Building a Firm Foundation with Mezzanine & Industrial Platform Flooring

Growing companies are often encouraged to think outside the box for solutions to meet their expanding needs. Well, we’re here to say, not so fast. What if we look at our warehouse space potential from the starting point of a box… more precisely, a cube? Cubic storage vs. linear footprint is an ideal way to take advantage of all of the available industrial space from wall to wall and floor to ceiling. Nothing makes better use of the intermediate space between floor and ceiling than an industrial work platform or mezzanine. These multi-functional mezzanines are cost-effective, space-optimizing solutions designed to maximize the use of your existing vertical cube space.

Mezzanine & Industrial Platform Applications

• Office space
• Storage space
• Equipment storage
• Multi-level pick modules
• Temperature-controlled rooms
• Locker or break rooms

Work platforms and mezzanines are comprised of columns, main beams, secondary beams, and decking. While the columns and beams support the structure, the decking makes the platform a functional space. There are a variety of mezzanine decking materials available and in some cases, a combination of materials is recommended to meet application needs. Depending on foot traffic and/or equipment use, choose the deck material that provides the safest and best overall function.

Sure-Footing is Guaranteed with the Right Decking Material

The type of flooring used on your mezzanine is predicated on the intended use. That being said, the initial consideration is between the need for solid vs non-solid surfaces.

Permeable Surfaces

Permeable surfaces are designed to allow light, air, and water (for fire safety) to pass through the floor. They can be manufactured from a number of materials including aluminum, structural fiberglass, carbon, and stainless steel. The materials are durable and slip-resistant but not recommended for use with wheeled carts or equipment. Bar grating or perforated metal flooring, for example, are often installed within pick module pallet flow lanes to prevent loose inventory or debris from falling through the rack.

Solid Surfaces

Solid surface materials are recommended for wheeled equipment and mezzanines with heavy foot traffic. Solid surface includes steel tread, solid metal, composite, and concrete floors. They are durable and offer a higher point load and wheel load capacities. Solid surfaces are also quieter than the bar grate alternative. Though these materials are defined as solid surfaces, they can be smooth and flat or can have a corrugated or textured surface as needed.

Flooring Accessories

Flooring accessories can be added to mezzanine decking surfaces to protect the work platform flooring and to add safeguards for workers and equipment. Areas of particular concern are high-traffic areas, pallet loading and unloading, around staircases and catwalks, and around equipment.

Slide Plate – rugged surface to protect the decking from damage. Particularly useful in empty pallet return lanes where pallets are often dropped and stacked.

Diamond plate – (also called tread plate) is installed on a portion of the deck to add slip resistance, particularly in areas where pallets are deposited “dropped” for inventory restocking. See the pick module image below. Diamond plate is very durable, resistant to corrosion, and has a heavy-duty capacity.

Considerations for Composite vs Concrete

Composite flooring offers comparable strength and integrity as compared to concrete; however, because it is lighter weight, substantial savings can be realized in the steel costs required to support the structure. Additionally, composite decking costs less per square foot and is faster to install than concrete, saving upwards of 3-5 weeks of installation time.

There are a lot of reasons to choose an industrial storage platform as a means to realize the best use of your facility and to optimize your operational productivity. The Apex Cos. team has extensive experience in every aspect of the design, installation, and implementation of mezzanine structures. Our team works with you every step of the way to realize your goals and ensure the design meets your productivity needs. Give us a call today, and let us help you maximize every cubic foot of your warehouse space.

To learn more about warehouse mezzanine design and applications, go to our supplemental blogs on the topic:

Mezzanine Design Overview & Commonly Used Materials

Freestanding vs Rack Supported Mezzanines