When floor space runs low, building up - not out - is often the smartest play in industrial warehousing. That’s why so many businesses now rely on mezzanine systems.
A mezzanine system is a raised platform, installed between the floor and ceiling, that creates an intermediate level within a facility. Commonly used in warehouses, distribution centres and manufacturing plants, mezzanines serve as valuable real estate for storage, office space, or operational zones.
But not all mezzanine platforms are created equal. A reliable mezzanine system must balance structural performance, safety and operational efficiency - all while meeting compliance standards. Get one part wrong, and you're opening the door to downtime, costly retrofits, or worse, safety risks.
Here, we break down the 10 essential components and design considerations that go into a high-performing, fully compliant mezzanine system.
1. Decking material selection
The surface of your industrial mezzanine is the first line of defence for durability and safety. Your choice of decking must align with the platform's use, environmental conditions and safety requirements.
Commonly used mezzanine decking options include:
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Unilin antislip panels: Ideal for high-traffic zones. R12-rated slip resistance and fire resistant properties.
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Timber particleboard: Cost-effective and versatile, suitable for dry storage.
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Steel grating: Excellent for ventilation and fire safety, especially where sprinklers or dust control are considerations.
When selecting decking, factor in anti-slip requirements, load-bearing strength, fire compliance and wear resistance. In short, choose a surface that can go the distance.
It’s also worth considering how your decking will interact with other materials used on the mezzanine. For example, steel grating works well with sprinkler systems because it doesn’t block water flow. Meanwhile, Unilin panels might be better suited to fulfilment centres where high slip resistance and noise reduction are higher up the priority list.
2. Primary structural support (beams & columns)
The bones of a mezzanine system are the steel beams and columns. These carry the entire platform's weight - including its live load (people, goods, equipment) and dead load (structural weight).
Key considerations include:
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Beam depth and flange thickness to ensure adequate span support and head clearance to underside.
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Column layout and bracing to prevent sway or sag.
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Steel grade and finish for corrosion resistance and durability.
All structural components should meet AS/NZS 1170 loading standards and be designed with sufficient safety factors in mind. Additionally, connection methods to the floor joists (side mount / top mount) can offer additional head room & customised beam lining can be implemented for integrating cabling, sprinkler systems or ductwork - ideal for facilities that are tight on space.
3. Flooring load ratings and capacity planning
It’s not just about how much weight your mezzanine can handle - it's also about how that weight is distributed and used. Start by:
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Determining the use case. Is it bulk storage, light-picking, or housing machinery?
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Calculating live and dead loads with allowances for future capacity.
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Consulting with a structural engineer to avoid costly under- or over-specification.
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Load ratings must match the intended use. For example, a warehouse mezzanine structure supporting pallets will need a different rating than one used for office spaces.
Careful planning at this stage helps you avoid the all-too-common issue of having to reinforce a platform post-installation - something that not only costs time and money but could disrupt current operations.
4. Guardrails and edge protection
Falls from height are one of the leading causes of injury in industrial settings. Every open mezzanine edge should be protected with compliant guardrails, balustrades or barriers.
Best practices include:
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Guardrails at least 1000mm high.
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Mid-rails and kickplates to prevent object fall-through.
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Impact-rated barriers near vehicular access points.
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All edge protection should meet or exceed AS 1657 and relevant OH&S codes.
Well-designed edge protection also includes visual contrast for better visibility in high-traffic zones and should be coordinated with access points to avoid causing bottlenecks.
5. Staircases and access ladders
How people get up and down from a mezzanine platform is just as important as the structure itself. Stairs must be designed for safe, regular use and located to support workflow. Design tips include:
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Stair treads with antislip surfaces.
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Consistent rise/run dimensions to minimise missteps.
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Enclosed or railed access to discourage unsafe shortcuts.
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For infrequent or maintenance access to tight spaces, caged ladders may be appropriate - but only where compliant and risk-assessed.
It’s also good practice to position staircases in a way that aligns with operational flow. Don’t bury your access points in a corner - place them where staff naturally move between floor levels.
6. Handrails and kickplates
Beyond main guardrails, finer safety details matter. Handrails provide grip and guidance, while kickplates prevent tools or goods from sliding off the mezzanine.
Depending on use:
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Install handrails at all stairs and openings.
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Use kickplates (100mm high) on edges near foot traffic or racking.
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Opt for powder-coated or galvanised finishes for longevity.
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Adding colour-coded or tactile handrails can improve usability, especially in darker or high-noise environments where visual and sensory cues help prevent accidents.
7. Connection & fixing systems
Every joint in a mezzanine system is a potential stress point. Whether bolted, welded, or anchored, fixings must transfer load effectively and prevent unwanted movement.
What to look for:
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Certified structural fixings with rated capacities.
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Vibration-resistant fasteners near machinery.
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Inspection points to allow easy maintenance checks.
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Avoid DIY shortcuts. A few wayward bolts can bring a whole structure to its knees.
In automation-heavy facilities, using vibration-dampening washers and bracing can minimise rattle and fatigue across connections.
8. Column grid & span optimisation
The spacing of mezzanine columns affects more than strength - it determines how usable the ground-level space remains. Here, smart design can:
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Increase forklift & pallet jack access.
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Support better racking layouts.
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Ensure operation efficiency
A common rule of thumb for cost effective design is to space columns between 3 to 6 metres apart, however spans reaching 9-10m and above are also achievable; this is dependent on load requirements and slab capacity. The trick here is to work backwards from your floor plan. Think about what equipment will need to move under the platform and where obstacles are best avoided.
9. Fire rating & emergency planning
Warehouses can be governed by strict fire and egress requirements, and mezzanines cannot be a weak link.
Design essentials:
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Fire-rated decking or structural steel coatings.
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Sprinkler head locations & clearances to shelving or racking.
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Clearly marked evacuation routes and emergency lighting.
All systems should comply with AS 1530 and local council fire engineering assessments. Also consider the addition of smoke vents or integrated detection systems for large mezzanine platforms that span multiple zones.
10. Integration with equipment & layout
Of course, no mezzanine exists in isolation. It needs to work with your broader warehouse systems. Plan the layout in relation to:
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Conveyor access.
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Automation infrastructure.
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Racking integration and clearance zones.
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Lighting, HVAC, and data cabling.
Why Choose Unistor for Mezzanine Systems
Building a mezzanine is an investment - and one that pays dividends when done right. At Unistor, we bring decades of experience in designing, engineering and installing mezzanine systems across logistics, manufacturing and warehousing sectors.
When you work with Unistor, you benefit from:
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In-house design team with a focus on compliance and precision
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Local manufacturing and efficient installation across Australia
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Custom fit-outs based on industry type, workflow and risk profile
From concept to handover, we take the guesswork out of mezzanine construction - because safety, performance and efficiency should never be up in the air.
Conclusion
A reliable mezzanine system is a carefully considered blend of engineering, safety and site-specific smarts. By focusing on these 10 key components - from decking and beams to access and layout - you can build a warehouse mezzanine structure that delivers real operational value, today and tomorrow.
Looking to get your mezzanine platform right from day one? Talk to the team at Unistor. We’ll walk you through the checklist, tailor the design, and make sure every bolt, beam and barrier is exactly where it needs to be.
