Struggling for space in your commercial premises? Look up.
The top half of many warehouses and commercial facilities sits completely empty. And many businesses will go ahead with expensive expansion or relocation before capitalising on all this underutilised warehouse headroom.
From warehousing to logistics to long-term storage, effective space utilisation is critical to the success of any business.
High-performance warehouse spaces do more with less. They avoid expansion and relocation while enhancing inventory management, order fulfilment and throughput.
At Unistor we specialise in the construction of warehouse mezzanine solutions and other multi-level warehouse structures that help you to make the most of what you’ve got.
In this guide we’ll share our expertise, outlining the cost savings from optimising warehouse headroom, guiding you on how to improve warehouse space utilisation, and offering strategies for maximising vertical space in a warehouse.
The problem with wasted headroom
Usually built with forklifts and other machinery in mind, warehouses tend to be quite tall structures. The average warehouse has a ceiling height of 6-8m, but larger facilities might stand 10, 15, even 20 metres tall.
Most businesses only use a fraction of that vertical space. This poor space utilisation can lead to a number of issues, including:
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Limited scalability: Without proper vertical storage, your ability to handle business growth or seasonal peaks takes a hit.
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The need to expand or relocate prematurely: Warehouse expansion and/or relocation are incredibly expensive processes, and can result in significant downtime.
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Operational inefficiencies: Underutilised warehouse headroom leads to inventory being spread across the warehouse, reducing the efficiency of transporting, organising and picking goods.
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Low ROI on your commercial lease: You're paying for cubic metres, not just floor area, so wasted vertical space equals wasted money.
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Higher energy costs: Large spaces that aren't fully utilised still need to be lit and potentially climate controlled, so your power bills may be higher than they need to be.
The solution: turning headroom into high-performance space
Better space management is key to reducing warehouse operating costs. So how do you improve warehouse space utilisation? One answer: through the use of mezzanines.
Mezzanines essentially turn your warehouse into a multi-storey building. They are an ultra-flexible and scalable way to capitalise on vertical space, and offer a wide range of potential applications:
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Additional storage: Expand your storage capacity vertically without increasing the footprint of your warehouse.
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Order staging and packing zones: Create a dedicated mezzanine for order staging – an upper-level fulfillment area designed for efficient packing and dispatch.
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Returns and quality control areas: Avoid disrupting main workflows by allocating a mezzanine level or area for managing returns and inspecting stock.
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Office pods and admin zones: Add a modular office mezzanine to create compact, elevated cubicles or admin spaces, and keep your floor space clear for operations.
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Automation-ready platforms: Support future automation with sturdy mezzanine structures designed to integrate ASRS, robot or conveyor systems.
Use cases and industry applications
What does warehouse vertical space optimisation look like in the real world? At Unistor we’ve helped a wealth of businesses across a range of industries to better capitalise on their space:
Ecommerce: a 50% increase in operational space
We helped Invenco, a fast-growing fulfillment services provider, to significantly increase their operational area and speed up order fulfilment by creating pick-pack mezzanines. The job was also completed with zero disruption to Invenco’s operations.
3PL: Support structures for NZ’s largest automated warehouse
We designed and built automation support structures and access systems for Cardinal Logistics, who run New Zealand's largest automated warehouse. We successfully maximised the use of space within a highly congested environment by creating multiple client-dedicated zones within a single warehouse.
Biotech: 360m² of extra operational space
We helped medical equipment manufacturer Medilogic build up by installing a clear span modular mezzanine floor for use as both extra storage and additional operational space.
Design considerations and compliance
You understand the potential of underutilised warehouse headroom. You’re committed to doing something about yours. The next step is to understand how to implement a warehouse space optimisation plan.
There are a few key safety and compliance considerations that you need to make when developing any space optimisation solution:
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Load-bearing requirements: The structure must be capable of safely supporting the weight of equipment, people and inventory.
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Fire regulations: Mezzanines must comply with local fire safety regulations, such as sprinkler coverage and the use of fire-resistant materials.
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Accessways and egress: Staircases, ladders and walkways must meet safety standards for access, emergency exits and maximum travel distances.
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Lighting and visibility: You need adequate overhead lighting for safety and operational efficiency.
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Ceiling clearance: You need adequate headroom both above and below the mezzanine.
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Permit and certification requirements: Structural modifications tend to require a building permit and might need sign-off from a certified engineer or building surveyor.
At Unistor we take care of all this for you through our principal contractor model. We design, engineer, certify and install your mezzanine, with minimal (often zero) downtime, allowing you to focus on running your business.
Benefits of mezzanine-based vertical expansion
Why choose to build a mezzanine? Beyond saving you from expansion or relocation, these structures offer a wealth of advantages over other vertical space utilisation options:
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Cost efficiency: Mezzanines are particularly effective at adding usable space without the need to lease more of it. When you compare the cost-effectiveness of different warehouse storage solutions, mezzanines tend to come out on top.
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Speed: Installing a mezzanine is far faster than relocating to or constructing a new premises. In many situations mezzanines can also be constructed without causing any operational downtime.
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Flexibility: Mezzanines are easily reconfigurable, so can change, scale and adapt to your evolving operational needs.
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Compliance: At Unistor all our mezzanines are designed and certified to meet Australian safety standards.
Capitalise on vertical space with Unistor
The answer to your space needs could be hovering right above your head. And if you’re considering space-maximising or space-saving warehouse upgrades, look no further than Unistor.
Our expert team brings decades of combined experience in delivering tailored mezzanine solutions.
Warehousing, distribution, logistics, fulfilment; whatever your needs, wants or situation, we’ll help you optimise your use of vertical space. Our end-to-end service covers design, certification, installation and project management, with every build customised to the precise operational needs of the client.
Ready to make the most of all that headroom? We’re ready to help.
Get in touch with our expert team today for a feasibility assessment or design consultation.
