Storage mezzanine for an industrial building

Utilising the height of a hall to create an additional floor is an effective way to increase storage or production capacity without the need for new building construction. A mezzanine is not just about adding a floor; it is a comprehensive engineered structure that must safely bear prescribed loads and integrate into the existing space. In this article, we summarise the key aspects that determine whether a mezzanine is technically and economically feasible for your property.

When a mezzanine is cost-effective

The economic viability of an intermediate floor depends on the ratio between the costs of supplying and erecting the structure and the price per m² of newly gained area. An intermediate floor is typically worthwhile if:

• Do you have sufficient hall height (usually over 6-7 m so that after installing the structure and flooring, the usable height remains adequate)?
• The existing concrete floor has sufficient load-bearing capacity to transfer reactions from the intermediate floor columns.
• Do you need to separate storage from production or administration from the warehouse?
• The price per m² of a new building is significantly higher than the price per m² of an intermediate floor.

What influences the structural design

The design of an intermediate floor is always bespoke. The main inputs for the calculation are:

1. Floor load capacity of the building: Mezzanine columns must be anchored into the existing concrete. If the floor lacks sufficient load-bearing capacity, we will design load-distributing bases or anchoring into new foundation pads.
2. Building height: It determines the usable clear height below and above the intermediate floor and the column layout; a denser column grid means a lighter and cheaper structure, but more obstructions in operation.
3. Load: We need to know the expected area load (e.g., 5 kN/m² for light storage, 10 kN/m² and more for heavy). The load affects deflection, strength and beam sizing.
4. Availability and logistics: The dimensions of the components must correspond to the possibilities for entering the hall and handling inside.

Building permit vs. Notification

Adding an intermediate floor is a building modification, and the specific procedure (notification versus permit) depends on the scope of intervention, change of use, and fire safety solution. Generally, a freestanding structure without interference with the load-bearing skeleton of the hall and without a change of intended use involves simpler administration. We recommend consulting your intention with a designer before ordering the structure. We will provide him with the static calculation and structural documentation as supporting material.

Process from survey to installation

1. Site survey: Our technician will perform a laser survey of the hall, check the floor and identify any possible clashes with installations.
2. Design and calculation: We prepare static calculations and working documentation. Structures are manufactured in accordance with standards. EN 1090-2 (EXC2).
3. Manufacturing: We manufacture steel components in our workshop. The surface treatment is usually hot-dip galvanisation according to EN ISO 1461 for corrosion protection.
4. Installation: Installation is carried out while the hall remains operational. We work in coordination with your operations to minimise downtime. Installation typically takes several days to weeks, depending on the scope.
5. Delivery: Upon completion, we hand over the finished structure with test protocols and documentation for notification.

Production and installation dates will be specified in the individual offer following the site survey.