How We Delivered a Unique Mezzanine Floor Solution Across Three Logistics Projects
When two leading fashion logistics companies and a third-party logistics provider approached us with greenfield projects, they all shared one core requirement: a mezzanine floor system with large, unobstructed spans. These long spans were essential to support high operational efficiency and layout flexibility—critical advantages in fast-moving logistics environments.
Each customer needed a mezzanine with main beam spans exceeding 36 feet and secondary spans up to 20 feet. These large spans, combined with heavy load demands, placed significant structural stress on the floor slab. By engaging early in the design phase, we worked closely with the customers and their consultants to engineer a slab and support structure capable of handling loads up to 60 tons per column—delivering strength without compromising usability.
Sprinkler systems are often installed beneath mezzanine beams, which reduces clearance and increases the risk of collision with forklifts. We took a smarter route—integrating the sprinkler pipes through the main beams using precision-machined punching patterns. Our engineers aligned all punching patterns during the design phase to create a consistent path for the pipework. This required advanced production planning, but resulted in a clean, space-saving solution with no loss of free height and improved safety.
Typical mezzanine designs rely on cross bracing, which can block key access areas. To preserve the full 36-foot spans and ensure completely unobstructed access beneath the structure, we developed a portal bracing solution. This eliminated the need for bracing elements blocking through ways, giving the clients the flexibility their operations demanded.
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