Why is a cold storage mezzanine floor beneficial?
You don’t have to take our word for it. Let us give you some data.
According to the latest study by the University of Michigan, nearly half of the food waste, about 620 million tonnes, could be eliminated by fully refrigerated food supply chains worldwide. Furthermore, the study published in the peer-reviewed journal Environmental Research Letters indicates that fully refrigerated supply chains have the potential to reduce the emissions of climate-warming greenhouse gases associated with food waste by 41% globally.
The researchers had been modeling food losses to find out where the cold chain can be improved to reduce food losses and emissions. Of course, every company and supply chain is characterized by unique features, but most use cold storage. This directs our focus toward an efficient organization of storage volume.
Let’s look at the mezzanine floor. Cold storage facilities are typically equipped with refrigeration systems to maintain consistently low temperatures. Different products need a specific temperature. For example, pharmaceuticals need about 35°F-46°F, fruits and vegetables 30-40°F, the temperature for meat and fish is about 32-36°F, and frozen foods should be -10°F to 0°F. With a mezzanine, you can add a level to your cold storage space and physically get more storage options. So, what benefits can you expect from a mezzanine floor?
The advantages of a mezzanine floor rack type cold storage
Increased capacity through efficient use of space. While some researchers say that a mezzanine floor takes up to 25% of a building’s floor area or less, others point out that it depends on the mezzanine floor type. You can place it in any storage area and position it to fit a specific and well-defined purpose: combine it with conveyors, a racking system, or set it above a dock or production equipment.
Easy access and compatibility with other equipment. You can use stairs, elevators, or even lifting tables (platforms) to access the mezzanine floor. It can be automated and contains a shelving system inside.
Customizable design and individual layout. It is your business, your rules. Mezzanine rack type cold storage is always designed with your unique storage requirements in mind. You choose the layout, type, size, structure styles, and floor material.
Save on energy costs. With a mezzanine, you can maximize natural light and maintain proper air circulation. This will have a positive impact on both employee well-being and energy consumption.
Please note that the design and installation must be carried out according to the load capacity of the intended use. As we’ve said, the International Building Code (IBC) parameters define the allowable minimum to heavy load in pounds per square foot (PSF) distributed over the platform. For instance, from 60 to 90 PSF (minimum use—conveyors or maintenance with limited access) to 250 PSF (storage warehouse—heavy/heavy manufacturing). Mezzanines should be built to the full expected load-bearing capacity of the intended use.
Brief view of mezzanine floor types for cold storage
We can divide the mezzanine floors as follows:
By Structural:
- Structural Mezzanines. Structural mezzanines are the heavy-duty choice. Built with steel beams and columns, they’re designed to handle substantial weight, which makes them perfect for areas with a lot of movement or heavy loads. They work best when planned at the start of a warehouse layout, but they can also be added later with some tweaks.
- Rack-Supported Mezzanines. These mezzanines use the existing racking system as their main support, so they’re a great way to add storage without new construction. However, they’re typically limited in how far they can extend cross-aisle, which means they’re harder to scale if you’re thinking big. Rack-supported mezzanines are best for warehouses that need to grow vertically and maximize space over existing shelving.
- Shelving-Supported Mezzanines. These mezzanines sit on top of your shelving units, making it easy to add storage for lighter goods. They’re ideal for facilities that need a more organized storage layout without requiring heavy structural support. It’s a solid choice if you’re looking to increase space without a huge upfront investment.
- Free-Standing Mezzanines. Free-standing mezzanines don’t rely on building support—they’re completely independent, with their own columns and structure. This flexibility makes them perfect for a variety of uses.
- Catwalk Mezzanines. Catwalk mezzanines are more like elevated walkways, allowing you to access machinery or equipment while keeping the floor open for other activities. They’re perfect for industrial settings where employees need a safe and efficient way to get above ground-level operations.
- Full Mat Mezzanine Flooring. It is a hybrid system that blends the features of catwalks, freestanding floors, and rack-supported mezzanines, providing exceptional versatility for warehouses and industrial spaces.
By Tiers
- One-Tier or Modular Mezzanine Floors. One-tier, sometimes called “modular mezzanine floors,” divides a single space into two levels. This tier doubles the floor area by creating an upper level that mirrors the ground space below. One-tier mezzanines are an effective way to expand storage or work areas without the need for new construction and are ideal for smaller facilities or those just beginning to utilize vertical space. These floors are generally quick to install and provide a cost-effective solution.
- Multi-Tier Mezzanines. Multi-tier mezzanines, often referred to as “Double Decker Mezzanine Floors” or even up to “4-tier structures,” offer multiple levels of added storage or workspace. A two-tier, or double-decker, mezzanine is common, but some facilities extend these mezzanines up to four levels, making them ideal for large-scale operations where maximizing vertical storage is essential. Multi-tier mezzanines require careful planning due to the increased weight and support needs at each additional level, but they are incredibly space-efficient for warehouses that handle high inventory turnover or diverse product categories.
By Decking Options
- Grating. Grating is popular for mezzanine floors as it allows light and air to pass through. Made from aluminum or steel, bar grating is low-maintenance and highly slip-resistant, making it a safe choice for cold storage facilities.
- Steel Plate. Steel plate, often made from 12-gauge steel, offers high durability and skid resistance, ideal for heavy traffic areas. Installed over a steel frame, this flooring can support large equipment and storage racks, with structural support from H-beams or tubes anchored to the concrete floor.
- Concrete. Concrete flooring is often supported by a corrugated steel deck and poured to a thickness of 4–5 inches.
- Resin Composite. Resin composite flooring withstands high traffic from carts and pallet jacks. Available in various thicknesses, it’s resilient, easy to cut, and adaptable for specific mezzanine layouts.
Of course, there are other options, but not all of them can be used in cold storage.
Incorporating a mezzanine floor into your cold storage facility is a strategic move that boosts storage capacity, operational efficiency, and adaptability without the hefty price tag of a full-scale expansion. Whether you’re managing perishable goods, pharmaceuticals, or any temperature-sensitive inventory, mezzanine floors offer the flexibility to meet your unique needs, from rack-supported to multi-tiered options.
Ready to take your facility to the next level? Contact a mezzanine flooring specialist at 503-640-5666 to explore solutions tailored to your cold storage requirements. This investment isn’t just about adding square footage—it’s about maximizing your space, streamlining your operations, and enhancing your bottom line. So why wait? Let’s build up, not out, and get the most out of every square foot!
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