Revamping an industrial mezzanine system demands careful planning and a keen eye for detail. When updating an existing mezzanine, the choice of flooring is crucial to the system’s safety, functionality, and effectiveness.

Basics of Industrial Mezzanine Flooring

Industrial mezzanine floors are integral to the optimal functioning of warehouses and facilities, ensuring efficient space utilization. Selecting the appropriate flooring material is critical when contemplating an upgrade or installation.

There are three primary types of industrial mezzanine floorings: concrete, steel, and wood.

1. Concrete Mezzanine Floors

Concrete floors are known for their durability, strength, and adaptability in various settings. If you are planning on upgrading your mezzanine with concrete floors, consider the following:

Strength and durability: Concrete floors have high load-bearing capacity, enabling them to support heavy equipment, pallets, and machinery. Their resistance to cracks and deformation ensures structural integrity even under substantial loads, reducing maintenance requirements.
Practical application: Their strength and wear resistance are ideal for storage areas, manufacturing spaces, and high-traffic zones. The concrete’s level surface facilitates the smooth movement of material handling equipment like forklifts and pallet jacks. Concrete’s non-combustible nature also ensures fire safety in industrial environments.
Maintenance: These floors are low maintenance, with routine cleaning and occasional refinishing enough to keep them in optimal condition. The application of sealants and coatings also increases their durability and resistance to staining.

2. Metal and Steel Mezzanine Floors

Metal and steel flooring options are valued for their strength and longevity. However, they may require attention to prevent rust and corrosion.

Durability: Metal and steel mezzanine floors are exceptionally durable, withstanding heavy loads, including industrial equipment and machinery. They maintain structural integrity even in harsh environments, offering long-term reliability and minimal wear and tear.
Rust resistance: While inherently strong, metal and steel may develop rust over time due to moisture in the workplace’s atmosphere. Applying specialized protective coatings or galvanization mitigates rust concerns, extending the floor’s lifespan.
Applications: Metal decks are highly versatile and can be used across numerous applications, including manufacturing plants, workshops, and areas housing heavy equipment. Their modular design allows for flexible layouts and expansions, allowing you to reconfigure your mezzanine storage system to meet fluctuations in inventory.

3. Wooden Mezzanine Floors

Wooden mezzanine floors offer versatility and a warm aesthetic, making them an attractive option for commercial applications. However, they are less durable and have a lower weight capacity than other deck options.

Aesthetic appeal: Wooden floors create an inviting, comfortable atmosphere. This makes them ideal for mezzanine office spaces and break rooms, improving the overall ambiance of workspaces, showrooms, and retail areas.
Versatility: These floors adapt to various applications, from office spaces to showrooms and areas with lighter loads. They can be customized in finishes, colors, and styles to align with specific design preferences.
Maintenance: Wooden floors require regular upkeep, including sanding, refinishing, and spot repairs, to preserve their appearance and structural integrity. Proper care and maintenance are essential to prevent issues like warping or deterioration due to moisture or heavy use.

Considerations When Updating an Existing Mezzanine Flooring

If it is time to replace your mezzanine, there are several key considerations when choosing the right flooring. These elements can impact the longevity, functionality, safety, and efficiency of your warehouse operations.

Understanding Your Industrial Operation Needs

Before selecting a suitable flooring material for your mezzanine, understand your industrial operation needs. The purpose and function of your mezzanine play a role in the flooring choice.

Function: Determine the primary function of your mezzanine. Is it primarily for storage, office space, production, or packing?
Traffic: Analyze the level of foot traffic and equipment movement on the mezzanine. High-traffic areas require durable and wear-resistant flooring.
Materials stored: If your mezzanine is a storage space, consider the type and weight of materials stored. Heavy loads require durable flooring options with a high load capacity.

Assessing Load Capacity Requirements

Load capacity is a critical factor when selecting mezzanine flooring. Ensure that the flooring material can safely support the anticipated loads.

Weight distribution: Assess how the weight will be distributed across the mezzanine. Are there concentrated loads or uniform distribution? This information helps determine the load-bearing capacity required.
Load calculation: Calculate the expected load per square footage (PSF) or square meter based on the intended use of the mezzanine. Different materials have varying load-bearing capacities.
Safety margins: Always incorporate safety margins when determining load capacity to account for potential variations in load distribution.

You also need to account for both the live and dead loads. The live load is the temporary, changeable load types like the weight of inventory, handling equipment, and people. The dead load refers to the weight of the permanent mezzanine structure. You need to select a mezzanine floor that won’t add too much to the dead load while supporting ample live loads.

Considering Safety Standards and Compliance

Safety should be a top priority when selecting mezzanine flooring, and ensuring that your flooring choice adheres to safety standards and regulations is crucial.

Non-slip surfaces: In areas with foot traffic, especially in industrial settings, choose flooring materials that offer non-slip properties to prevent accidents. This could include textured metal flooring or the addition of non-slip grip stickers.
Fire resistance: Depending on your industry, fire-resistant flooring may be a requirement. Check local fire safety regulations to ensure compliance.
Chemical resistance: If your operations involve handling chemicals or corrosive substances, choose flooring that can withstand chemical exposure.
Accessibility: Ensure safe access to the mezzanine by incorporating handrails like Bluff Manufacturing Stairways and Landings for added safety and support during ascents and descents.

Updating Existing Mezzanine Flooring

When to Update Existing Mezzanine Flooring

Ensuring your mezzanine’s continued functionality and safety is essential for the efficiency of your industrial or commercial operations. Whether dealing with an aging floor needing refurbishment or considering a complete replacement, several factors signal that it’s time to update your flooring.

Assessing the Current Condition of Your Flooring

Before making any decisions regarding repair or replacement, assess your existing mezzanine flooring.

Visible damage: Examine the flooring for any visible signs of wear, such as cracks, warping, or general deterioration.
Safety concerns: Identify any safety hazards. This could include loose or damaged sections that might pose risks to employees or equipment.
Structural soundness: Evaluate the overall structural integrity of the flooring. Ensure that it can continue to support the intended loads safely.

When to Repair vs. When to Replace

In many cases, replacing the entire mezzanine floor is the right option to ensure the safety of workers and inventory. However, if there is only minor damage, you may be able to repair the flooring. Consider the following when determining whether to replace or repair your mezzanine flooring.

Extent of damage: If the damage is minimal and localized, repair work may be the most cost-effective solution. Replacement is the only viable option in situations involving extensive damage or structural issues.
Cost analysis: Conduct a thorough cost analysis, comparing repair expenses against replacement costs.
Long-term objectives: Keep your long-term operational goals in mind. If you anticipate facility expansion or major upgrades in the near future, it may be better to opt for replacement with a suitable flooring material.

Installation Considerations

Whether installing new mezzanine flooring or replacing an existing one, installation considerations can impact your operations. Consider the following:

Downtime planning: Strategically plan for downtime during installation or replacement to minimize disruption to your day-to-day operations.
Safety enhancements: Consider installing features such as sturdy handrails, guardrails, protective kick plates, and secure gates to enhance the overall safety of the mezzanine.
Future-proofing: Factor in future expansion or modification needs during installation to allow for flexibility in layout or additional capacity as your operations evolve.

Why Hire a Professional?

When it comes to updating mezzanine flooring, the expertise and precision of the installation process can impact the functionality, safety, and longevity of your mezzanine system.

While some may consider a DIY route to save costs, entrusting the task to a professional mezzanine flooring installer can provide a range of benefits, including:

Skill and experience: Professional installers possess in-depth knowledge of various mezzanine flooring materials and their suitability for diverse industrial settings. Their expertise ensures that your flooring is installed correctly to maximize performance.
Precision and safety: Professionals are adept at securing flooring materials, ensuring load-bearing capacity, and implementing safety features, reducing the risk of accidents and structural issues.
Compliance with regulations: Industrial facilities must adhere to safety and building codes. Professional installers know these regulations, ensuring that your mezzanine flooring installation aligns with all relevant standards, safeguarding your employees, and compliance with legal requirements.
Efficiency and timeliness: Professionals work efficiently and adhere to timelines, minimizing downtime for your business. Equipped with the necessary tools and resources, they ensure prompt completion, recognizing the importance of getting your mezzanine system operational as swiftly as possible.
Customization and adaptability: Each industrial space has unique requirements for mezzanine flooring. Professionals customize installations to meet your needs, whether creating designated floor spaces for storage, offices, or showrooms or accommodating future expansion plans. They will ensure seamless alignment with your operational objectives.
Quality assurance: Reputable flooring contractors provide warranties and guarantees for their work. This offers peace of mind, knowing that any issues arising from the installation will be promptly addressed at no additional cost.

Tips for Choosing the Right Flooring Contractor

Selecting the right contractor ensures a smooth and efficient installation that meets your operational needs and safety requirements. Some essential tips for choosing the right flooring contractor include:

Credentials and licensing: Ensure the contractor is licensed, insured, and certified. This signifies their commitment to adhering to industry standards and regulations.
Experience and portfolio: Review the contractor’s portfolio and ask about their experience with projects similar to yours. Ask for references and speak with previous clients to gauge their satisfaction with the work.
Clear communication: Effective communication is essential. Choose a contractor who listens to your needs, provides clear explanations, and keeps you informed throughout the process.
Competitive pricing: While cost is a consideration, don’t base your decision on the lowest bid. Evaluate the overall value, considering the contractor’s expertise, reputation, and the quality of materials they propose.
Timeline and schedule: Ensure the contractor can meet your project timeline and minimize disruptions to your operations.
Safety protocols: Ask about their safety measures and commitment to ensuring a secure work environment. Safety should be a priority.
Warranty and support: Understand the contractor’s warranty terms and post-installation support. A reliable contractor should stand behind their work.

Explore the Range of Mezzanine Flooring Options at SRS-i

At SRS-i, we carry an extensive selection of mezzanine flooring options, from rugged concrete to versatile metal. Some of our most popular options include:

ResinDek® over B-Decking

SRS-i’s ResinDek® over B-Decking is a strong mezzanine deck system with a solid floor constructed using a resin deck layered over B-decking. The B-deck is designed with a white underside, which serves the dual purpose of enhancing the aesthetic appeal and improving light reflection beneath the mezzanine. This flooring type offers four primary solid ResinDek® overlays.

The Unfinished ResinDek® has a skid-resistant surface and is easy to install over corrugated metal B-decking. It also resists delamination, setting it apart from Plywood or OSB. It also comes with a 10-year warranty and competitive pricing.
The Gray Diamond Seal variant is engineered for enduring durability, complete with anti-static protection, ensuring it maintains a polished appearance over extended periods. It’s also user-friendly, easy to clean, and resistant to common stains, scratches, and wear.
The TriGard® coated ResinDek® is tailored to withstand the stresses of ultra-high rolling traffic, like those used in robotic storage and retrieval applications.
The Electrostatic Dissipative (ESD) Finish is the ideal choice for electrically sensitive equipment operations. It’s designed to prevent static shocks and disruptions from electrostatic discharges, ensuring smooth operations.

Steel Diamond Tread Plate

Our Steel Diamond Tread Plate is specifically crafted for heavy-duty operations. This solid decking variant is available in smooth steel and an elevated diamond pattern.

The diamond pattern is a strategic design choice for environments prone to wet conditions. Its elevated pattern ensures that the floor remains a stable walking surface, reducing the risk of slips and falls.

Solid Diamond Grip Flooring

SRS-i’s Solid Diamond Grip Flooring is a plank-style decking solution that stands out for its durability and wear resistance. Designed with safety in mind, its surface features anti-slip diamond-shaped high-grip dimples. These dimples enhance the flooring’s aesthetic appeal and ensure maximum traction, minimizing the risk of accidents.

Solid Concrete Deck

Our Solid Concrete Deck is the ideal choice for businesses that need a flooring solution that offers unparalleled strength and durability. This flooring type is characterized by its 4”-thick layer of concrete installed over the white underside B deck. Its rugged construction ensures it can withstand heavy loads and intense operations, making it a favorite among industries with heavy machinery.

Bar Grating

The Bar Grating option, constructed from galvanized steel, aluminum, or fiberglass, offers a versatile, innovative flooring choice. This design is characterized by its vertical bearing bars, which are joined at intervals to perpendicular top bars, forming a load-bearing panel.

One of its standout features is its ability to allow optimal light and air circulation. This design choice ensures that mezzanines feel more open and less confined. Businesses can choose between the smooth or serrated bar grating variants depending on specific operational needs.

Galvanized Plank Grating

The Galvanized Plank Grating uses planks instead of bars. These steel planks undergo a careful coating process with zinc, a durable and cost-effective material. The plank design promotes the free flow of air and light, enhancing the sense of openness in mezzanine spaces.

Maximize the Efficiency of Your Industrial Mezzanine System

At SRS-i, we understand the significance of flooring considerations when updating an existing mezzanine. Our experienced team can evaluate your warehouse requirements and provide expert installation advice and a range of mezzanine systems and accessories to enhance your facility’s functionality.

Contact us today at (800) 589-7225 to speak with a project manager, or explore our options and find the perfect mezzanine flooring solution for your industrial facility.

Key Flooring Considerations When Updating an Existing Industrial Mezzanine System