Manufacturing is an industry where every square metre of space counts. However, it’s also an industry where vertical space is often overlooked for more traditional methods of expansion or even relocation. This is where a well-designed mezzanine floor comes in to help you gain more usable space. At Premier Mezzanines we’ve helped countless manufacturing clients unlock the hidden potential of their space by installing bespoke mezzanines that suit all needs, load requirements and support future growth.
What Is A Mezzanine Floor?
Simply put, a mezzanine floor is an intermediate platform built in the gap between the floor and roof of an existing structure. In a manufacturing context this extra space could act as an area for storage, assembly, tooling, supervision or even inspection. Manufacturing mezzanine floors are usually required to carry heavier loads as opposed to office or retail floors. Furthermore, they are also often required to integrate material-handling access such as pallet gates or lifts; this helps them to align with existing production workflows.
Why Manufacturers Choose Mezzanine Floors
Production is all about real, practical benefits; here are some of the main reasons we see clients opting for a mezzanine floor:
- Unlocking Vertical Space: Warehouse units and production facilities often have generous ceiling heights. Utilising a mezzanine floor lets you turn what was once empty space into production or storage.
- Avoiding Relocation or Major Expansion Works: Building an extension is expensive, and moving can be extremely disruptive. Often mezzanine floors are the more cost-effective and less disruptive choice.
- Improve Workflow and Efficiency: Freeing up valuable ground-floor space is extremely beneficial to improving workflow. Moving non-ground-floor essential works onto a mezzanine can help twofold.
- Futureproof Your Facility: Extra space offers flexibility, allowing you to adapt said space to suit future manufacturing needs as you expand.
- Strong Return on Investment: Due to the fact you are using your existing building to its full potential, the cost per square metre is often much lower than moving premises.
Typical Applications for Manufacturing
There are many applications that mezzanine floors are suited to, especially within manufacturing. Some of the most common use cases we see include:
- Storage of Raw Materials or Finished Products
- Sub-Assembly or Kitting Areas
- Tooling or Maintenance Workshops
- Inspection or Quality Control
- Supervisor Offices
- Integration with Conveyors or Handling Systems
Mezzanine Floor for Manufacturing – Design Considerations
Load Capacity: Mezzanine floors are designed to support different levels of weight; this is referred to as ‘load capacity’. From dense storage to heavy machines, you must consider every use case which might be applicable to your floor.
Workflow and Access: It’s vital to consider how people, goods and materials will move to and from the mezzanine. Pallet gates, staircases, lifts and ramps are all viable methods and must be considered. Placement is key when discussing access as well as head height around the floor.
Fire Rating and Safety: For all mezzanine installations of any size, safety is essential. Mezzanine floors must comply with your local building regulations and the fire-safety strategy of your building. This can include guardrails, edge protection, fire-rated decking and partitioning.
Integration with Existing Services: It goes without saying that you must consider the existing mechanical, electrical and plumbing services. It’s vital to avoid conflicts. Furthermore, it’s critical to ensure your building’s existing floor and foundation can support the loads transferred.
Building Control and Regulations (UK): When considering a mezzanine floor in the UK, building controls must be adhered to. Often planning permission isn’t needed for a mezzanine install; however, you’ll still need to ensure compliance with structural and fire-safety regulations. On occasion you may need to submit to your local authority or a building inspector.
The Buying Process
So you’ve considered everything you’ve needed to and you’re ready to go ahead, but what does the process entail?
- Site Survey – One of our expert team will have to visit the site to assess your current facility. This inspection will include floors, columns, head height and workflows to help better understand your requirements.
- Design and Engineering – We will take the information provided and gained from the site visit and design a bespoke mezzanine floor which suits your needs. We will then prepare a drawing for approval.
- Manufacturing of Components – Steels, beams, decking and all extras, including handrails and staircases, are fabricated and loaded, ready for delivery.
- Installation – Our installation team will erect the structure in a timely, professional and, most importantly, safe manner. Installing all extras such as staircases and pallet gates.
- Sign Off and Certification – We’ll provide you with structural calculations, fire safety documentation and hand over the completed project.
- Handover and Aftercare – Once installed, we’re still here to support you. We have many return clients who need modifications, repairs or even another mezzanine. We’re always just a phone call away to answer any queries.
Cost Factors
Budgeting for a mezzanine floor requires a deeper understanding of cost variables. So, what can affect it?
Size: Obviously it goes without saying that the more square meterage of floor you want, the more expensive it will be. This cost is made up of steel, decking and labour.
Height and Number of Tiers: Like the size, more height and extra tiers use more materials, so they will incur further costs.
Load Capacity: Simply put, the higher the load capacity needs to be, the more expensive the floor will be. This is due to the more robust structure that needs to be utilised.
Decking Material: Depending on the choice of flooring used, prices will change. Most of the floors we provide are decking, which is multipurpose and suits the needs of many.
Access Equipment: The arrangement of pallet gates, staircases and chutes all factor into cost.
Fire Protection: If fire protection is necessary, then additional costs will need to be added. We can always quote for this separately to give a clear idea of over costs.
Fit Out and Additional Services: If you’re thinking about using the mezzanine floor to house an office, you will need fit out services to construct the office walls, etc.
Case Study Snapshot: Bola Manufacturing
Here at Premier Mezzanines, we have helped many clients in the manufacturing industry harness their vertical space. One particular example was Bola Manufacturing, a sporting goods manufacturer who came to us needing additional production space. The solution provided? A mezzanine floor totalling over 200 m². Click here to read the full case study and see our work in action.
Conclusion
To conclude, a mezzanine floor isn’t just a structural addition; it’s a calculated business move for manufacturers who want to get more from their existing building. Maximising height, improving workflow and increasing capacity are all real-life benefits which can be sought from a simple, quick install. At Premier Mezzanines we have a long history of helping our clients from initial concept to aftercare and beyond. We bring the expertise so you can focus on what you do best: manufacturing. If you’d like to speak to our experts, then please get in contact through our short contact form and we will be in touch.