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Industrial mezzanine racking systems are essential for optimizing storage efficiency in warehouses. They come in various types, each designed to meet specific storage needs and maximize available space. By installing a mezzanine rack, businesses can significantly increase their available floor space without incurring the expense of expanding their building footprint.
In this guide, you can understand how to build a mezzanine rack step by step.
Beneficial for Warehouse owners and managers needs
Planning Mezzanine Racking
Load Capacity and Weight Distribution
When planning your warehouse layout, understanding load capacity and weight distribution is crucial for safety and structural integrity. Different types of inventory and workflows require varying load capacities, so it’s essential to assess your specific needs.
Space and Layout
Analyzing the available space and designing a layout that suits your needs is crucial for the efficiency of your mezzanine. Consider the dimensions of your warehouse or facility, and plan the mezzanine layout to optimize the use of vertical space. A well-designed layout not only maximizes storage but also facilitates easy movement and access, contributing to better workflow and productivity.
Material and Construction
The Common materials and construction methods used for Industrial mezzanines include steel, aluminum,gavenize steel. Steel is preferred for its strength and durability, aluminum for its lightweight properties. Evaluate the material based on your operational requirements and the environmental conditions of your facility.
Compliance and Safety Standards
Meeting industry regulations and incorporating safety features and measures are non-negotiable aspects of mezzanine installation. Ensure your mezzanine complies with local building codes and OSHA regulations. Safety features like guardrails, staircases, and load gates are essential to protect workers and maintain a safe working environment.
Calculate Cost of Mezzanine Racking
Size
The size of the mezzanine is the primary factor affecting its cost. A larger area requires more materials and a longer installation time. While expanding usable space through other means—such as renting additional space or constructing a new facility—can be significantly more expensive, adding a mezzanine is often a more cost-effective solution.
Height
The height of the mezzanine also plays a crucial role in determining costs. Taller structures necessitate longer columns and additional materials, which increases expenses. For instance, building a work platform 14 feet high is more complex and labor-intensive than one that is only 4 feet high. Additionally, the stair system must be designed to accommodate the height, further impacting the overall budget.
Design
The design of the mezzanine can vary widely, with most manufacturers favoring standard rectangular shapes for ease of production. However, custom designs are possible and can meet specific operational needs. While unique shapes may increase costs for some manufacturers, they often have minimal impact on the overall price when designed efficiently. Adjustments to column placement may also be necessary based on activities occurring beneath the mezzanine, potentially affecting costs.
Capacity Per Square Meter
One often-overlooked factor is Capacity Per Square Meter that the mezzanine will support. Standard designs typically accommodate 500KG/SQM , but higher load capacities require larger horizontal beams and sturdier materials, which can significantly raise costs. Understanding your loading requirements is essential for accurate budgeting.
Additional Considerations
Shipping Costs: These can vary based on distance and quantity ordered; larger orders may reduce shipping costs per unit.
Installation Complexity: If installation occurs in a congested area or requires special accommodations (like fire safety systems), labor costs may increase.
Permits and Regulations: Ensure compliance with local building codes, which may necessitate additional expenditures.
Design and 3D rendering for mezzanine rack
Install Mezzanine racking For Warehouse Step by step
Step 1: Prepare the Site
Delivery and Organization: Ensure all parts and components are delivered to a designated area in the warehouse that is protected from the elements. Organize the components for easy access during installation.
Step 2: Establish Layout
Mark the Installation Area: Use chalk lines to outline the layout based on approved design drawings. Ensure that aisle widths comply with OSHA guidelines to facilitate safe movement.
Step 3: Erect the Starter Bay
Install the First Rack Bay: Assemble the first rack bay, ensuring that beam elevations are accurate. Confirm the configuration with a site contact person if available.
Step 4: Achieve Plumb Installation
Level and Adjust: Use shims as needed to ensure that the starter bay is plumb both cross-aisle and down-aisle. Once level, securely tighten all bolts.
Step 5: Install Connectors
Secure T-Bolts and Wedge Locks: Determine the number of T-bolts required for each connector. Install T-bolts with heads facing inward, turning them 90 degrees clockwise. Tighten Wiz nuts to specified torque values (90 ft-lb or more).
Step 6: Anchor the Racks
Install Anchor Bolts: Use one anchor bolt per column, ensuring a diameter of 0.5 inches with a nominal embedment of 2.5 inches into the floor. For larger base plates, use multiple anchors as necessary.
Step 7: Complete Remaining Bays
Install Additional Frames: Erect all remaining rack bays, ensuring they are plumb in both directions. Anchor footplates similarly to the starter bay, avoiding any forceful adjustments after tightening.
Step 8: Finalize Installation
Install Accessories and Conduct Checks: Add shelf accessories like wire decking and crossbars. Perform a thorough inspection to ensure all components are secure and functioning properly before placing any goods on the racks.
Looking For a Mezzanine Racking Manufacturer For Your Projects?
Heda Shelves is a leading mezzanine racking manufacturer in China. We provide a one-stop solution for warehouse storage racking and warehouse mezzanine projects. Ask for a quote now!
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