Oct
What Most Companies Get Wrong About Warehouse Mezzanine Floors
- 2025
- Becky
When warehouse owners are looking to improve the layout of their unit or increase storage capacity there are plenty of efficient and space-saving options they can incorporate. Anything from different racking systems that maximise capacity to wall partitioning systems that can divide the warehouse floor into zones. But, when your floor space is at maximum capacity you either have the expensive option of building alterations, relocation or, what are becoming the go-to solution – warehouse mezzanine floors.
Yet, while mezzanine floors can easily create additional floor space, finding a compliant solution that works for your business is harder to achieve. In our blog we look at the dos and don’ts of installing warehouse mezzanine floors.
What is the purpose of warehouse mezzanine floors?
When you step into most warehouses, you usually find a significant volume of unused vertical space sitting directly above your head. Mezzanine flooring simply utilises an area that would otherwise go unused and turn it into a valuable asset, maximising storage space.
A mezzanine will provide numerous solutions for your warehouse including:
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Quickly creating more floor space
A mezzanine sits above the traditional footprint of your warehouse and creates an additional floor. However, the big bonus is the fact there is limited building work involved in their installation, they are typically quick to install with minimal disruption to your everyday warehouse operations.
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Reduce costs and increase profitability
Most business owners would prefer to avoid the high cost and disruption of extending their current unit or relocating to a bigger warehouse. However, when space is limited this can impact on business growth. A factory mezzanine floor is a cost-effective storage solution that allows your business to expand. Plus, as a modular solution, you can easily adapt or extend your mezzanine in the future as your business continues to grow.
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Enhance your operations
A warehouse relies on numerous teams to ensure it runs at optimum productivity. The roles of inventory control, warehouse operations, order fulfilment, sales teams, administrators and project managers all need to interlink to ensure a seamless deliver on customer orders. Warehouse mezzanine floors can bring your teams together into one space by creating unique work zones that suit your requirements. You can even add soundproofing to your mezzanine to create an office space that still feels quiet even in the middle of a busy industrial environment.
What is the structure of a mezzanine floor?
Most mezzanines will bear common design features, each incorporated for safety, storage, or access requirements. Here at Teepee, our floors can be designed with all of the following:
Key Design Features of Mezzanine Flooring:
- Columns – the mezzanine platform is raised above the warehouse floor with columns and metal support beams made from steel or aluminium.
- Access – custom-designed staircases are the most commonly used methods to access the mezzanine including straight, U-shaped, or L-shaped options. However, you can also have the option to install goods lifts and hoists for safe vertical movement of heavy items.
- Floor space – you can choose from either a fully enclosed floor with walls and partitions or partially enclosed to leave an ‘open’ balcony-style appearance. You can also opt for a partial extension across the floor to allow visibility of ceiling of the next floor level.
- Flooring – you can choose options such as timber decking and steel chequer plate
- Safety features – this includes details such as handrails and safety barriers.
- Lighting and electrics – including emergency lights and cable trays. We can also install alongside HVAC systems.
What are the key mistakes a business can make with a warehouse mezzanine floors?
While warehouse mezzanine floors are a great cost-effective and efficient storage solutions for giving your warehouse a boost, there are a number of key considerations needed in the planning and design of your new structure.
Not meeting warehouse mezzanine floors Building Regulations
While a mezzanine floor is viewed as a ‘temporary’ structure, which usually avoids needing planning permission, it still has to meet other regulations.
Before designing and installing your storage mezzanine floor you will need to consider the following:
- Landlord Approval – If you lease the property, you will need permission from your landlord before installing a mezzanine.
- Ceiling height – to provide enough head clearance on a mezzanine you will need to allow a height of approximately 4.5m between the floor and the ceiling.
- Safety standards – you must include edge protection such as handrails and kicker boards.
- Building regulations approval – all new factory mezzanine floors need to meet Building Regulations requirements to ensure it is certified for safe use.
Not choosing the right type of warehouse mezzanine floors to meet business requirements
Mezzanine floors can be used for a wide variety of functions – additional space for an office, creating extra storage or used as a production area. But, understanding what the mezzanine will be used for will determine critical factors including the design of the structure and what safety features to incorporate.
Not all mezzanine floors suit every environment therefore pick the right type for your business:
- Warehouse mezzanine – these structures are designed to hold heavier loads than those in commercial or retail units making them ideal for additional storage.
- Industrial mezzanine – if you’re looking to use the space for loads such as manufacturing processes, mechanical plants or production space you will need an industrial mezzanine floor.
- Office mezzanine – these office mezzanine floors are designed for additional office facilities and space and include partitioning walls, insulation and even soundproofing to block out warehouse sounds.
- Multi-tier mezzanine – if you’re looking to maximise the vertical space in your high-bay warehouse you can opt for a multi-tier structure which builds levels on top of a standard mezzanine.
Not meeting the loading capacity of warehouse mezzanine floors?
The loading capacity of your mezzanine is critical. A typical warehouse mezzanine is engineered to hold between 360kg and 1,000kg per square metre. But, if your requirements changed and you decided to add heavier stock or machinery on to the structure it will place additional stress on the structure. Over time, the additional load will weaken the structure and increase the chance of it collapsing.
When we design warehouse mezzanine floors, the structure will be bespoke to your specific weight requirements. We will conduct structural assessments to determine the load distribution and design the quantity, thickness, spacing and size of the steel sections to ensure the structure is safe.
Not meeting fire regulations
Another area to pay particular attention is fire safety and access requirements. Even though mezzanines are classed as “temporary structures,” they must comply with regulations relating to load capacity, fire escapes, lighting, and access. All mezzanine floors require fire escapes with clearly marked routes and access for emergency services with other options including suspended ceilings, column casings, fire protection with staircase enclosures and sprinklers.
Be aware that UK building regulations may also require a fire-rating of one hour on certain structures.
Not designing the mezzanine for warehouse operations
How will the mezzanine fit seamlessly in your space – a key factor when retrofitting into an operational warehouse. If you don’t consider how the mezzanine will fit in your footprint and work around existing racking or machinery, it could change the flow of your warehouse resulting in bottlenecks.
The final design of your mezzanine should look at how your team access and exit the space, enhance your current processes and improve the operational flow of your space to increase space optimisation. Will you need on-floor design features such as doors, windows, and wall partitions to create separate rooms for offices, canteens, clean rooms, or segregated work zones? If you’re using the space to store stock or for manufacturing, have you considered how the items will get on and other the floor? Do you need to provide adequate space for other equipment or automation systems?
Don’t worry, when you work with Teepee, we’ll create mezzanine solutions that help you work through all the small details which make the difference between a successful mezzanine that boosts your operations.
Failing to future-proof your mezzanine structure
Warehouse needs often change which is why you should always future proof storage equipment such as racking and shelving to allow for growth and additional storage areas. The same concept should apply to your mezzanine floor. As a modular structure, there are options to extend, reconfigure or relocate the structure to provide new storage solutions when required.
One of the smartest moves a warehouse can make is to design mezzanines with future flexibility by increasing the weight loading capacity of the structure. Even if automation or heavier loads aren’t on the horizon today, they may well be in three or five years’ time. Building in extra load tolerance at the outset saves costly modifications down the line.
Of course, any new systems such as conveyors, AMRs and shuttle systems will create additional loads on the structure and you should only add new equipment once you have spoken to your supplier and a structural engineer.
Need a mezzanine – work with Teepee
Thinking of having a mezzanine installed? Here at Teepee, we have over 40 years of industry expertise in storage solutions. Work with us and we’ll provide you with a free site survey and design consultation with our design team to ensure your bespoke mezzanine is tailored exactly to your business. We can typically install your warehouse mezzanine floor, from design approval to completion, in as little as 3 to 6 weeks.
Mezzanine floor FAQ:
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How much do warehouse mezzanine floors cost?
The cost of a mezzanine floor depends on several key factors. Larger floors and those built to support heavy industrial loads will naturally cost more due to the stronger materials and structural supports required. However, other factors will impact on the price including extras such as goods lifts, pallet gates, lighting, partitions and finished flooring. Other factors include fire rating (typically 30–60 minutes), access equipment like staircases or conveyors, and any bespoke design or fit-out needs. Costs can also vary depending on the complexity of the project.
At Teepee, every mezzanine is tailored to your facility, get in touch for a no-obligation quote to find out how much a mezzanine might cost your business.
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What happens if a mezzanine floor is overloaded?
Overloading can cause deflection, vibration, or even structural failure. This not only puts your staff at risk but also breaches safety and compliance laws. Installing a mezzanine that’s not correctly rated for its intended load is one of the most common mistakes warehouse operators make. You’ll typically need a minimum internal height of 4.5 to 5 metres to allow for safe head clearance above and below the mezzanine. This ensures the space remains functional and compliant with building regulations.
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How high does my warehouse need to be for a mezzanine floor?
You’ll typically need a minimum internal height of 4.5 to 5 metres to allow for safe head clearance above and below the mezzanine. This ensures the space remains functional and compliant with building regulations.
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Can I add shelving or pallet racking on warehouse mezzanine floors?
Yes, but the mezzanine must be engineered for the additional load. Storage mezzanine floors that support racking or shelving require higher load ratings and may need reinforcement columns or thicker decking materials.
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How do I ensure my mezzanine is compliant and safe?
Work with a reputable installer like Teepee, who will handle the design, engineering calculations, Building Regulations submissions, and fire safety requirements. Every mezzanine should come with load signage, handrails, kickboards, and certified drawings.
