Mezzanine levels add valuable space in warehouses and industrial facilities; but the floor system used must meet both structural and functional requirements. Unlike ground slabs, mezzanine floors must be lightweight yet strong, vibration-resistant, and tailored to the type of load they carry: people, pallets, equipment, or storage racks.
This guide explores the most common mezzanine flooring systems used in industrial settings, their pros and cons, and which to specify based on performance, budget, and use case.
One of the most durable and common choices, this system uses profiled metal decking as permanent formwork topped with a 75–100 mm reinforced concrete slab. It's ideal for heavy-duty applications such as pallet storage or rolling loads. The concrete topping provides high compressive strength and fire resistance, while the steel profile acts as both a mold and structural component. It requires greater structural support but delivers outstanding longevity and stiffness under foot or wheel traffic.
A cost-effective option for light-duty or personnel-only mezzanines, this system uses steel purlins or joists overlaid with chipboard, plywood, or OSB panels. It's lighter and faster to install than concrete but less durable under pallet loads or wheeled equipment. The panels can be replaced easily, but moisture resistance is limited unless coated. Suitable for offices, light shelving, or occasional access zones; not recommended for forklifts or heavy trolleys.
Used in manufacturing environments or mezzanines above mechanical zones, open bar grating allows airflow, drainage, and light transfer between levels. It’s suitable for plant platforms and maintenance walkways, offering excellent slip resistance and load capacity. However, it’s uncomfortable for prolonged walking and unsuitable for wheeled equipment. Choose serrated grating with sufficient load rating (e.g. 5 kN/m² or higher) based on foot traffic and equipment.
Pre-engineered composite panels, combining steel skins with an insulated or reinforced core, offer a lightweight and fast-installed solution for mezzanines with moderate load needs. These systems are used in modular builds and dry storage mezzanines where speed and weight reduction matter more than impact resistance. They're generally not suitable for heavy pallets or machines but work well under shelving, packaging stations, or cleanrooms.
For extreme durability, steel plate flooring can be used; either welded directly to framing or bolted in panels. Chequer plate offers slip resistance; smooth plate is easier to clean. This system handles high loads and heavy point impacts well but increases weight significantly. It’s common in engineering workshops, mezzanine docks, or areas with heavy carts or tool trolleys. Noise and vibration can be a concern unless properly isolated.
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