A Complete Guide to Mezzanines & Catwalks

A Complete Guide to Mezzanines & Catwalks

People tend to call any elevated platform a “mezzanine” these days, but that can be a big mistake, especially in the permitting process. The terms equipment (or work) platform and mezzanine both refer to structures that create an intermediate floor. There are some important nuances however, and whether you call a structure a mezzanine or an equipment platform can have serious implications when it comes to the ease of getting building permits, as well as construction costs. The impact on your taxes and depreciation will also vary depending on the term used.

What’s a warehouse mezzanine? What’s a work platform?

A mezzanine is a relatively permanent structure that is typically installed within an existing building or industrial facility. It is a raised platform that is constructed above the ground floor, typically supported by existing columns or posts, and is designed to provide additional floor space for storage, office space, or other purposes. Mezzanines can be designed and installed in a wide range of configurations to meet the specific needs of the facility.

Multilevel Pick Module

A warehouse platform, on the other hand, is a raised platform that is typically designed and constructed as a stand-alone structure with the aim to provide additional floor space for storage, manufacturing, or other industrial processes. Warehouse platforms are generally larger and more robust than mezzanines and are designed to support heavy loads and equipment.

The pivotal differences: Is it part of the facility? What will you be using it for?

The critical distinction lies in the platform’s association with the facility. It hinges on whether the authorities classify the mezzanine as an integral part of the building or as capital equipment. Numerous newly constructed buildings incorporate what they refer to as “mezzanine levels” into their structural design. When a platform is deemed an inherent component of a building rather than capital equipment, it may be subject to compliance with building codes, restroom requirements, accessibility standards, and may influence tax rates and depreciation schedules.

Another key factor is the intent – It is imperative to ensure that building permit authorities and regulatory bodies fully grasp the purpose and design of the structure. To achieve this, it’s advisable to refer to your mezzanine project using designations such as “work platforms,” “elevated platforms,” “storage platforms,” “equipment platforms,” etc. These terms offer greater precision and clarity compared to the overly encompassing and sometimes imprecise term “mezzanine.”

This can impact your taxes since in some states mezzanines are considered part of the square footage of the facility, while platforms aren’t. This can seriously impact on property taxes every year, as well as depreciation deductions since capital equipment depreciates differently.

Practical Applications

Combined with various warehouse automation equipment, mezzanines can provide a great option to grow in your existing footprint by optimal usage of the cube in a variety of applications:

  • Storage
  • Production
  • Offices/Administrative Space
  • Equipment positioning
  • Picking Modules

Utilizing the vertical space with a mezzanine means that you need to move material between levels without creating bottlenecks. This means that you will need automation equipment to move materials up and down between levels. The technology for this purpose can be grouped into 3 general categories:

  1. Spiral Conveyors. This type of conveyor has a small footprint and provides excellent throughput, usually for handling of cartons, totes and less than pallet loads.Pick Module with slat conveyors, belt conveyors and roller conveyors
  2. Incline Conveyors. Though it is less space efficient than spiral conveyors, the incline conveyor is a very economical and robust option for automated handling of a wide variety of loads.
  3. Vertical Lifts. These sturdy pieces of equipment have a small footprint and are particularly effective in setups where heavier loads or bulky items need to be lifted.

In a warehouse environment one of the most important advantages of elevated platforms is their high-density storage application. Generally speaking, these can be classified in 3 groups:

  1. Rack Supported Mezzanines. These mezzanine configurations combine high bay pallet racking with walkways between the rack. The racks can be fitted with carton flow for dense order picking and mixed storage of pallets. Rack supported mezzanines allow a multitude of options for customization and are a very economical choice for vertical space utilization.Shelving Mezzanine
  2. Shelving Mezzanines. Applied in configurations for handling small items such as parts or tools. This type of platform maximizes the number of storage bins, allowing for a great number of SKUs to be organized in a concentrated space while remaining easily accessible for pickers.
  3. Multilevel Pick Modules. These highly customizable solutions integrate various storage solutions that enable a very efficient movement of product by combining elements of mezzanines with conveyors, spirals, pallet/carton flow, static racking and shelving, pick/put to light etc. They are specially designed with zoning and provide significant cost savings for broken pallet, full-case or open-carton picking.

How we can help you

The choice between a mezzanine and a warehouse platform ultimately depends on the specific needs of the facility and the goals of the business. As a true systems integrator, ABCO Systems also has a vast experience in designing and delivering these kinds of solutions, including a very efficient navigation of the permitting process. Reach out to us today to get started!

4 Reasons Warehouse Mezzanines Are The Perfect Storage Solution

4 Reasons Warehouse Mezzanines Are The Perfect Storage Solution

The time when you need to expand brings both a feeling of elation and dread. Expansion means that you have achieved a milestone in your business. Give yourself a pat on the back because you’ve earned it.

However, an expansion also brings worries. Moving to or construction of a new facility is expensive. You will incur considerable downtime and productivity may suffer.

Warehouse mezzanines offer a fast, economical, and effective solution to this problem. Here are 4 reasons why you should consider a mezzanine upgrade for your warehouse expansion.

1. Double Your Effective Space

Most warehouse buildings have high ceilings. You are wasting space by limiting activities to a single floor. Make effective use of that space by installing a warehouse mezzanine.

The new area created gives your warehouse flexibility for almost any application. Need a secure area for more valuable products? How about an area for assembly lines, new office spaces, or boardroom areas?

You can use that additional space for whatever your current needs are. Another benefit is that it will give your facility a clean and organized look. This is a big boost to your brand image especially if your warehouse receives frequent visits from partners or client representatives.

2 Level Mezzanine

2. Save Money

A mezzanine upgrade is one of the most cost-effective ways to acquire more space. The installation and labor cost is going to be a lot cheaper than buying real estate for a new warehouse. Maintenance for warehouse mezzanines is minimal and affordable.

And since you will be staying in your current building, you can use your existing heating and cooling systems. Not only will you be saving on energy cost, you will also reduce your carbon footprint.

3. Highly Customizable

You can customize the mezzanine to suit any size, shape or configuration. Depending on the use, additional accessories such as protective guards and handrails, conveyors, or gravity chutes can be incorporated into the mezzanine floor.

We can also disassemble and move constructed mezzanines at any time. If you need to make changes, these can be done readily.

4. Less Disruption Means Less Downtime

During construction of the mezzanine, we usually can work around all the existing equipment and obstructions in the warehouse. All activities beneath the mezzanine can go on with minimal disruption.

You can continue your day to day operations without any hitch. You don’t have to worry about customers waiting or your employees not having a place to work.

Are you ready to give warehouse mezzanines a try? Contact us and let’s get started.

Benefits Go Beyond Price for Warehouse Mezzanines

Benefits Go Beyond Price for Warehouse Mezzanines

We have discussed in the past whether the prices for warehouse mezzanines justify their inclusion in your distribution center or warehouse. In this earlier article we break out some cost scenarios for mezzanines  and help you figure out whether the cost of a mezzanine is a good investment for your company. Let’s look at cost as only one part of the equation for mezzanines and delve into some additional ones as well.

Warehouse Mezzanines

Cost: If you are near one of the coasts or in a place where real estate cost if high, say you are looking at the price for mezzanines in New Jersey, it makes sense to put a mezzanine into your building because that will be less than gaining space by acquiring more real estate.

You pay for the mezzanine once, whereas your square footage is a monthly recurring cost. The true beauty of investing in a mezzanine is that you increase your usable space without increasing your monthly rent. And if you own your distribution center you get an increase of floor space without having the cost of building out.

Flexibility: Mezzanines can be used to support almost any application that you can think of in the warehouse. Not just for additional storage but as pick modules, or as office space or GOH storage, the use of mezzanines vary for your individual situation and your individual goals.

How you use your mezzanine will affect the end cost so be sure to factor that into your calculations. For instance flow rack with an integrated conveyor system will be more expensive than office space

However cost should not be your only consideration for how you use your mezzanines, you also need to think about your process and how you can get the best ROI.

Less disruption: Often we can install a mezzanine without interrupting the day to day operations of your distribution center or warehouse. This means that you are not losing any money or incurring downtime while you are increasing the productivity of your distribution center when you add a mezzanine. Compare that to moving your operations to gain space.

So while the price of mezzanines is an important consideration there are other benefits that you should consider as well. If you are thinking about adding a mezzanine or you are interested in seeing how we can help optimize the space that you have, give ABCO Systems a call and let’s talk.