Industrial Mezzanines: Supporting Fulfillment in 2021

Warehouse deck with guard rail

Industrial Mezzanine Platform

Keeping Up with E-Commerce During COVID-19

In the wake up the global pandemic, the shift of consumer purchasing to online retail has accelerated. According to the U.S. Department of Commerce, fourth quarter 2020 e-commerce sales are estimated to have increased 32.1 percent (±2.1%) over the fourth quarter of 2019. Additionally, online spending represented 21.3% of total retail sales for the year.

With the rapid expansion of e-commerce, distribution centers and manufacturing facilities are under constant pressure to keep up with these incoming online orders. One of the largest obstacles that these facilities face is how to manage the rise in demand with their existing footprint. What happens when new machinery is required to speed up throughput, but no space for that machinery exists? When it is time to expand, is it more cost-effective to acquire new land or to build upward within the existing facility? With the dollar value of commercial buildings expected to increase by 5%, and warehouse construction leading this sector, these are the questions that are being asked.

As e-commerce giants continue to build out their logistics infrastructure, they are seeking cost-effective methods of expansion as the solution. One of the most simple and cost-effective ways these facilities are improving capacity is by installing industrial steel mezzanines.


Stairs leading to mezzanine floor

What is a Mezzanine?

In industrial settings, a mezzanine is an elevated floor/platform that is installed between the floor and ceiling. Typically, these are freestanding structures, bolted together with structural steel components, that can be dismantled or relocated if needed. Industrial steel mezzanines are often custom designed to satisfy the various requirements that their application calls for. They may vary widely in their square footage, column spans, decking types, capacities, number of floor levels, and more. In warehouse applications, a mezzanine is typically installed for the storage of machinery, equipment, inventory, or other materials to free up space at the ground level. In fulfillment centers, mezzanines may be used for storage as well, but are more commonly installed to create additional working space for personnel and machinery such as conveyor and sortation systems.


Mezzanines vs Other Expansion Methods

E-commerce giants have plenty of options when considering ways of adding or freeing up floor space; however, mezzanines have gained attention as one of the most cost-effective methods. The reality is, permanent building floors typically require significant annual costs to maintain (e.g. HVAC, lighting, taxes). With a mezzanine, fulfillment centers can take advantage of the overhead space that they are already paying for, and can do so without the high costs associated with new building construction. Additionally, since mezzanines are identified as capital equipment, they can be depreciated in 7-years -- offering significantly reduced taxable income over their lifetime when compared to 39-year depreciation for real property. In some states, mezzanines may even be exempt from property taxes as well. For fulfillment centers spanning hundreds of thousands of square feet, choosing between an additional floor/building expansion vs a mezzanine installation is often a multi-million-dollar decision.


Rolling conveyor on mezzanine floor

Mezzanine Applications for Fulfillment Centers

Warehousing and fulfillment operations are outfitted with plenty of material handling/automated systems to store, retrieve, package, scan, and sort goods. Raised platforms, such as mezzanines, are often installed to support these systems and free-up floor space. Common machinery found on mezzanines in fulfillment operations include:

  • Automated conveyors used to sort incoming packages
  • Scanners to properly identify package dimensions
  • Automatic weighing scales for package weight verification
  • Sorters to batch groups of packages to be sent to smaller distribution hubs for final customer delivery

This machinery consumes a considerable amount of floor space and can span over 1,000 ft. in length, but mezzanines offer the level of design flexibility required to provide a stable elevated surface for them. This creates valuable floor space below for additional operations, such as other automated systems, forklift traffic, and more. Most mezzanines can be designed to accommodate obstructions such as building columns, or to meet to specific requirements such as square footage, column spans, and load ratings; however, the extent of these capabilities vary by manufacturer. Other storage solutions, such as platforms supported by rack or shelving, do not offer this same level of design flexibility.


Expectations Through 2021

With the trend in e-commerce set to remain strong going into 2021, industrial steel mezzanines will continue to be identified as a strategic cost-saver for fulfillment centers that are in the planning stages of being built or in process of renovation. Their practicality and highly customizable nature make them a preferred solution for the most perplexing material handling challenges. For those looking to add floor space without unnecessary HVAC costs, and with significant tax benefits, look no further than a mezzanine.




More Blogs

wildeck delta lift

Delta Lift helps Dealer Solutions & Design Save Time


VRCs and RMLs: Advantages of Each

Mezzanine used for parts storage

Considerations for Purchasing a Mezzanine


Wildeck Pewaukee: A Summary of Progress Made