Mezzanine Floors Up and Away
14th March 2025
Geoff Green of MiTek discusses all things mezzanine with editor Peter MacLeod, covering space optimisation, flexibility, installation and safety.
In the ever-evolving logistics industry, optimising warehouse space is crucial for operational efficiency. One effective solution gaining prominence is the implementation of mezzanine systems. In a recent episode of “Logistics Business Conversations,” host Peter MacLeod discussed this topic with Geoff Green, Sales Director at MiTek, shedding light on the benefits and considerations of
mezzanines in logistics.
Before we get into the meat of the conversation, MacLeod first asked Green for a generic definition of a mezzanine, as the term can sometimes be misunderstood. He described mezzanines as intermediate floors installed between the main floors of a building, effectively doubling or tripling usable space without the need for external expansion. In warehouses, they serve various purposes, including storage, office space, and production areas, allowing businesses to maximise vertical space and improve workflow efficiency.
There are several key reasons why logistics businesses choose to specify mezzanine systems, prime among them being the need to optimise available space. Mezzanines enable companies to utilise ‘spare’ vertical space, alleviating the need for building extensions or even relocation to larger premises. This is particularly beneficial in urban areas where real estate costs are highest.
Mezzanines are considered a cost-effective method to achieve this compared to the cost of constructing new facilities, providing additional space without significant capital investment.
Flexibility is another reason they are popular: mezzanine structures can be customised and reconfigured to meet changing operational needs, offering adaptability as businesses grow or diversify,
for example if a 3PL gains a contract that involves product that is significantly different in weight, size, volume or shape to its existing SKUs.
Furthermore, by designating specific functions to mezzanine levels, companies can streamline processes, reduce congestion on the main floor, and enhance overall productivity.
Addressing Installation Concerns
A common concern cited by customers when discussing a mezzanine installation is the potential disruption to the facility’s regular operations. However, Green was keen to dismiss this fear, emphasising that with proper planning and coordination, installations can be executed with minimal impact on daily operations. For example, scheduling work during off-peak hours and maintaining clear communication with all stakeholders are key strategies to ensure a smooth installation process.
With safety considerations paramount in any warehouse environment, mezzanines must comply with building regulations and safety standards to protect both personnel and equipment. This includes installing appropriate guardrails, ensuring load-bearing capacities are not exceeded, and providing safe access points such as stairs or lifts. Regular inspections and maintenance are also essential to uphold safety standards.
Green says that the long-term benefits of mezzanines can be guaranteed by designing layouts that can accommodate future changes, something at which he says MiTek is particularly skilled. By creating a futureproofed design, businesses are better able to accommodate expansion in volume, technological advancements, and evolving industry practices. Green advises involving experienced designers and engineers in the planning stages to create such flexible and scalable mezzanine solutions.
Case Study: Successful Mezzanine Implementation
A notable example of a successful mezzanine installation quoted by Green is a leading eCommerce company in the UK that faced challenges with limited warehouse space due to rapid growth. By installing a mezzanine system, it effectively doubled its storage capacity within the existing facility. This not only saved costs associated with building a new warehouse but also improved order fulfilment times by enhancing the organisation of inventory and streamlining picking processes.
In summary, mezzanine systems offer a practical and cost-effective solution for businesses seeking to optimise warehouse space and improve operational efficiency. By addressing installation
challenges, adhering to health and safety standards, and designing flexible layouts, companies can leverage mezzanines to support growth and adapt to the dynamic logistics landscape.
For a more in-depth discussion on mezzanines in logistics, visit the Logistics Business website and click on the ‘podcasts’ tab to listen to the full episode of “Unlocking the Levels: Exploring
Mezzanines in Logistics” featuring Geoff Green of MiTek.
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