A structural steel mezzanine adding storage floor inside an existing warehouse.
The challenge: A distribution business needed extra storage floor in an existing warehouse without extending the building. The mezzanine had to carry pallet racking loads, tie into the existing portal frame, and be completed without disrupting the warehouse below.
Our approach: We designed the mezzanine on new columns independent of the existing frame, with a steel beam grid and open grate flooring. Beams were shop-drilled and match-marked, and the columns were set on new footings with chemical anchors. The deck was built in sections and craned in through the existing loading door, so the warehouse below kept operating.
The outcome: The mezzanine was installed over a week with the warehouse running underneath. The deck carried the specified pallet racking loads, and the independent columns meant no load was added to the existing frame. The client later added a second run of racking on the new floor.
Hot-rolled mild steel columns and beams (UB / UC), open steel grate deck panels, safety handrail and kick plates, chemical-anchored base plates. Scope included engineering coordination, fabrication, delivery, craned installation and handrail.