How to build a mezzanine floor

The first step to building a cost-efficient, robust mezzanine floor is detailed preparation.
We will assess your premises, design a bespoke mezzanine that is specific to the needs of your business and provide an accurate quote thanks to our award-winning high-performance engineering software called IQD (Intelligent Quote Designsuite).

We begin by measuring and planning for essential factors such as:

• The dimensions of the floor
• The load the floor slab can bear
• The number of supporting columns required and their spacing
• Staircases and access points
• Construction materials
• All safety requirements.

What is the process to build a mezzanine floor?

The installation process itself demonstrates the care we take to deliver an optimum service to every client.

Stage 1:  Plant and materials delivery

Along with the construction materials for your mezzanine floor, equipment from skips to forklift trucks and mobile scaffold towers are delivered to the site. After careful offloading from a flat-bed lorry in line with Health & Safety regulations, everything is checked against the project plan and delivery notes to make sure every item has arrived. Materials are then arranged in place, set out in the most efficient order for a swift build. All conflicting work has been planned out in advance to ensure continuity of working – the whole process is smoother with Hi-Level Mezzanines.

Stage 2: Site preparation

We make sure floor levels are as expected, carrying out requisite measurements. We then plot and mark out the position of every column using chalk lines. This is where our qualified structural engineers, innovative digital design process and advanced solutions show their worth. Our mezzanines are value engineered to make the most of every penny you spend.

Stage 3: Steel installation

Our team fix cleats to carry the horizontal beams (called purlins), drill holes using a 110 volt drill with socket attachment ready for resin fix studs, stand and secure the columns in place then begin installing the beams. One horizontal beam is attached to two columns to form a “goal post” shape, then this is repeated throughout. Once two “goal posts” are in position they are tied together and bolted using a minimum three joists. To  make the structure secure, tie rods and the rest of the purlins are slotted in.

Stage 4: Health and safety

We install nets under the structure as working at height fall arrest. Throughout the build, all workers will wear correct levels of PPE which may include safety footwear, high visibility jacket or waistcoat, eye protection, hearing protection or gloves which will be provided as the risk assessments identify.

Stage 5: Decking boards go in

Decking boards (we have a wide variety of options) are installed on the purlins. All columns, beams and deck beams have been bolted together before any decking is lifted or fitted to the floor area. The extent of the mezzanine is now visible and the benefits become clear, and Hi-Level Mezzanines’ experts add value throughout the process.

Stage 6: Installing ancillary items

Pallet gates, handrails and staircases are installed. Staircases can often be built ahead of time and positioned when the time is right, connecting the mezzanine to the floor below and in some cases to another mezzanine above. Otherwise, stairs risers are lifted upright and bolted into position, then treads are fitted from the bottom working towards the top.

Stage 7: Mezzanine final checks

Remaining bolts are installed and checked for accurate torque values to create a robust, secure and safe structure.

Stage 8: Fire-rating installation

If required, we install fire-protection elements such as a ceiling, fascia, column casings, and staircase enclosures.

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