Catwalk Mezzanines

Catwalk mezzanines are elevated walkways or platforms typically used in warehouses, manufacturing facilities, or distribution centers. They allow workers to access areas at a height without obstructing the floor space below. These mezzanines span between racks, shelves, or machinery, providing a walkway for employees to efficiently navigate between storage areas or equipment.

Quick Fact: Did you know that catwalk mezzanines can turn the “dead air” in your warehouse into valuable asset?

Catwalk mezzanines are often designed to be adjustable and can be customized based on specific facility needs. These structures are particularly useful in warehouses with tall shelving or pallet racking systems, as they enable access to multiple levels without requiring additional machinery like forklifts.

Advantages of Catwalk Mezzanines

Catwalk mezzanines utilize vertical space, allowing businesses to store materials or equipment at higher levels without occupying additional floor space. These mezzanines provide easier and safer access to elevated storage levels or equipment.

Rather than investing in a larger facility or expensive storage systems, catwalk mezzanines allow businesses to expand upward.

Catwalk mezzanines reduce the reliance on forklifts for retrieving items from high shelves. This can reduce forklift traffic on the warehouse floor.

Permits & Regulations For A Catwalk Warehouse Mezzanine

The Occupational Safety and Health Administration (OSHA) sets forth specific regulations to ensure the safety of catwalks and elevated platforms in the workplace. While OSHA does not mandate permits for the installation of these overhead space structures, compliance with their safety standards is essential. Key OSHA regulations include:

Guardrail System Requirements (29 CFR 1910.29):

• Top Edge Height: Handrail bar grating must have a top edge height of 42 inches (±3 inches) above the walking-working surface.
• Strength: Guardrails should withstand a force of at least 200 pounds applied in any downward or outward direction.
• Midrails: Installed midway between the top edge of the guardrail and the walking-working surface or deck, capable of withstanding a force of at least 150 pounds. 

Walking-Working Surfaces (29 CFR 1910.22):

• Surface Conditions: All walking-working surfaces must be kept clean, orderly, and in sanitary condition.
• Load Capacity: Surfaces should support the maximum intended load without failure.
• Access and Egress: Safe means of access and exit must be provided for all walking-working surfaces.

Stairways and Ladders (29 CFR 1910.25 and 1910.23):

• Stairways: Standard stairs should be used for access when regular travel between levels is necessary.
• Alternating Tread-Type Stairs: Permitted when space constraints prevent the use of standard stairs.
• Fixed Ladders: Should be used only when stairs are not feasible, and must comply with specific design and load requirements.

Openings and Holes (29 CFR 1910.29): Openings in walking-working surfaces must be guarded to prevent falls. Covers for holes should support at least twice the maximum intended load and be secured to prevent accidental displacement.

Why Bolted Connections are Important for Industrial Catwalk?

Bolted connections improve structural integrity of catwalk mezzanines, as they ensure that the system can support the necessary loads, including equipment and personnel. These connections allow for flexibility in design, enabling modular setups that can be easily customized or expanded as needed.

Bolted connections allow quicker installation and require less specialized equipment compared to welding. Moreover, bolted systems reduce the risk of corrosion by facilitating the use of corrosion-resistant materials, making them ideal for environments exposed to moisture or chemicals. Maintenance and inspection become more straightforward with bolted connections.

Additionally, compliance with building codes often requires the use of bolted connections.

Catwalk System Project Process

Quick Fact: Industrial catwalks aren’t just for storage—some companies use them to create elevated workstations, break areas, or observation decks for better operational oversight.

It begins with a thorough needs assessment, where stakeholders evaluate the specific requirements of the warehouse, such as space optimization, load capacity, and operational flow. This step includes discussions with warehouse staff to understand how the mezzanine will fit into daily operations.

Next, the design phase follows, where detailed plans are developed. This involves creating layouts that incorporate the catwalk mezzanine, considering factors like height, dimensions, and safety features. During this phase, structural engineers or designers may utilize CAD software to visualize the design.

Once the design is finalized, the procurement stage begins, where necessary materials, including steel components, bolts, and safety features like guardrails, are sourced. After securing the materials, the installation phase can commence, typically involving skilled laborers who assemble the mezzanine structure on-site. This process may include bolting components together, ensuring all safety features are correctly installed, and conducting inspections throughout to maintain quality control.

Quick Fact: Retrofitting a catwalk mezzanine into an existing warehouse doesn’t just save space—it often extends the life of the facility with underused vertical space.

After installation, a thorough inspection is conducted to verify structural integrity and safety compliance. Finally, training sessions may be held for warehouse staff to familiarize them with the new mezzanine and ensure proper usage and safety protocols.