Warehouse mezzanine racking systems are designed for facilities with ceiling heights of 4.5m and above where usable volume sits wasted above the ground floor. Instead of expanding the building footprint, a multi-tier mezzanine rack structure creates two or three functional storage levels from the same floor area. Boracs engineers each system using cold-rolled steel Q235B with load ratings from 500kg to 1500kg per square meter per tier. The framework integrates columns, primary beams, secondary beams, and decking into a bolt-together assembly — no on-site welding required. Upper levels handle carton and small-parts storage, while the ground floor can combine with selective pallet racking for full-pallet access. With powder-coated surfaces meeting ISO9001:2015 and FEM 10.2.02/10.2.09 standards, these systems are installed in over 60 countries and ship at 50+ container loads annually from our 30,000m² facility in Nanjing.
Key Features
- 2-3 tier configurations — selectable based on ceiling height and floor loading capacity of the building
- Load capacity: 500-1500kg/m² per level — ground floor supports pallet racking integration for heavier unit loads
- Cold-rolled steel Q235B frame — columns 90×70×2.0mm, primary beams 120×50×2.0mm for structural rigidity
- Bolt-together assembly — no welding on site; installation time approximately 2 days per 100m² of platform
- Integrated access systems — staircase (width 800-1200mm, 30-38° incline), guardrails (height 1000mm), and swing/slide gates
- Modular expansion — additional bays can be bolted on without dismantling the existing structure
- Surface treatment: electrostatic powder coating — 60-80μm film thickness, RAL color options, corrosion-resistant for indoor environments
Specifications
| Material | Cold-rolled steel Q235B |
| Load Capacity (per level) | 500-1500 kg/m² |
| Number of Levels | 2-3 tiers (custom-engineered) |
| Column Section | 90×70×2.0mm / 100×70×2.0mm |
| Primary Beam Section | 120×50×2.0mm / 140×50×2.5mm |
| Secondary Beam Section | 60×40×1.5mm / 80×40×1.5mm |
| Bay Width | 2000-3000mm (customizable) |
| Bay Depth | 2000-3000mm (customizable) |
| Platform Thickness | 60-150mm (depending on decking type) |
| Clearance Between Levels | 2000-3000mm (adjusted to stored goods height) |
| Surface Treatment | Electrostatic powder coating, 60-80μm |
| Accessories | Staircase, guardrails, safety gates, pallet gates, handrails |
| Design Standards | FEM 10.2.02, FEM 10.2.09, CE, ISO9001:2015 |
Applications
- E-commerce and 3PL distribution centers — upper levels for carton picking and returns processing, ground floor for full-pallet storage and staging. Common configuration: 2-tier with 2500mm clearance per level.
- Automotive parts warehouses — mezzanine rack systems organize SKUs of varying sizes across levels. Heavy components (engine blocks, axles) stored on the ground tier with pallet racking; lighter trim and electrical parts on upper shelves.
- Pharmaceutical and cold storage facilities — wire mesh decking on upper tiers maintains airflow in temperature-controlled environments while consolidating storage of boxed pharmaceutical products and medical supplies.
- Manufacturing facility mezzanines — platforms positioned above production lines or assembly areas serve as elevated storage for WIP (work-in-progress) inventory, reducing forklift travel and keeping materials within reach of the production floor.
Why Choose Boracs
- 20+ years of manufacturing — Boracs has operated its Nanjing facility since 2004, with a 30,000m² factory floor dedicated to warehouse racking production. Annual output exceeds 50 container loads shipped to 60+ countries.
- In-house engineering team — every mezzanine storage system is designed from CAD layout drawings through structural calculation reports. We size columns, beams, and connections to your warehouse parameters and local codes.
- Full certification package — products manufactured under ISO9001:2015 quality management systems. Design complies with FEM 10.2.02 (static calculations) and FEM 10.2.09 (operational recommendations). CE marking provided on request.
- Complete accessory supply — staircases, guardrails, pallet gates, conveyor openings, and lift shafts are all fabricated in-house. No third-party coordination required; single-source procurement simplifies ordering and installation.
- Direct factory pricing — no trading company markup. We quote ex-works or FOB terms from Nanjing port. Lead time: 25-35 days after drawing approval and deposit. Email kevin@boracs.com or WhatsApp +86 153 4831 7266 for a quotation.
Frequently Asked Questions
What is the load capacity of a mezzanine racking system?
Our mezzanine racking systems support 500-1500kg per square meter per level. The exact rating depends on column gauge, beam section, and decking type selected during engineering. The ground floor can additionally integrate pallet racking structures for heavier unit loads, while upper tiers typically handle carton and small-parts storage within the specified range.
How many levels can a mezzanine rack have?
Standard configurations run 2-3 levels. The number of tiers is determined by your warehouse's clear ceiling height, existing floor load-bearing capacity, and local building regulations. As a rule of thumb, each tier requires 2.0-3.0m of clearance depending on what is stored. Our engineering team calculates the optimal configuration from your building drawings.
Can mezzanine racking be combined with pallet racking?
Yes. Our mezzanine storage systems are routinely integrated with selective pallet racking, drive-in racking, and medium-duty shelving on any level. A common arrangement places pallet racking on the ground tier for full-pallet storage, with shelving or open decking on upper levels for manual-pick items. This hybrid approach maximizes both density and accessibility.
What decking options are available for mezzanine floors?
We supply four decking types: (1) Cold-rolled steel checker plate, 3-5mm thick, rated up to 1500kg/m² with anti-slip pattern; (2) Marine-grade plywood, 18-22mm thick, lighter and faster to install; (3) Wire mesh panels, 50×50mm or 100×100mm grid, for ventilation and fire code compliance; (4) Particle board flooring, 22mm thick, a cost-effective option for light goods up to 500kg/m². Selection is based on stored goods, foot traffic, and fire rating requirements.
Do you provide structural engineering drawings for mezzanine systems?
Yes. Every order includes a full documentation package: CAD layout drawings showing bay sizes and access points, structural calculation reports sized to FEM 10.2.02/10.2.09 standards, and step-by-step installation manuals. We review your warehouse drawings, floor load data, and local code requirements before releasing production drawings for your approval.
Ready to Get a Quote?
Send us your warehouse dimensions, required load capacity, and preferred number of levels. Our engineering team will return a layout drawing and quotation within 24 hours.
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