The right mezzanine floor can change the way a warehouse operates. It can turn unused height into productive space, support new workflows, reduce congestion, and create room for growth without altering the building footprint. Yet one element often determines whether a mezzanine enhances operational efficiency or becomes a long-term limitation: the flooring beneath it.
Warehouses often approach mezzanine projects with a focus on overall structure, load capacity, and available space. But the choice between a solid decking panel and an open grating system shapes how the mezzanine feels under foot, how it behaves under load, and how it integrates with equipment and workflow. The floor influences noise, vibration, safety, compliance, and even how comfortable a space is for workers moving across it all day.
On one side are panel-based floors such as Unilin flooring panels and ResinDek engineered flooring. These offer a continuous, enclosed surface suited to modern warehouse operations. On the other side are Meiser steel grating systems, chosen for their airflow fire sprinkler penetration, durability, and technical performance in industrial environments.
Understanding how these systems differ in construction and behaviour is essential when planning a mezzanine that will support both current operational needs and the future of your warehouse.
How Panel-Based Mezzanine Floors Are Constructed
Panel-based mezzanine floors use solid boards fixed to beams or joists at set intervals. Systems such as Unilin and ResinDek provide a continuous surface that supports pedestrian movement, rolling equipment, and high-frequency picking activity. These panels lock tightly into place, creating a stable and rigid deck that behaves predictably under industrial load.
Joist spacing is determined by structural requirements and the type of equipment that will operate above. Panels are well suited to conveyor lines, picking modules, workstations, and any workflow that depends on smooth and consistent rolling behaviour. They also reduce noise and vibration, which is important in multi-level facilities.
How Grating-Based Mezzanine Floors Are Constructed
Grating systems such as Meiser are built from open steel grids that allow light, air, and water to pass through. They are welded or mechanically fastened to the mezzanine structure. The open-grid surface changes how the floor carries weight, how it transmits vibration, and how it interacts with the environment around it.
Because weight is transferred through individual bars rather than a continuous surface, the substructure often requires stronger beams or wider-flange joists. Grating floors are commonly selected for industrial platforms, maintenance access areas, and mezzanines designed around fire-engineered ventilation or drainage requirements.
Structural Support Differences
Different flooring types demand different structural strategies.
Panel Floors
-
Distribute load across a continuous surface
-
Support rolling loads reliably
-
Require closer joist spacing
-
Provide predictable behaviour for dynamic equipment
The deck becomes part of the structural system, helping stabilise the mezzanine under movement.
Grating Floors
-
Transfer load through steel bars to beams
-
Require stronger or differently spaced structural members
-
Are suited to static loads but not rolling equipment
-
Allow for open airflow and drainage
Grating places specific demands on the engineering design, especially where fire modelling or ventilation is important.
Load-Bearing Behaviour
Panel Floors
Panels support rolling equipment such as trolleys, pallet jacks, and pick carts. They provide a uniform surface where the load is shared evenly across the deck. Floors using systems like Unilin or ResinDek are commonly selected for multi-level storage, packing zones, and conveyor-heavy operations.
Grating Floors
Grating excels when static loads or environmental performance are the priority. Rolling equipment is not suitable for grating because wheels can catch, and the surface does not support smooth travel. Load is carried by the individual grid bars, which changes how the floor must be engineered.
Movement, Flex, and Vibration Differences
The feel of a mezzanine floor is shaped by its construction.
Panel Floors
-
Lower vibration levels
-
Consistent footing for workers
-
Reduced operational noise
-
Better stability for conveyors and equipment
These qualities matter for productivity and worker comfort.
Grating Floors
-
More vibration transfer
-
Louder under foot
-
Less suited for environments with sensitive equipment
-
Strong performance in industrial zones where airflow matters more than comfort
These characteristics shape how the floor performs in day-to-day warehouse activity.
Structural Efficiency and Weight Considerations
Panels are generally lighter than steel grating. A lighter deck means:
-
Less structural steel required
-
Simpler installation
-
Lower overall project weight
-
Better efficiency for multi-level mezzanines
Grating is heavier and often demands stronger beams or more robust understructure. The trade-off is improved airflow, spill-through capability, and performance in fire modelling.
Which Mezzanine Applications Each Flooring Type Suits Best
Panel Floors Are Ideal For:
-
Pick modules
-
Conveyor-supported platforms
-
Packing and processing areas
-
Automation-ready zones
-
Warehouse offices
-
High foot-traffic paths
Panel systems provide the smooth surface needed for modern warehouse workflows.
Grating Floors Are Ideal For:
-
Fire-engineered mezzanines
-
Maintenance catwalks
-
Industrial platform areas
-
Environments requiring airflow or drainage
-
High-durability technical spaces
Grating is chosen for its functional advantages in industrial settings.
Final Considerations
The construction method behind a mezzanine floor determines how it performs, how it must be engineered, and how effective it will be in supporting daily warehouse activity. Solid decking panels such as Unilin and ResinDek provide stability, rolling performance, and comfort. Grating systems like Meiser offer strength, ventilation, and industrial durability. Choosing the right option requires careful consideration of workflow, safety, compliance, and long-term operational goals.
Unistor works with warehouse operators across Australia to ensure each mezzanine is engineered with the right flooring system for its purpose, providing a structure that performs from day one and adapts as operations evolve.
Talk to Unistor
Speak with Unistor’s engineering team to select the right mezzanine flooring system for your warehouse and ensure your structure is designed for long-term performance.
