage is accessible below and on the perimeters while making use of the added square-footage of the mezzanine above… ensuring a very cost-effective overall use of the pallet rack. Like IWP’s, flooring options are varied to accommodate the platform function. As well, railings, stairs, conveyors and lifts can be attached to the structure but may require additional structural support beams.
Pros of rack supported mezzanine construction:
Things to consider when deciding on rack supported mezzanines:
Overall, the mezzanine is a great use of that cube space you are already paying for. Both choices are cost-effective when compared to new construction and downtime to build your new platform can even be minimized with proper planning. Apex Warehouse Systems engineers can help you decide if either of these choices makes the most sense for your growing warehousing needs. Our design standards guarantee that building codes, load-bearing considerations, fire & safety requirements, etc. are included in your complete project package. Call us today!
If you’d like to see some of our recent mezzanine builds, check out our gallery page… or give us a call and we’ll tell you all about them!
Article Updated: 05/26/2022 Back to Blog
As a business grows, additional space is needed to accommodate this expansion. Unfortunately, adding on to a building or moving to a new building is often an expensive investment that can halt operations for an extended period.
One way to add space to your building while avoiding an addition is a rack supported mezzanines, also known as a mezzanine racking system. They are a cost-effective solution that add additional capacity to a warehouse or distribution center by utilizing vertical space.
The number of levels varies from between operations. These systems can be up to 5 or 6 levels tall if there is vertical space.
Read below to learn more about rack supported mezzanines, including key benefits and features.
A mezzanine racking system offers many important advantages to a distribution center’s operation, including:
High Throughput
Rack supported mezzanines allows for multiple loading and unloading locations of pallets and/or cartons simultaneously within the system. This can be accomplished via conveyors, VRCs, and pallet drop areas, as described in the next section.
High Density
A major advantage of rack supported mezzanines is that they provide additional vertical storage. It allows for your entire storage space to be utilized.
High Selectivity
Can be accessed by multiple employees at once. This can often eliminate ‘downtime’ during the picking process.
Something you’ll have to consider when going from a one-level system to a multi-level rack system is how you’ll move your items from the upper levels to the ground level for distribution.
There are several material handling systems that can be integrated into rack supported mezzanines. Each will successfully get your items to the ground level. Which one works best for you will depend on factors including your budget, your current picking process, and how drastically you’d like to change your picking process (such as if you’d like to semi-automate your operation).
Here are material handling options that work well with rack supported mezzanines:
VRCs are ‘elevator-like’ systems designed specifically to bring pallets or cartons of material to and from the upper levels of the mezzanine system.
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A conveyor system can be integrated into the catwalk system to transport products to and from the upper levels of the system.
Pallet drops are platforms located on each level of the mezzanine system. Pallets are placed on this platform by a lift truck so that employees can load products on that level of the system from the pallet. The pallet drop typically has a safety gate to ensure employees can’t fall from the pallet drop area.
Chutes allow the picker to efficiently move any product from the upper level of the system to the floor level.
Rack Supported Mezzanines can have a variety of components implemented into the system, including:
Staircases: numerous models and options available including number of rails, angles, risers, tread, and step width.
Handrails: integrated to keep employees safe.
Flooring: several options available resin board, corrugated decking, bar grating, open steel planking, and concrete. Each type of floor is better suited for different functions and operational features.
Gates: We can incorporate gates into your mezzanine to expedite proper material handling. Options include single swing gate, double swing gate, sliding gate, lift-out safety gate, and safety pivot gate.
Safety Netting: The netting can ensure the safety of your stored materials and employees. The netting can stop your stored items from falling off the upper level to the lower level
Flue Keepers: Flue keepers can be attached to the uprights to maintain correct transverse flue space. The flue keepers will prevent pallets and cartons from impinging into the transverse flue space.
Kickplates: Can be Implemented to prevent personnel traveling on the upper levels from tripping by eliminating space along aisles and row ends. Kick plates are recommended to be installed on the upper levels of the system at all aisle row ends and along all main aisles.
There are many operations that are a good fit for rack supported mezzanines.
As discussed, these types of systems allow you to utilize unused vertical warehouse space, thereby increasing your storage footprint in the same space. Because of this, if your operation is considering moving buildings to add storage space, this system may be a good alternative.
If you store many cartons, this type of system is typically a good fit. This type of system allows for high density and selectivity of carton storage on all levels.
The third point we’ll touch on is if you have certain types of bottlenecks in your picking process, this type of system may be right for you. For example, if pickers are often waiting on other pickers to complete a pick. This type of system will allow your pickers to be in the same aisle at the same time. Also, due to the increased space utilization you can better separate SKUs based on what items are typically picked together.
REB is highly knowledgeable and experienced in designing, project managing, and installing rack supported mezzanines.
As a systems integrator, we’ll work with you to provide a turnkey system. From design, products procurement, subcontractor management, install, and permitting support, REB handles it all for you.
REB has a talented team of in-house project managers and project designers, all highly experienced in the material handling industry. We’ll work with you to make sure that your system is the best fit for your operation, installed and completed on-time and within budget.
We’d appreciate the opportunity to help you further, whether that be more information or a quote. Fill out the contact form on this page or call (800) 252-5955 to get in touch with a REB representative.
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