Types of rack mezzanines and features of their design. Warehouse mezzanine Why mezzanine racks are good

Warehouse mezzanine- a multi-tiered metal shelving structure, separated by floors with floor panels made of chipboard, plywood, profiled sheets, gratings or solid metal sheets with notches. The mezzanines were designed to maximize the use of space height by increasing the number of storeys in the warehouse. They come in two main types of designs:

  • multi-tier shelving systems;
  • mezzanines on the platform.

Multi-tier shelving system

Mezzanine on the platform

The mezzanine design allows you to increase the usable area of ​​the warehouse; it is used to accommodate office space, light shelving structures, and additional retail space.

The mezzanine easily integrates with other types of cargo and shelf racks, and can be either a free-standing structure or based on cargo or shelf racks.

The load-bearing part of the mezzanine is the shelving. These can be frontal or shelf racks. The fact that the racks are the power part of the mezzanine structure excludes the possibility of their free arrangement.

The design of the racks includes the following elements:

  • vertical racks, the length of which determines the height of the rack (up to 12 m),
  • horizontal beams that support the weight of the load (in the case of shelf racks, shelves are used instead of beams),
  • diagonal braces connecting vertical beams to each other and providing the necessary structural rigidity.

Typically, the components of the racks are made of bent perforated profiles. The bent profile allows for sufficient stability and strength of the structure, with low metal consumption. The holes in the vertical posts are used to attach horizontal beams or shelves. The small pitch of the holes allows you to easily adapt the design of the rack to suit various types cargo.
The floor panels are strong enough to withstand not only the weight of workers, but also light warehouse equipment, such as a hand-held pallet truck, a transpallet, an electric truck, or a manual hydraulic stacker.

Advantages of the mezzanine:

  • increase in coefficient beneficial use space by 100% or more;
  • the product processing process is carried out simultaneously at several levels;
  • completely collapsible design, which allows you to change and move it depending on the circumstances.

On the mezzanine it is possible to combine racks of any type: pallet, console, shelf. They make it possible to work simultaneously on several levels, giving quick access to any product at any level, ensuring rational organization of warehouse flows. Employees are lifted to the upper floors of the mezzanine using stairs equipped with railings. To load goods onto the upper floors of the mezzanine, lifting mechanisms (lifting tables), elevator equipment or warehouse equipment (stackers, forklifts) are used.

In class A warehouses, a mezzanine is often also called a superstructure above the picking and shipping area (mezzanine). In fact, this is a built-in balcony, which again can be used as storage space, including for the construction of shelving systems for various purposes. It is necessary to understand that the load on the floor on such balconies is lower than that of the main warehouse. Goods are delivered to the mezzanine area using stackers or a lift table/elevator

Mezzanine racks (mezzanines on frontal pallet racks, shelf mezzanines) are racks with flooring with several tiers (levels) of storage in aisles where there are one or more floor levels at different heights.

Employees can usually access pedestrian levels by using stairs.

Goods are loaded through sliding, swing or revolving gates. In warehouses, storage mezzanines are quite often built (mounted) into a system of racks installed previously.

But although the racks and mezzanines on the racks have essentially the same design, they are not the same in terms of functionality, since employees are constantly located on the tiers, as well as on the 0th level of the rack mezzanine.

The key difference between a mezzanine on racks and a mezzanine on columns is that the load-bearing structural elements of a mezzanine rack are the parts and components of the rack itself.

As a rule, these are cold-rolled frame racks and beam profiles, which are made of low-carbon steel and galvanized strip.

Mezzanine racks have the following advantages:

  • fast production times;
  • the ability to integrate the structure into racking systems that are already in stock;
  • low production metal consumption;
  • low production costs;
  • ease of installation due to the low weight of the parts;
  • the ability to quickly bring parts to the location, etc.

The disadvantages of mezzanine shelving are:

  • low fire resistance, impact resistance to loading equipment;
  • restrictions regarding the width of passages, the spacing of racks (usually no more than three to four meters);
  • lack of design methods and standards that are adapted to domestic conditions;
  • difficult maintainability of components;
  • demands on the quality of floors and timely maintenance.

It is worth noting that it is possible to combine the designs of a mezzanine platform on columns and a mezzanine on shelving.

Availability on the market different options the design of the warehouse mezzanine is, of course, a big plus, because... makes it possible to obtain an effective solution when planning and organizing a warehouse.

The installation of platform mezzanines in a warehouse allows not only to fill the room as much as possible in height (this can be done thanks to high-rise shelving), but to expand the range of stored goods and provide the ability to store in combination.

Organize on different tiers of the mezzanine different types warehousing is a widespread solution today.

The maximum possible floor height of 5 meters will make it easy to install any type of low cargo racking system or provide floor storage. But at the same time, questions arise regarding the types of racks that can be installed on other floors of the mezzanine, and whether there are restrictions.

One of the limitations is the load capacity of the mezzanine. In principle, for ultra-high loads it is feasible to design a mezzanine platform, but its cost can be comparable to renting premises. Accordingly, the question of the appropriateness of such a decision arises.

Another limitation concerns the loading equipment used on the mezzanine tiers. We are not talking about electric stackers, reach trucks, or loaders. The upper tiers of racks are loaded using conveyor lines, light stackers, different types carts.

Taking these limitations into account, it is easy to identify the types of racks that can be installed on mezzanines: shelving gravity, auto-racks, shelf racks, 2/3-level pallet front systems. High-density pallet systems (gravity, padded, push back and shuttle) and mobile freight systems are not installed.

Taking into account the load capacity of the mezzanine, it is possible to install mobile shelves, auto-racks and, in fact, without restrictions - archival mobile racks.

It is optimal to install the lightest racking equipment on higher tiers, where there are also areas for individual collection of cargo.

Mezzanine (otherwise: mezzanine, mezzanine) is one of the most convenient and popular solutions used in a modern warehouse.

A mezzanine (from Italian mezzanino) is a metal structure, independent of the main load-bearing elements of the building, providing the organization of one or several floors (pedestrian levels), installed inside the warehouse.

The main purpose of mezzanines is to maximize the use of room height when storing and processing boxes and piece goods. This is especially true in small warehouse spaces.

Mezzanines: design options

Shelving-mezzanine design (pass-through mezzanine)

In such a mezzanine, the carrier is the shelving system itself, and the pedestrian levels are attached to the shelving racks. In fact, such a mezzanine is the same type of multi-story shelving (usually shelf-based) that does not allow free arrangement.

Scope of application:

Storage and processing of boxes, piece and non-standard cargo. Archival storage.

More information about walk-through mezzanines can be found in the section rack-mezzanine structures. In this section we will talk about the second type of mezzanine structures - mezzanine platforms.

Detached mezzanine – technical mezzanine (mezzanine);

The mezzanine is a platform on which both light shelving structures and office furniture can be randomly placed.

Free-standing mezzanines are used for a variety of purposes:


Mezzanines: main technical characteristics

  • Column spacing is up to 12m.
  • Number of storeys – up to 4 levels.
  • Level height – up to 5m.
  • Pedestrian flooring

Types of pedestrian mezzanine flooring

An important point When ordering a mezzanine, you need to select the flooring material. Depending on the conditions in which the mezzanine is operated, its design, and load requirements, the flooring can be made of:

  • solid metal sheet with corrugation and support made of profiled sheet;
  • pressed or welded grating;
  • plywood with support made of profiled sheet;
  • plywood with an additional coating of “technical linoleum” and a support made of profiled sheet.

The use of plywood on mezzanines requires additional treatment of the flooring with fire-retardant compounds in accordance with established technology.

Delivery and installation

The mezzanine is delivered to the site disassembled, with a full set of components and is ready for installation. Installing a mezzanine does not require strengthening the foundation or reconstructing the floor. All connections in the structure are prefabricated, so the mezzanine can be quickly moved to a new location in case of a change of storage space. All steel elements of the mezzanine are powder coated, which protects the mezzanine from corrosion and gives it a good aesthetic appearance.

Accessories

Additionally, the mezzanine can be equipped with accessories to best suit the technological needs of the warehouse and the safety of workers:

  • various types fencing railings,
  • mesh modules and partitions to divide the mezzanine space.
  • swing and sliding gates,
  • modules for safe unloading and loading of palletized cargo,
  • protectors “bumpers” to protect the supporting columns of the mezzanine from impacts of handling equipment.
  • various types of lifts, conveyors and cargo conveyors to high mezzanine levels.

Reliability and guarantees

The AMET company provides a lifetime guarantee for mezzanine structures of its own production.

Materials used and methods for designing mezzanines

Safety and reliability of structures are the main priority of our company, therefore AMET mezzanines are designed in strict accordance with all industry standards.

  • SP 53-102-2004. General rules design steel structures.
  • SNiP II-23-81*. Steel structures. Design standards.
  • Manual on the design of steel structures (to SNiP II-23-81*.)
  • SNiP 2.01.07-85*. Loads and impacts.

For the production of mezzanines (mezzanines), thick sheet steel (GOST 19903-74), wide-flange I-beams (GOST 26020-83), corner profiles (GOST 8509-86), curved welded profile (GOST 30245-94 or TU 36-2287-80) are used ), profiled sheet (GOST 24045-94)

Steel grades are used according to STO 02494680-0045-2005 (standard of the Melnikov TsNIIPSK) or according to GOST 27772-88.

Currently, the meaning of the term mezzanine is blurred. A mezzanine is also called a racking system and a mezzanine in class A warehouses. The racking system can be either single-story or multi-story. In most cases, the mezzanine as a racking system is used for storing small-piece goods, and allows for more efficient use of warehouse space, on which it is no longer possible to build a high-rise racking system for storing pallet cargo.

A mezzanine in class A warehouses is a superstructure over the picking and shipping area. In fact, this is a built-in balcony, which again can be used as storage space, including for the construction of shelving systems for various purposes. It is necessary to understand that the floor load on such balconies is lower than that of the main warehouse and can vary from 1.5 tons to 4.5 tons per 1 sq.m. Goods are delivered to the mezzanine area using stackers or a lift table. In general, the mezzanine area is intended for storing low-turnover, small-piece or high-value goods.

We will help with designing, ordering and choosing a mezzanine for a warehouse. Organization and consulting.

Manufacturing companies have to allocate significant areas to store their goods. But there is a certain limit to the expansion. In this case, the warehouse is ready to help. It allows you to use the available space more efficiently. With the help of such a device, it becomes possible to create several levels in one warehouse. In this case, it is possible to place tens of times more units than before.

What are warehouse mezzanines

To put it simply, a mezzanine is an ordinary rack on which storage is carried out. But it has several levels. In some cases, the space can also be used to organize office or service premises. In some cases, racks are assembled in such a way that loading on them can be done manually or using additional equipment.

Pros of use

Many owners of transport and other companies have already appreciated the advantages of mezzanines. The advantages include:

  • ease of configuration change;
  • ease of assembly;
  • access from different sides;
  • the ability to automate sorting;
  • possibility of installing elevators for staff;
  • long service life;
  • ease of moving cargo at height;
  • good appearance.

Mezzanine systems can be designed specifically for a specific area. They can be made exactly the way the customer wants them to be. The levels do not have to be the same. Some of them may have greater or lesser height. To increase the speed of movement of personnel, flights of stairs or elevators are installed. Transport belts and sorting units can be installed at various levels of racks, which speed up the warehousing process many times over. Typically, steel is chosen as the material for making shelving. high quality. It is this that can provide the required endurance and rigidity of the frame.

Scope of application

Mezzanines are becoming widespread today. This applies not only to industrial warehouses, where products manufactured by a specific plant are stored. These racks are suitable for storing food products, cosmetics and medicines. Such racks are an excellent solution for repair shops where it is necessary to ensure orderly storage of components. Mezzanine systems are used in large libraries and archives. They make it possible to create the required climate for better preservation of documents. You can store any products in open form or in special containers. Owners of large stores, for example, Amazon, have ensured that robots can freely service shelves through the use of special tags and barcodes.

Please note! Today you can find a house project with a mezzanine from many designers. Often a shelving unit is used to organize an additional level in a small room. For example, it may contain sleeping place, and below it is a study.

Varieties

Mezzanines have several varieties. They relate to both the assembly method and the method of fastening the mezzanines. Among them are:

  • mezzanines on columns;
  • pallet;
  • combined.

Mezzanines with column structures are also called free-standing. Often these are the ones used in open warehouses. This mezzanine consists of steel components that form several floors. The design turns out to be quite durable so that it can be used to organize the storage of necessary goods, as well as office premises. Floorings, which are also made of steel, are laid on the mezzanine frame. To ensure the safety of personnel, additional railings are provided. Most often, racks of this type are made for a specific order, so they will require certain investments.

The second type of racks is also called hinged. They received this name due to the fact that most often they complement existing pallet racks. In this case, they are installed on top, as if hung. They don't require individual approach in production, so such mezzanines can be purchased in specialized stores and begin self-assembly. On such mezzanines it is not possible to organize an automated storage and sorting system, so they are more often processed manually. If necessary, you can always increase the height of the racks when additional space is needed.

Please note! Combined types of mezzanines involve the installation of hanging mezzanine shelving structures on top of column ones. A separate type of mezzanine is shelf-type. Such mezzanines are used for storing small-sized products.

To do right choice mezzanines for your warehouse, you need to know exactly the height and area of ​​​​the room. This will allow how many levels the racks will have and what specific design will suit best. The volume of stored units is also taken into account. Such a calculation will allow us to determine which specific territory can be covered with mezzanines. It is best to make custom racks. You should only contact trusted companies that have already acquired a reliable reputation. They will be able to provide all required certificates and other documentation. In addition, they are responsible for the quality of the raw materials from which the structure will be made. Warranties are also an important component.

If possible, it is better to visit the production lines yourself to ensure the quality of the products. It is necessary to know how long the equipment used to produce the racks has been in use. Is it the first hands or was it acquired after long-term use. If the machines have been in operation for a long time, then their full maintenance should be carried out no longer than five years ago. This is an important factor, because due to small errors that will be made in each connecting link, the entire mezzanine structure may simply collapse under the load.

The desire to save should not affect the quality of the material from which mezzanines are made. It is better to place an order during non-seasonal times, for example, in winter. It is during this period that the lines are least loaded and the manufacturer will be ready to provide a discount. Some companies provide an additional discount if mezzanines are ordered long before assembly is required and paid in full. When ordering mezzanines, a contract must be concluded. It specifies the rights and obligations of the parties, as well as the responsibilities and warranty obligations of the manufacturer. The exact date and amount of payment made is noted, as well as the date when the finished mezzanines can be picked up or seen assembled in the warehouse. The process of assembling such racks can be seen in the video.



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