More storage space is almost always an issue while outgrowing a business. Employees are cramped with stock all over the workspace. It also gets harder to navigate floorplans that were previously adequate. Naturally, the first thought would be to get a bigger space. A better approach would be looking up.
Adding a mezzanine floor gives the ability to build up floor space. Without the costs of renting a bigger building, and without an extension, you can gain an entire floor of space in an existing building if the ceiling can accommodate it. Mezzanine floors, unlike shelving or storage products, are structural products, so they impact your decision making and the purchasing process itself.
Ceiling Height
A height of about 6 meters is suggested for the level of a mezzanine to be reasonable. There needs to be enough space to work or to store stuff at the ground level and enough space to work comfortably at an upper level.
The usable upper level height has minimum height considerations. Traditionally, these accessories take up 200-300mm. Assume there is some sort of action taking place at the upper level which would take up additional height. If there is an upper level shelving archive for infrequent access, about 2,000mm would be an acceptable height. If employees work at these upper levels, 2,400mm is more appropriate. Anything tight in this realm causes a problem. The problem becomes obvious if someone needs to be on the upper floor for an entire work day.
For your first measurement, you will want to measure the lowest ceiling obstruction. Remember to measure from the bottom of the ceiling, not the top.
There are three structural approaches for mezzanine floors. The optimal choice depends on your needs.
The most flexible are free-standing mezzanines. These are supported by a column and beam structure and are completely independent of the building.
Rack-supported mezzanines are ceiling supported by stacked pallet racking. This is the sturdiest option but the upper level layout will not be flexible.
Shelving-supported mezzanines work on the same principle but use shelving modules in place of pallet racking. They are commonly used in archives or parts storage applications where the loads are of a lighter nature and the upper level needs to be densely shelved.
There are Planning and Building Regulations related to the construction of mezzanine floors. A mezzanine floor is a permanent structural addition to a building, so Building Regulations apply to this in England and Wales — in particular Part A (structure), Part B (fire safety), and Part M (access and use). Building Regulations approval must be in place prior to construction; this cannot be done retrospectively.
Contra to the previous Building Regulations, in most circumstances, especially in relation to industrial and commercial buildings, the construction of a mezzanine floor is considered to be a permitted development and, therefore, the construction of a mezzanine floor is unlikely to require planning permission. It is highly recommended that, prior to the construction of a mezzanine floor, the construction and relevance to Building Regulations are discussed with a Building Control approved inspector.
When a building is modified in the form of a mezzanine, the aspects of a buildings fire safety need to be cited, primarily, fire escape routes, the compartmentalization and/or the configuration of sprinklers. Adding fire protection systems and removing any or all fire protection systems as a part of the building alterations is a consideration. A fire risk assessment must be conducted each time a building is altered. The alterations to the design, of a building for example, a mezzanine floor, should be designed in such a way so to incorporate additional fire protection systems and all additional systems necessary to meet the needs of that design. It is important to be in compliance with the law. In situations where a stairway serves three or more floors of a building, it is important to incorporate fire protections/safety systems.
None of this should be considered insurmountable, nor is it likely to be ignored. Any recognized mezzanine installer will include these details as part of their design process. If you receive a quote with no reference to Building Regs, you should question this.
Load capacity
For general storage, mezzanine levels are typically set to a uniformly distributed load (UDL) of 360kg per square metre. Bulkier storage — heavy components, bulk goods — may need 480kg/m² or greater. The UDL should be specified to reflect your intended use, rather than be set to a standard figure.
This also entails knowing exactly what you are planning to place on top of the structure before you define it. It costs a lot to change the loading post construction.
Access
Building regulations define the standard means of access to a mezzanine floor using stairs. For the movement of products, as opposed to i.e. people, a design stage consideration of a pallet gate and a goods lift or scissor lift is warranted. Although it is possible, it is almost always a challenge to add these features after the mezzanine has been installed.
What it costs
Mezzanine floors are a large investment when comparing to a racking system, but are more affordable than relocation. The most critical cost determinant variables include the load, floor dimension, structure type, stairs and access arrangements, fire protection measures, and the need for planning.
Mezzanine costs should be compared to the total costs associated with acquiring additional premises rather than the costs associated with doing nothing. These costs include increased rent, business rates, service fees, relocation costs, and the inconvenience associated with the move. Well constructed which Integrated designs a mezzanine, its costs appear rather uncomplicated.
If you are considering whether your existing building could be utilized to a greater extent before relocating to a larger building, you should start with a building survey. In most cases, the answer is no. This is because the existing building does not have the required structural capacity or ceiling height to accommodate a mezzanine. However, you cannot rule out the option unless a survey has been conducted.