What is The Difference Between a Mezzanine Floor and Pallet Racking?

Among the various warehouse storage solutions, pallet racking and mezzanine floors are two of the most popular options. However, they differ significantly in design and functionality. Today, OKE Storage will guide you through the key differences between these two storage systems to help you choose the best solution for your specific needs.

The main differences between warehouse mezzanine floors and traditional pallet racking are as follows:

Mezzanine floors create additional usable space by constructing new levels above the ground, often using pallet racking as the core structural framework. This vertical, multi-tiered design can effectively double or even triple the available floor space, maximizing the three-dimensional use of the warehouse.

With a mezzanine floor, you can continue using the pallet racking below while also utilizing the new upper level for extra storage, significantly increasing overall capacity. In contrast, traditional selective pallet racking is installed directly on the warehouse floor and does not provide additional vertical floors.

In addition to the components of traditional pallet racking, mezzanine floors include uprights, beams, decking, back mesh panels, guardrails, and other essential parts. They also feature stairs, stairway connections, floor options, and safety locks to ensure secure access between levels.

The stairs are designed with thickened, non-slip treads and raised handrails on both sides to prevent slipping or accidental falls, providing users with a safe and confident experience while moving between floors.

Mezzanine floors offer a strong load-bearing capacity and resist deformation. Each pallet level can support up to 500 kg, while the flooring can handle between 300 kg to 1000 kg per square meter, making them ideal for managing larger inventory volumes efficiently.

The spacing between mezzanine floor levels typically ranges from 2.2m to 2.7m, with the top shelf height usually around 2m. Unlike traditional pallet racking, mezzanine systems have no strict limitations on aisle width or rack width. In contrast, traditional adjustable pallet racking usually features aisle widths of about 3.2m and shelf widths around 2.4m.

Mezzanine floors are commonly constructed from steel plates or wooden boards. Various types of steel plates—such as patterned, flat, and perforated—are used to meet diverse requirements. The flooring includes holes in Type II elongated slots or round shapes, all designed to comply with fire safety standards across different countries.

Entrance areas of mezzanines often utilize diamond plate flooring, while outdoor mezzanine storage facilities typically use metal deck plates. Other popular floor types include grating plates, B-decks, and plywood floors. Traditional pallet racking systems do not require consideration of these flooring options.

Applications:
Mezzanine floor systems are versatile—not only suitable for goods storage but also capable of supporting conveyor systems, heavy equipment, and machinery. They find extensive use in industries such as automotive parts manufacturing and electronics.

In comparison, pallet racking systems are specifically engineered for storing palletized goods, including heavy items. They are commonly deployed in logistics centers, warehouses, and distribution facilities.

Summary
Both mezzanine floor racking and pallet racking offer unique advantages, providing effective and efficient storage solutions tailored to different needs.

If fast access to goods is your priority, pallet racking is the ideal choice, with a variety of configurations available to suit your requirements. On the other hand, if your goal is to significantly increase your warehouse’s storage capacity, structural mezzanine flooring offers an excellent way to expand usable space vertically.

We hope this brief overview helps you select the right system for your operations. Before making a final decision, consider reaching out to OKE Storage for a quick, free consultation, including personalized quotes and custom design drawings. Contact us today to get started!