Engineered Rack Supported Mezzanines & Multi-Tier Pick Towers
For modern logistics hubs, 3PL distributors, and manufacturing plants facing high real estate and leasing costs across the UAE, GCC, and Africa, expanding upwards is the most economical strategy. A Rack Supported Mezzanine System integrates heavy-duty pallet racking frames or industrial shelving as the structural upright columns, supporting intermediate floor decks, catwalk walkways, safety handrails, and pallet drop gates.
By eliminating dedicated structural columns, this hybrid configuration converts redundant vertical clear height into valuable working footprint, simultaneously tripling high-density pallet positions below and active carton picking or assembly operations above.
Cubic Space Optimization: Achieve up to 100% to 200% increase in operational square meterage within your existing building footprint, entirely avoiding civil construction delays or costly facility relocation.
Technical Specifications & Structural Options
| System Feature | Engineering Specification | Application Suitability |
|---|---|---|
| Design Standards | EN 15512, FEM 10.2.02, SEMA, AISC | Seismic & dynamic load compliance |
| Floor Load Rating | 300 kg/m² to 1,500+ kg/m² (Uniformly Distributed) | Manual cart, powered pallet jack, or office use |
| Decking Varieties | Galvanized Steel Grating, Checkered Plate, 38mm Plywood / B-Deck | Fire sprinkler penetration or smooth rolling carts |
| Upright Capacities | Up to 24,000 kg structural column load rating | Heavy multi-tier palletized lower storage |
| Vertical Access | Industrial Staircases, Vertical Reciprocating Conveyors (VRC), Pallet Gates | Safe personnel access and rapid cargo transfer |
Engineered System Configurations
Heavy-Duty Pallet Rack Mezzanine
Utilizes heavy-duty pallet racking runs to support open intermediate platforms. Pallets are handled via reach-trucks into ground and rack locations, while the upper level accommodates open storage or automated assembly.
Multi-Tier Catwalk Picking Modules
A multi-level layout linked by integrated catwalk corridors between shelving rows. Ideal for high-SKU inventory picking, apparel, electronic components, and omnichannel order fulfillment.
Office & Testing Platforms Over Racks
Enclosed air-conditioned supervisor offices, quality control laboratories, or packaging stations constructed atop structural rack modules, reserving valuable ground surface for fast-moving goods.
Industrial Heavy Component Decks
Reinforced steel support joists and dense roll-formed uprights engineered to support heavy tooling, automotive spares, and mechanical assemblies with forklift-accessible swing safety gates.
Core Safety Features & Engineering Assurance
Structural reliability in high-throughput warehouse environments requires rigorous calculations and safety engineering. Every ILS mezzanine structure is delivered with documented finite element analysis and safety hardware:
- Self-closing pivot pallet safety gates for fork truck transfer
- Heavy gauge kick-plates (toeboards) and robust perimeter handrails
- Sprinkler-compliant perforated grating for Civil Defense approval
- Reinforced baseplates with chemical anchor bolt arrays per slab test
- Certified beam locking pins with dynamic anti-dislodgement tabs
- Stamped structural load calculation plaques mounted on every access run