Efficient use of space is crucial in modernwarehouses, distribution centers, factories, retail locations, and offices. As the demand for maximizing storage capacity and improving operational efficiency grows, mezzanine systems and shelving have become essential components in warehouse and facility design. These solutions enable businesses to optimize
vertical and horizontal storage, improve organization, and increase productivity.
What are Mezzanine Systems?
A mezzanine system is a raised platform orintermediate floor within a building, typically constructed between the main floors. It creates additional usable space by utilizing the vertical area of a facility without the need to expand the building footprint. Mezzanine floors are versatile and can serve a variety of storage, office, or production needs.
Types of Mezzanine Systems
Structural Mezzanines
- Constructed with steel supports and decking materials.
- Designed for heavy loads and long-term use.
- Common in warehouses and industrial environments.
- Can support shelving, pallet racks, workstations, offices, or equipment.
Shelving Mezzanines
- Integrated with shelving racks.
- Maximize storage density by combining shelving and installed platform levels.
- Often used for small parts storage or inventory picking.
Modular Mezzanines
- Prefabricated and bolted together.
- Flexible and easy to install or reconfigure.
- Ideal for businesses anticipating potential layout changes.
Rack-Supported Mezzanines
- Built on top of existing pallet racks.
- Combines racking and mezzanine advantages.
- Enhances vertical storage capacity without additional floor space.
Typical Applications of MezzanineSystems
- Increasing warehouse storage space.
- Creating office space above production areas.
- Setting up packing or assembly stations.
- Establishing break rooms or meeting rooms.
- Adding extra floor space in retail and distribution centers.
What is Shelving?
Shelving refers to the system of horizontalsurfaces supported by vertical frames used for storing and organizing items.
Shelving solutions range from simple wall-mounted shelves to elaborate multi-tier racking systems to store everything from small parts to bulky goods.
Common Types of Shelving
1. Boltless Shelving (Clip Shelving)
- Easy to assemble without bolts or nuts.
- Adjustable shelves suitable for lightweight to medium loads.
- Often used in retail, archives, and small parts storage.
2. Mobile Shelving
- Mounted on tracks and moves laterally.
- Saves floor space by eliminating unnecessary aisles.
- Used in offices, libraries, and archives.
3. Wire Shelving
- Made from metal wire grids.
- Open design promotes air circulation.
- Often used in food storage, medical, and electronics sectors.
4. Cantilever Shelving
- Supports long or bulky items horizontally (e.g., pipes, lumber).
- Allows easy access without front columns.
5. Heavy Duty Shelving
- Designed for heavy loads.
- Common in warehouses and industrial settings.
6. Flow Shelving
- Uses gravity rollers to move products forward.
- Optimizes picking efficiency and stock rotation (FIFO).
Benefits of Mezzanine Systems and Shelving
Mezzanine Systems Benefits
- Maximizing Space: Incrementally increases usable floor space vertically, effectively doubling or even tripling warehouse capacity without new construction.
- Cost-Effective Expansion: Significantly cheaper and faster compared to building an addition or moving to a bigger facility.
- Versatility: Can be used for storage, offices, manufacturing, or break rooms.
- Improved Workflow and Organization: Segregates processes and storage areas neatly.
- Customizable: Designed to specific load and usage requirements.
- Enhances Safety: Properly installed mezzanines meet safety codes and improve workplace ergonomics.
Shelving Benefits
- Organization and Accessibility: Makes it easier to categorize, locate, and retrieve items.
- Flexibility: Shelves can be reconfigured, added, or removed as storage needs change.
- Space Optimization: Vertical storage enhances the use of cubic space.
- Increased Productivity: Reduces picking time and inventory errors.
- Durability: Various materials and designs provide solutions for a wide range of industries and load requirements.
- Cost-Effective: Compared to automated systems, shelving provides a low-cost solution.
Mezzanine systems and shelving representfoundational infrastructure for modern storage and workplace efficiency. By utilizing vertical space and providing organized, accessible storage, these solutions help businesses to meet growing demands in competitive environments.
Selecting the right combination of mezzanine design and shelving type depends on specific operational needs, load requirements, and space constraints, but a well-planned installation can dramatically improve capacity, productivity, and safety.
Case Studies
1. Manufacturing Facility Expansion withStructural Mezzanine
Background:
A mid-sized manufacturing company needed to expand its assembly line and create
additional space for inventory without relocating. The existing warehouse footprint was fixed.
Solution:
Installed a structural mezzanine spanning 3,000 sq. ft.
- Designed to support 125 pounds per square foot live load.
- Included heavy-duty shelving on the mezzanine for parts storage.
- Staircases and safety rails installed per OSHA standards.
- Added lighting and electrical outlets for new workstations on the mezzanine.
Benefits:
- Total usable floor space increased by 50%.
- Workflow improved by segmenting production and storage vertically.
- Cost to install mezzanine was 40% less than leasing additional warehouse space.
- Enhanced worker safety and facility organization.
2. Retail Fulfillment Center ShelvingOptimization
Background:
A retail company’s e-commerce fulfillment center faced increasing order volume
and needed to improve picking speed and storage density.
Solution:
- Integrated boltless shelving for small parts and wire shelving for packaged goods.
- Installed mobile shelving units in warehouse office areas to maximize space.
- Organized inventory by SKU and product category.
- Introduced flow shelving for fast-moving products to enable FIFO picking.
Benefits:
- Picking time reduced by 22% due to better organization.
- Storage capacity increased by 35% without expanding floor space.
- Improved inventory accuracy.
- Easier restocking and inventory audits.
3. Warehouse Using Rack-SupportedMezzanine for Pallet Storage
Background:
A distributor required more pallet storage capacity but had limited facility space.
Solution:
- Installed rack-supported mezzanine, building storage racks on lower level and a mezzanine floor above them.
- Allowed forklifts to access racks below mezzanine.
- Upper mezzanine used for carton storage and order picking shelving.
Benefits:
- Doubled pallet storage capacity.
- Maintained forklift accessibility on the lower level.
- Flexible design allowed easy reconfiguration later.
- Minimal disruption during installation.
- Design Examples
Example 1: Modular Mezzanine for Officeand Storage
- Floor Space: 2,500 sq. ft. mezzanine platform.
- Load Capacity: 100 psf for mixed office and storage use.
- Access: Two staircases and an elevator lift for equipment.
- Enclosures: Partially enclosed offices with glass panels.
- Additional Features: Integrated lighting, HVAC ducts, and electrical wiring.
Example 2: Shelving Layout for SmallParts Inventory
- Shelving Type: Boltless steel shelving.
- Shelf Heights: Adjustable, 12-inch to 36-inch increments.
- Aisle Width: 36 inches for easy picker access.
- Capacity per Shelf: 200 lbs.
- Layout: Organized by product category, color-coded for easy navigation.
- Additional: Label holders, bin dividers, and anti-tip safety features.