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  • admin
  • 5 月, 周二, 2026
Cases

Custom 500kg/m² Mezzanine Floor for North American Electronic Equipment Retail Warehouse

Designed for a North American electronic equipment retailer, this custom steel mezzanine floor delivers maximum storage capacity in a space-constrained facility. Built with a uniform load rating of 500kg/m² and tailored to fit a strict 2-meter height limit (due to the warehouse’s low ceiling), the solution efficiently doubles usable floor space while meeting the client’s unique operational and logistical needs.

Space-Optimized Design for Low-Ceiling Warehouses
The entire structure was precision-engineered to fit within the client’s 2-meter height restriction, without compromising structural integrity or load capacity. This custom design allowed the retailer to add a full upper storage level without costly renovations or facility modifications.

Fast-Track Production & Seamless Consolidated Shipping
After finalizing all technical specifications with the client, we accelerated production to align with their container loading schedule. The mezzanine was shipped alongside goods from their other Chinese suppliers in a single consolidated container, eliminating delays and extra logistics costs—showcasing our efficiency and commitment to collaborative problem-solving.

Vibrant, High-Quality Finish & Durable Construction
The mezzanine features a durable two-tone powder-coated finish (blue frame with bright yellow railings and stairs) that meets the client’s branding and safety visibility requirements. Built from heavy-duty structural steel, the system is designed for long-term use in a busy retail warehouse environment.

Positive Client Feedback & Repeat Business
The client expressed high satisfaction with the final installation, praising the build quality, precise fit, and professional finish. As a testament to their confidence in our work, they placed a follow-up order within just three months of receiving the initial project.

Safe, Compliant, and Operationally Ready
The mezzanine includes OSHA-compliant safety railings, anti-slip stair treads, and secure connections, ensuring a safe working environment for warehouse staff. The modular design also allows for future reconfiguration as the client’s inventory needs evolve.

    • admin
    • 5 月, 周二, 2026
    Cases

    Custom Mezzanine Floor System with Fire-Compliant Perforated Steel Decking

    CASE STUDY · MEZZANINE FLOOR

    Custom Mezzanine Floor System with Fire-Compliant Perforated Steel Decking

    By Admin · May 19, 2026 · Home › Cases › Custom Mezzanine Floor

    Tailored for a North American laser beauty equipment facility, our three custom 500 kg/m² steel mezzanine floors are designed to maximize vertical space while meeting project-specific safety and fire protection requirements. The system includes purpose-built perforated steel decking, designed to be coordinated with the overhead fire sprinkler system to support appropriate fire protection planning while providing a durable platform for equipment, inventory, and daily operations.

    This project demonstrates how a customized steel mezzanine system can combine structural performance, efficient space utilization, and coordinated fire protection considerations within an existing commercial facility.

    Custom steel mezzanine flooring system for a North American equipment facility

    Custom steel mezzanine flooring system for a North American equipment facility

    Project Overview: Three Custom Steel Mezzanine Floors

    The project involved three custom steel mezzanine platforms for a laser beauty equipment facility in North America. The design was developed around the facility’s available vertical space, equipment requirements, and operational layout.

    The key project specifications include:

    • Project type: Custom steel mezzanine flooring

    • Number of platforms: Three

    • Platform load capacity: 500 kg/m² uniform distributed load

    • Decking: Custom perforated steel panels

    • Main structure: Steel columns and supporting beams

    • Application: Equipment placement, storage, and additional usable workspace

    The load capacity refers to the specified uniformly distributed platform load. Actual allowable loading for individual equipment, concentrated loads, and local structural conditions should be confirmed through the project engineering calculations.

    Fire-Safe Perforated Steel Decking and Sprinkler Coordination

    The custom perforated floor panels feature regularly arranged openings designed to support coordination with the facility’s fire protection system. Compared with a continuous solid deck, perforated decking may allow more sprinkler water to pass between levels, depending on the opening size, open area, panel arrangement, and surrounding obstructions.

    For a mezzanine project, decking selection should be considered alongside sprinkler coverage, the type of stored materials, equipment locations, and the building’s existing fire protection design.

    The perforated decking in this project was selected with these coordination requirements in mind. The final suitability of the deck and sprinkler arrangement must be verified against the applicable local fire codes and the approved fire protection design.

    Perforated steel decking for a custom mezzanine floor system

    Custom steel mezzanine flooring system for a North American equipment facility

    Why Does Mezzanine Sprinkler Design Matter?

    A mezzanine introduces another level into an existing building and can change how sprinkler water reaches the spaces above and below the platform. Beams, stored goods, machinery, and the floor panels themselves may affect sprinkler distribution.

    Before finalizing a mezzanine layout, the project team should consider:

    • Existing ceiling sprinkler locations and coverage.

    • Whether additional sprinkler protection is required above or below the mezzanine.

    • Decking openings and potential obstructions to water distribution.

    • Storage height, commodity classification, and equipment arrangement.

    • Access for inspection, maintenance, and future system modifications.

    A perforated deck does not automatically make a mezzanine sprinkler-compliant. A qualified fire protection designer should determine the appropriate arrangement under the codes and standards adopted for the project.

    Multi-Tiered Mezzanine Flooring for Better Space Utilization

    Multi-tiered mezzanine flooring creates additional usable levels within an existing building footprint. When the building height, floor structure, access arrangements, and operational requirements permit, a multi-level system can help businesses make better use of otherwise unused vertical space.

    For facilities handling equipment, components, or packaged products, the layout can be tailored to separate storage, handling, and work areas across different levels.

    Important considerations for multi-tiered mezzanine flooring include:

    • Structural load capacity: Each level must be designed for its intended uniformly distributed and concentrated loads.

    • Clear height: The available height must accommodate the platforms, equipment, stored products, and required working clearances.

    • Columns and beam layout: Structural members should be coordinated with the ground-floor workflow and equipment positions.

    • Stairs and access points: Personnel routes, loading openings, and material-handling arrangements should be considered early.

    • Fire protection coordination: Each level may change sprinkler coverage, access for emergency response, and the overall fire protection strategy.

    • Future flexibility: A modular layout may allow adjustments if storage requirements or operating processes change.

    The number of tiers and their elevations should be determined from the actual building dimensions and engineering requirements rather than selected solely to maximize floor area.

    Steel columns and support beams for a multi-tiered mezzanine floor

    Steel columns and support beams for a multi-tiered mezzanine floor

    500 kg/m² Heavy-Duty Load Capacity

    The project features a specified uniform platform load capacity of 500 kg/m². The perforated decking, support beams, and columns form an integrated steel structure designed around the intended loading conditions.

    This capacity can be relevant for facilities that need to accommodate equipment, inventory, or regular operational activities on an elevated platform. However, the allowable load at any particular point depends on the final structural design, the distribution of loads, and the support conditions.

    When requesting a quotation, buyers should provide the expected equipment weights, footprint dimensions, loading method, and any concentrated or dynamic loads. This information helps the engineering team assess the platform requirements more accurately.

    custom mezzanine floor in American

    Durable Steel Construction and Customization

    The mezzanine system uses structural steel framing with a corrosion-resistant finish selected according to the project requirements. The design can be adapted to the facility’s layout, including platform dimensions, staircase positions, deck specifications, and access arrangements.

    A customized steel mezzanine may help businesses add usable workspace or storage capacity without relocating to a larger building. Its practicality depends on the existing building structure, floor slab capacity, available height, operational workflow, and applicable local requirements.

    The modular concept also provides flexibility for future changes, subject to structural verification and any required approvals.

    Customer Reviews and Feedback for mezzanine floor

    Customer Reviews and Feedback for Mezzanine Floor

    Safety Access and Integrated Design

    Safe access and edge protection are important parts of mezzanine planning. Depending on the project scope and applicable requirements, the system can incorporate safety railings, anti-slip stair treads, secure deck connections, and designated material-handling openings.

    The final design should coordinate personnel access, loading operations, emergency egress, and fire protection provisions. Applicable occupational safety and building code requirements must be confirmed for the project location rather than assumed to be identical in every market.

    Our Mezzanine Design and Quotation Process

    Every warehouse has different dimensions, loading requirements, and operating conditions. Omni-Racking can review project information and develop a customized storage proposal around the customer’s requirements.

    A typical project review includes:

    1. Review the facility: Confirm the warehouse dimensions, available height, floor conditions, and existing obstructions.

    2. Define the loading requirements: Identify the intended platform load, equipment weights, storage arrangement, and operating activities.

    3. Plan the mezzanine layout: Review the number of levels, column positions, stairs, loading openings, and access routes.

    4. Coordinate fire protection: Provide the relevant layout and decking information for review by the project’s qualified fire protection designer.

    5. Confirm the technical proposal: Finalize the specifications, drawings, scope of supply, and quotation after the necessary technical details have been reviewed.

    For projects involving fire-rated construction or sprinkler modifications, the responsibilities for engineering approval, fire protection design, installation, and local permitting should be agreed upon before production.

    Request a Custom Multi-Tiered Mezzanine Solution

    Planning a multi-level warehouse mezzanine or reviewing mezzanine sprinkler design for a new facility?

    Send us your warehouse dimensions, required platform load capacity, intended application, and available layout drawings. Our team can review the project requirements and discuss a suitable steel mezzanine and decking configuration.

    Contact Omni-Racking to discuss your warehouse mezzanine project and request a customized proposal.

    Relevant Case Studies

    Custom Heavy-Duty Mezzanine Floor with Lift for Warehouse Storage

    Custom Mezzanine Floor with Ramp for Warehouse Storage

    Custom 800kg/sqm Mezzanine Floor with Integrated Medium-Duty Shelving

    FAQ

    Frequently Asked Questions About Customized Mezzanine Floor

    What is mezzanine sprinkler design?

    Mezzanine sprinkler design involves assessing how an elevated platform affects fire sprinkler coverage and determining whether the existing system needs to be modified or supplemented. The appropriate solution depends on the decking, obstructions, stored materials, building layout, and applicable local requirements.

    Perforated steel decking may be suitable for certain sprinkler-protected applications, but suitability depends on the panel openings, open area, obstruction conditions, and applicable fire protection standards. The complete arrangement should be reviewed by a qualified fire protection designer.

    Multi-tiered mezzanine flooring is a steel platform system with two or more elevated levels within a building. It can create additional usable space for storage, equipment, or operations, subject to the available building height, structural loading, access requirements, and local regulations.

    It refers to a specified uniformly distributed load of 500 kilograms per square metre. It does not mean that every individual piece of equipment or every concentrated load is automatically acceptable. Equipment weights, load distribution, and the structural design must also be checked.

    Useful information includes the warehouse length, width and clear height, required number of levels, intended use, estimated platform loads, equipment dimensions, preferred decking, and any available floor plans or layout drawings. Fire protection requirements should also be identified early in the project.

    Not necessarily. Requirements depend on the building's construction, use, size, adopted codes, existing fire protection provisions, and the specific mezzanine design. The project should be reviewed by the appropriate local building and fire protection professionals before the design is finalized.

    Have a Similar Project in Mind?

    Tell us your warehouse dimensions and storage needs — we'll design a custom solution within 24 hours.

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    • admin
    • 5 月, 周二, 2026
    Tire Storage Shelving

    Tire Storage Shelving

    Tire Storage Shelving

    Home › Products › Tire Storage Shelving

    RACKING SYSTEM

    Tire Storage Shelving

    Versatile, adjustable steel shelving for tire storage warehouses, workshops, and 4S retail storage — load capacity up to 500 kg per level.

    ⚖️ Load per Level：200–500 kg

    📐 Height Range：2,000 - 3,000 mm or customized

    📦 Shelf Levels：3 / 4 / 5 customized

    🎨 Color Options：Blue / Orange / Grey / White customized

    WhatsApp Inquiry

    KEY FEATURES

    Why Choose Our Tire Storage Shelving

    Boltless / Bolted Design

    Quick assembly without tools, saving time on installation and reconfiguration

    Adjustable Shelf Height

    Height adjustable in 50-75 mm increments to accommodate any type of goods

    Modular & Expandable

    Easily add bays or levels as your inventory grows over time

    Anti-Corrosion Powder Coat

    Industrial-grade finish for long service life in any warehouse environment

    Cost-Effective Storage

    Most affordable option for general warehouse and retail storage needs

    Wide Application Range

    Suitable for warehouses, garages, retail stores, offices, and workshops

    SPECIFICATIONS

    Technical Specifications

    ParameterSpecification
    Product NameTire Storage Shelving
    MaterialCold-rolled steel / Carbon steel
    Structure TypeBolted fixation
    Load per Level200–500 kg (customizable)
    Total Load CapacityUp to 2,000–3,000 kg per unit
    Shelf Levels3 / 4 / 5 adjustable levels or customized
    Height Adjustment50-75 mm increments
    Surface FinishPowder coated / anti-rust coating
    Color OptionsBlue / Orange / Grey / Black (custom available)
    ApplicationWarehouse / 4S Retail / Garage / Retail / Workshop

    APPLICATION SCENARIOS

    Where It's Used

    Custom tire storage rack for tire distributor in Toronto Canada
    tire storage racking1
    tire storage racking4
    tire storage racking3
    tire storage shelves 4
    tire storage shelves 3

    Request a Free Quote

    Fill in the form and our team will respond within 24 hours with a detailed quotation.

    📞 +86 155 8886 2609
    💬 WhatsApp: +86 183 5312 5419
    ✉ info@omniracking.com







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      Custom Mezzanine Floor with Lift | 500㎡ Heavy-Duty Project
      • admin
      • 5 月, 周三, 2026
      Cases

      Custom 500㎡ Heavy-Duty Mezzanine Floor with Integrated Lifting System

      CASES · MEZZANINE FLOOR WITH LIFT

      Custom Heavy-Duty Mezzanine Floor with Lift for Warehouse Storage

      By Admin · October 13, 2026 · Home › News › Mezzanine Floor with Lift

      Project Overview: A Custom 500㎡ Industrial Mezzanine Floor

      When warehouse floor space becomes limited, expanding vertically can be a practical alternative to extending the existing building. However, a heavy-duty warehouse mezzanine floor requires more than a steel platform. The structural layout, load capacity, existing building conditions, and material handling process must all work together.

      For this project in Central Asia, Omni-Racking designed a custom 500㎡ heavy-duty mezzanine floor with an integrated lifting system to help the customer make better use of the available warehouse height.

      The customer required a strong steel platform capable of supporting a uniformly distributed load of 1,000 kg/m². The design also needed to accommodate the existing concrete load-bearing columns and provide an efficient way to transfer goods between the ground floor and the upper level.

      Instead of applying a standard mezzanine configuration, our team developed a project-specific structural layout and integrated a rail-guided lifting platform with electric roller shutters.

      Custom 500 sqm heavy duty mezzanine floor for warehouse storage

      Custom 500 sqm heavy duty mezzanine floor for warehouse storage

      Key project specifications:

      • Project type: Custom heavy-duty steel mezzanine floor

      • Project location: Central Asia

      • Platform area: Approximately 500㎡

      • Required floor loading capacity: 1,000 kg/m²

      • Main beam span: 7.5 m

      • Main beam specification: 500 mm high H-beams

      • Material handling: Rail-guided lifting platform

      • Access configuration: Electric roller shutters

      • Engineering support: Customized layout, installation drawings, and lift control wiring diagrams

      The project demonstrates how a customized mezzanine floor with lift can address both structural requirements and day-to-day warehouse material handling needs.

      Why Choose a Custom Mezzanine Floor?

      Every warehouse has different dimensions, column positions, clear heights, storage requirements, and material handling processes. A standard steel platform may not fit the existing layout or provide the required load capacity.

      A custom mezzanine floor allows the structure to be designed around the actual conditions of the warehouse.

      For this Central Asian project, the main challenge was to create a heavy-duty platform while coordinating the new steel structure with the existing concrete columns.

      Custom steel mezzanine floor with 7.5 meter main beam span

      Custom steel mezzanine floor with 7.5 meter main beam span

      1. Customized Structural Design for Existing Warehouse Conditions

      The customer’s existing concrete load-bearing columns influenced the mezzanine layout and beam arrangement.

      Our engineering team repeatedly adjusted the structural design to accommodate the existing building conditions while achieving a 7.5 m single main beam span.

      The solution incorporated 500 mm high H-beams for the main beams, with the structural configuration selected according to the project requirements.

      For warehouses with existing columns, restricted installation areas, or non-standard dimensions, a customized steel mezzanine floor can provide greater layout flexibility than a standard platform system.

      2. Heavy-Duty Mezzanine Floor with 1,000 kg/m² Loading Capacity

      The customer required a uniformly distributed load capacity of 1,000 kg/m², making structural design a critical part of the project.

      The load capacity of a heavy-duty mezzanine floor depends on the complete structural system, not just the thickness of the floor decking.

      Important design considerations include:

      • Main beam span and section size

      • Secondary beam arrangement

      • Steel column dimensions and spacing

      • Floor decking type

      • Connections between structural components

      • Existing building conditions

      • Intended storage loads and operating requirements

      For this project, the structural layout was developed around the specified loading requirement and the available warehouse space.

      Actual allowable loads should be confirmed through project-specific structural calculations and applicable local requirements.

      Mezzanine Floor with Lift: Integrated Goods Lifting Solution

      A mezzanine floor creates an additional usable level, but moving inventory between floors can become a bottleneck if the material handling system is not planned properly.

      For this project, the customer required a lifting solution to support vertical goods movement between the ground floor and the elevated platform.

      Omni-Racking incorporated a rail-guided lifting platform into the customized mezzanine floor system.

      Mezzanine floor with rail guided goods lift and electric roller shutter

      Mezzanine floor with rail guided goods lift and electric roller shutter

      1. Rail-Guided Lifting Platform

      The lifting platform provides a dedicated route for moving goods vertically between levels, helping the warehouse operator coordinate storage and handling activities.

      The lifting equipment was configured according to the local electrical voltage requirements specified for the project.

      The final lift capacity, platform dimensions, travel height, lifting speed, and safety interlocks should be determined according to the actual goods, operating frequency, and local safety requirements.

      2. Electric Roller Shutters for Lift Access

      Electric roller shutters were integrated with the lifting platform to manage access at the relevant loading and unloading positions.

      The project also included circuit diagrams and technical guidance for the lift and roller shutter interlock system.

      When designing a mezzanine floor with goods lift, the platform structure, lift opening, loading area, and access protection must be considered together. The final configuration should prevent unsafe access to the lift opening and comply with applicable local regulations.

      3. Coordinated Design for the Complete System

      A warehouse mezzanine with lift should not be treated as two unrelated products.

      The structural design needs to coordinate with:

      • Lift location and travel path

      • Floor openings and landing positions

      • Roller shutter dimensions

      • Goods loading and unloading areas

      • Electrical connections and control arrangements

      • Installation and maintenance access

      Planning these elements together helps reduce layout conflicts and supports a more practical installation process.

      Engineering Drawings and Installation Support

      For a customized industrial mezzanine floor, accurate drawings are essential for coordinating the steel structure and associated equipment.

      For this project, Omni-Racking provided detailed installation drawings and circuit diagrams for the lifting platform and roller shutter interlock system.

      Our team also offered online technical guidance during installation to help the customer understand the assembly sequence and coordinate the relevant components.

      For overseas projects, clear technical documentation and remote communication can be particularly valuable when the customer arranges local installation.

      The exact scope of engineering and installation support can be discussed according to each project’s requirements.

      Custom mezzanine floor engineering drawing with integrated lifting system

      Custom mezzanine floor engineering drawing with integrated lifting system

      Project Results: A Tailored Heavy-Duty Warehouse Platform

      This project illustrates how a custom mezzanine system with lift can be configured to address demanding warehouse requirements.

      The main solution features included:

      • Approximately 500㎡ of additional elevated platform area

      • A specified uniformly distributed load capacity of 1,000 kg/m²

      • A customized 7.5 m main beam span

      • 500 mm high H-beams for the main beams

      • A rail-guided lifting platform for vertical goods movement

      • Electric roller shutters integrated into the access arrangement

      • Installation drawings and lift control wiring documentation

      • Online technical guidance for installation coordination

      Rather than relying on a standard mezzanine design, the solution was developed around the customer’s existing building conditions, structural requirements, and material handling needs.

      For warehouse operators who need additional storage or working space without extending the building footprint, a properly engineered mezzanine floor can be an effective option.

      Looking for a Custom Mezzanine Floor with Lift?

      Omni-Racking provides customized steel mezzanine floors and warehouse storage solutions for projects with different layouts, load requirements, and handling needs.

      Whether you need a heavy-duty mezzanine floor, a warehouse mezzanine with goods lift, or a steel platform integrated with an existing racking system, we can evaluate your requirements and develop a suitable project-specific proposal.

      To help us prepare a preliminary design and quotation, please share:

      1. Warehouse length, width, and clear height

      2. Required mezzanine floor area and platform height

      3. Required loading capacity in kg/m²

      4. Type, dimensions, and weight of the goods

      5. Required lift capacity and lifting height, if known

      6. Existing warehouse layout or building drawings

      7. Project location and applicable local requirements

      Based on this information, we can review the layout, recommend a suitable structural configuration, and discuss the appropriate lifting and access arrangements.

      Contact Omni-Racking to discuss your custom mezzanine floor project.

      Send us your warehouse drawings and requirements to start your project evaluation.

      Relevant mezzanine floor case studies

      Have a Similar Project in Mind?

      Tell us your warehouse dimensions and storage needs — we'll design a custom solution within 24 hours.

      Whatsapp Us Now
      Email for Free Design
      • admin
      • 5 月, 周三, 2026
      Cases

      Custom Heavy-Duty Pallet Racking for Cable Reels

      CASES · WAREHOUSE DESIGN

      Custom Cable Reel Storage Rack for a Chilean Cable Manufacturer

      Project Overview

      Omni-Racking recently completed a custom cable reel storage rack project for a leading cable manufacturer in Chile, South America.

      The customer needed a heavy-duty pallet racking system for large cable reels while improving warehouse organization, storage density, and operational safety.

      Unlike standard palletized products, cable reels can create highly concentrated loads on rack components. Their different diameters, weights, and handling requirements also make standard warehouse racking unsuitable for many cable storage applications.

      After reviewing the customer’s cable reel dimensions, weight requirements, and warehouse operations, our engineering team developed a customized cable reel racking system specifically for heavy cable drum storage.

      The final solution uses reinforced pad beams and heavy-duty bolted connections to provide stable support for the customer’s cable reels.

      custom cable reel storage rack system for cable manufacturer in Chile

      Customer Requirements

      The customer is a major cable manufacturer in Chile, producing cables for power transmission, telecommunications, and industrial applications.

      The warehouse needed to store multiple cable reels efficiently while maintaining safe access for daily loading and unloading operations.

      The main requirements included:

      • Safe storage of heavy cable reels
      • High load-bearing capacity
      • Better warehouse space utilization
      • Easy loading and unloading
      • Accommodation for different reel sizes
      • Long-term structural stability
      • Reliable performance under concentrated loads

      Because individual cable reels can weigh several tons, the rack system needed to be engineered around the actual load conditions rather than simply using a standard pallet rack configuration.

      Why Cable Reel Storage Requires a Custom Rack Design

      Cable reels are different from conventional pallet loads.

      A pallet distributes its load over a relatively large and predictable contact area. A cable reel, however, can transfer a significant amount of weight through a much smaller support area.

      This creates several important design considerations:

      • Concentrated loading
      • Reel diameter
      • Reel width
      • Reel weight
      • Support spacing
      • Forklift handling
      • Rack beam strength
      • Connection stability

      For this reason, a cable reel storage rack should be designed according to the actual operating conditions of the warehouse.

      A standard pallet rack may provide sufficient capacity on paper, but the support structure must also be suitable for the concentrated loads created by cable drums.

      Drawings for custom cable reel racking

      Initial Design: Adjustable Pad Beam System

      During the initial engineering stage, Omni-Racking proposed an adjustable pad beam system.

      The support pads were mounted on the pallet rack beams using sliding bolted connections.

      This configuration offered greater flexibility for warehouses handling cable reels with different dimensions.

      The support positions could be adjusted according to the diameter and width of different cable reels.

      Advantages of the Adjustable Design

      The original design provided several benefits:

      • Flexible support positioning
      • Adjustable spacing for different reel diameters
      • Easier adaptation to future product changes
      • Improved flexibility for warehouse operations
      • Bolted connections for easier adjustment

      For cable manufacturers handling a wide range of reel sizes, this type of adjustable cable drum storage rack can be particularly useful.

      Engineering Optimization Based on Actual Operating Conditions

      During further discussions with the customer, our engineering team received more detailed information about the actual warehouse operation.

      The additional information showed that:

      • The cable reels were relatively heavy
      • The reel dimensions were relatively consistent
      • The customer prioritized structural strength
      • Long-term durability was more important than frequent adjustment

      This changed the engineering priority.

      Instead of maximizing adjustability, the final solution needed to maximize strength, stability, and long-term reliability.

      Based on these actual operating conditions, Omni-Racking recommended optimizing the original design.

      Final Solution: Heavy-Duty Bolted Pad Beam System

      The final cable reel storage rack system adopted a fixed heavy-duty bolted pad beam design.

      Instead of using sliding adjustable connections, each support pad was securely fixed to the beam structure using heavy-duty bolted connections.

      This configuration created a stronger and more stable support structure for the heavy cable reels.

      1. Higher Load-Bearing Performance

      The reinforced pad beam structure is designed to handle the concentrated loads generated by heavy cable reels.

      The fixed support configuration also reduces unnecessary movement during daily warehouse operations.

      2. Reinforced Internal Structure

      Additional reinforcement stiffeners were incorporated into the pad beam structure.

      These reinforcements help distribute concentrated loads more effectively and reduce localized stress on the beam.

      3. Secure Bolted Connections

      The support pads are securely connected to the main beam using heavy-duty bolts.

      Compared with a flexible sliding configuration, the fixed connection provides a more stable support position for cable reels.

      4. Improved Long-Term Durability

      Because the customer handles heavy cable reels on a regular basis, long-term structural performance was an important consideration.

      The reinforced design was developed to provide reliable performance under continuous industrial use.

      Cable Reel Storage Rack Installation

      The completed system was installed in the customer’s warehouse in Chile.

      The final rack configuration provides dedicated storage locations for heavy cable reels while keeping the warehouse layout organized.

      The rack system also allows forklifts to access the stored reels efficiently during daily warehouse operations.

      custom cable reel storage rack system for cable manufacturer in Chile

      Project Results

      The customized cable reel racking system helped the customer improve the overall organization and efficiency of its warehouse.

      The main benefits included:

      • Increased storage capacity
      • Better cable reel organization
      • Improved warehouse space utilization
      • Safer heavy-load storage
      • More stable reel positioning
      • Easier loading and unloading
      • Improved long-term structural reliability

      More importantly, the final solution was developed around the customer’s actual operating conditions rather than simply adapting a standard warehouse rack.

      Why Custom Cable Reel Racking Matters

      For cable manufacturers, electrical contractors, and industrial distributors, cable reels can represent one of the more challenging types of warehouse inventory.

      A suitable cable reel storage rack should consider more than the total weight of the stored products.

      Important factors include:

      Cable Reel Weight

      Heavy reels can create substantial concentrated loads on the support structure.

      Reel Diameter

      Different reel diameters may require different support spacing.

      Reel Width

      The width of the reel affects the required rack depth and support configuration.

      Handling Equipment

      Forklift type and operating method should be considered during the rack design process.

      Warehouse Layout

      Rack dimensions should be coordinated with:

      • Warehouse columns
      • Aisle width
      • Forklift turning radius
      • Available clear height
      • Existing storage equipment

      Long-Term Operating Conditions

      The rack should be engineered for repeated loading and unloading rather than only the initial installation.

      Cable Reel Rack vs. Standard Pallet Racking

      Although cable reel racks can be based on heavy-duty pallet rack structures, the support configuration is different from conventional pallet storage.

      Feature Standard Pallet Racking Cable Reel Storage Rack
      Stored goods Palletized products Cable reels / cable drums
      Load distribution Relatively distributed Highly concentrated
      Support Pallets / wire decking Pad beams / dedicated supports
      Main design concern Pallet load Reel weight and contact points
      Reel diameter consideration Usually not required Important
      Customization Standard configurations available Often highly customized
      Typical application General warehouses Cable manufacturers and distributors

      This is why a specialized cable drum rack can provide a better solution than simply placing cable reels on standard pallet rack beams.

      Applications of Cable Reel Storage Racks

      Custom cable reel racking systems can be used in a variety of industrial applications, including:

      • Electrical cable manufacturers
      • Power cable manufacturers
      • Telecommunications cable manufacturers
      • Wire manufacturers
      • Electrical equipment distributors
      • Industrial warehouses
      • Cable storage centers
      • Construction material warehouses

      Depending on the reel dimensions and load requirements, the rack structure, support beams, and safety components can be customized accordingly.

      How We Design a Custom Cable Reel Rack

      At Omni-Racking, we normally evaluate several key parameters before designing a cable reel storage system.

      Please provide:

      1. Cable reel diameter

      2. Cable reel width

      3. Maximum reel weight

      4. Number of reels

      5. Warehouse dimensions

      6. Clear warehouse height

      7. Forklift type

      8. Required storage levels

      Based on this information, our engineering team can develop a customized rack layout and recommend an appropriate support structure.

      Need a Custom Cable Reel Storage Rack?

      If your warehouse needs to store heavy cable reels, cable drums, or other concentrated industrial loads, a customized racking system can provide a safer and more efficient storage solution.

      Omni-Racking provides:

      • Custom cable reel storage racks
      • Heavy-duty pallet racking
      • Cable drum storage systems
      • Warehouse layout design
      • CAD drawings
      • Structural engineering support
      • Customized quotations
      • Export services

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      • admin
      • 5 月, 周六, 2026
      Cases

      Custom 800kg/sqm Mezzanine Floor with Integrated Medium-Duty Shelving

      This custom-engineered mezzanine floor system was designed to maximize vertical storage space for the client’s warehouse operations, combining structural integrity with operational convenience.

      Key Specifications & Design Features
      Heavy-Duty Load Capacity: Built to support a uniform load of 800kg per square meter, the steel mezzanine structure is engineered for long-term durability under full operational loads.

      Integrated Medium-Duty Shelving: The system seamlessly integrates with medium-duty shelving units on the upper level, providing organized, accessible storage for a wide range of inventory items.

      Forklift Access Solution: A hinged side door is installed for safe and efficient forklift loading/unloading, eliminating the need for additional material handling equipment. For enhanced space efficiency, optional sliding wheeled doors are available, offering flexible access configurations tailored to the client’s workflow.

      Premium Powder Coating Finish: The structure features a high-quality powder coating process, resulting in a smooth, uniform finish with consistent color application across all components. This professional surface treatment not only enhances the system’s visual appeal but also provides robust corrosion resistance, extending the service life of the steel components.

      Project Benefits

      This solution demonstrates our ability to deliver customized storage systems that address both structural and operational needs. By combining a high-load mezzanine floor with integrated shelving and tailored access doors, we helped the client significantly expand their storage capacity while maintaining safe, efficient material handling processes. The superior powder coating finish further underscores our commitment to quality craftsmanship and attention to detail.

        • admin
        • 5 月, 周五, 2026
        Cases

        500kg/m² Heavy Duty Mezzanine Floor with Ramp for Warehouse Storage | Custom Industrial Platform

        CASE STUDY · MEZZANINE FLOOR

        Custom Mezzanine Floor with Ramp for Warehouse Storage

        By Admin · October 8, 2026 · Home › Case › Mezzanine Floor

        A warehouse mezzanine floor is a practical way to create additional usable space inside an existing building without expanding the warehouse footprint.

        But not every mezzanine project can use a standard design.

        This project is a good example. A North American air conditioning filter wholesaler needed a custom steel mezzanine floor with a ramp for frequent loading and unloading of small goods. The customer also had specific requirements for the floor structure, layout, and connection with the existing storage system.

        Based on the customer’s warehouse conditions and operating requirements, we developed a 500 kg/m² heavy duty mezzanine floor with a custom ramp.

        Warehouse mezzanine floor with ramp

        Project Overview

        This was a customized warehouse mezzanine floor project for a North American wholesaler.

        The customer wanted to make better use of the available warehouse space while keeping the existing building structure and storage layout.

        Unlike a standard mezzanine platform, the project required several customized features:

        • 500 kg/m² floor load capacity
        • Custom steel mezzanine structure
        • Approximately 2.2 m platform height
        • Ramp instead of a conventional staircase
        • Corrugated steel sheet flooring
        • Connection with the existing beam shelving system
        • Bolted and pre-drilled structural components
        • Wire mesh decking with Pallet Racking

        The final solution was designed around the customer’s actual warehouse operation rather than using a standard off-the-shelf platform.

        Key Specifications

        Product Custom Steel Mezzanine Floor
        Application Warehouse Storage & Small Goods Handling
        Load Capacity 500 kg/m²
        Platform Height Approx. 2.2 m
        Access Custom Ramp
        Floor Decking Corrugated Steel Sheet
        Structure Structural Steel
        Design Customized to Customer Requirements

        Why a Mezzanine Floor with Ramp?

        The customer’s warehouse operation was an important factor in the design.

        The warehouse mainly handled small commodities, and workers frequently used small hand carts to move goods.

        For this application, a conventional staircase would not be the most convenient solution for moving goods between the ground floor and the elevated platform.

        The customer therefore specifically requested a ramp instead of stairs.

        However, the platform height was approximately 2.2 meters. This meant that simply adding a ramp was not enough. The ramp length and slope had to be carefully considered to make the system practical for hand-cart operation.

        Our design team evaluated the platform height, available space, and expected material-handling method before determining the ramp configuration.

        This is one of the key advantages of a custom mezzanine floor: the structure can be designed around the actual workflow of the warehouse.

        Custom 500 kg/m² Heavy Duty Mezzanine Floor

        The required floor load capacity for this project was 500 kg/m².

        The structural design was developed according to the customer’s requirements, including the platform dimensions, load capacity, floor construction, and intended use.

        For a warehouse mezzanine, the load capacity is not determined only by the floor panels.

        The complete structure needs to work together, including:

        • Steel columns
        • Main beams
        • Secondary beams
        • Floor decking
        • Structural connections
        • Ramp structure
        • Existing building conditions

        For this project, our design team used structural calculation and modeling to check the required material sizes and structural strength before production.

        Corrugated Steel Sheet Mezzanine Flooring

        The customer did not want a conventional open steel grating floor.

        Instead, they requested corrugated steel sheets as the main floor surface and planned to install locally sourced wooden flooring above the steel sheets.

        This required the mezzanine structure and floor system to be designed according to the actual flooring configuration.

        The combination of a structural steel frame and customized floor decking provides flexibility for different warehouse applications.

        Depending on the project requirements, mezzanine floors can also be designed with other flooring options such as steel grating, checkered plate, plywood, or composite decking.

        Connection to Existing Warehouse Storage

        Another special feature of this project was the relationship between the mezzanine floor and the existing storage system.

        Three sides of the platform were positioned against the warehouse walls, while one side was connected to the existing beam shelving system through a steel grating floor.

        This created a more integrated storage layout rather than treating the mezzanine as an isolated platform.

        For existing warehouses, this type of customization can be particularly useful when the customer wants to combine:

        • Warehouse shelving
        • Mezzanine storage
        • Picking areas
        • Packing areas
        • Hand-cart access
        • Additional working space

        The exact connection method should always be determined according to the existing structure and project requirements.

        Ramp Design for Warehouse Material Handling

        Designing the ramp was one of the more important parts of this project.

        Because the platform was approximately 2.2 meters high and the customer planned to use small hand carts, the ramp needed to provide a practical route for moving goods between levels.

        The available warehouse space also limited the possible ramp length.

        Our design team therefore went through multiple calculations and layout adjustments before confirming the final ramp configuration.

        This is why custom warehouse mezzanine design is important for projects with specific material-handling requirements.

        A ramp that works well for one warehouse may not be suitable for another because the required platform height, available floor area, equipment, and traffic conditions can all be different.

        Pre-Drilled Steel Components for Easier Installation

        To simplify installation, the structural components for this project were pre-drilled before shipment.

        This allows the main components to be connected by bolting during installation and helps reduce the amount of on-site modification required.

        For export warehouse projects, prefabrication and accurate component preparation can make installation more straightforward, especially when the system is being installed by a local team.

        Where Can a Warehouse Mezzanine Floor Be Used?

        A custom steel mezzanine floor can be designed for many different warehouse and industrial applications.

        Typical applications include:

        Warehouse Storage

        Create additional storage space without expanding the existing building footprint.

        Order Picking

        Use the upper level as a manual picking area for small and medium-sized products.

        Packing Areas

        Create dedicated packing and order preparation space above existing storage areas.

        Spare Parts Storage

        Mezzanine platforms are suitable for organizing small components, spare parts, and inventory.

        Manufacturing Facilities

        A steel mezzanine can also be used as an additional working platform or production support area.

        Warehouse Shelving Integration

        Mezzanine floors can be combined with shelving or racking systems to create multi-level storage solutions.

        Custom Mezzanine Floor Design

        Every warehouse has different dimensions, building conditions, storage requirements, and material-handling processes.

        For this reason, we do not recommend selecting a mezzanine floor based only on a standard size or load rating.

        Our design process can take into consideration:

        • Warehouse length and width
        • Available clear height
        • Required platform height
        • Floor load capacity
        • Stored goods
        • Storage racks or shelving
        • Ramp or staircase requirements
        • Hand-cart or forklift operation
        • Loading and unloading areas
        • Existing building conditions

        Based on these details, we can develop a customized steel mezzanine floor system for the project.

        Why Choose a Custom Steel Mezzanine Floor?

        A custom mezzanine floor can help warehouse operators make better use of existing vertical space without changing the building footprint.

        Depending on the application, a well-designed mezzanine can provide:

        • Additional usable floor space
        • Better warehouse space utilization
        • More organized storage
        • Dedicated picking or packing areas
        • Flexible access options
        • Integration with existing shelving and racking

        For warehouses with limited floor space but sufficient clear height, a steel mezzanine platform can be a practical alternative to expanding the building.

        Request a Custom Mezzanine Floor Design

        Planning a warehouse mezzanine floor with ramp or a custom industrial steel platform?

        Send us your warehouse dimensions, floor plan, required load capacity, platform height, and intended use.

        If you have a CAD drawing, warehouse layout, or photos of the installation area, our team can review the project requirements and recommend a suitable mezzanine floor structure.

        Omni-Racking provides customized warehouse mezzanine floors, steel platforms, racking systems, and industrial storage solutions for overseas projects.

        FAQ

        Frequently Asked Questions

        What is a mezzanine floor?

        A mezzanine floor is an elevated platform installed inside an existing warehouse or industrial building to create additional usable space above the existing floor.

        Yes. A mezzanine can be designed with a ramp when the warehouse operation requires wheeled carts or other equipment to move goods between levels. The ramp configuration should be designed according to the platform height, available space, equipment, and project requirements.

        The required load capacity depends on the intended application and structural design. This project was designed for 500 kg/m². Other mezzanine projects can be customized for different load requirements.

        Yes. Depending on the existing storage system and structural conditions, a mezzanine can be designed to work together with warehouse shelving or racking.

        For an initial design and quotation, it is helpful to provide the warehouse length, width, clear height, required platform size, load capacity, intended use, access requirements, and project location. A CAD drawing or warehouse layout is even better.

        Have a Similar Project in Mind?

        Tell us your warehouse dimensions and storage needs — we'll design a custom solution within 24 hours.

        Whatsapp Us Now
        Email for Free Design
        • admin
        • 4 月, 周三, 2026
        Midum Duty Shelving

        Midum Duty Shelving

        (1) This type of shelving mainly consists of uprights, beams, and shelves (including reinforcing ribs). The uprights are connected by U-shaped uprights, horizontal braces, and diagonal braces (the horizontal and diagonal braces are available in rectangular tube and C-shaped steel structures). The beams are welded from beam rods and hanging corners.

        (2) The connection method is that the beams are hung on the uprights, and the shelves are laid on the P-shaped beams. We will select beams and shelves of different materials according to the weight and other characteristics of the goods to maximize your investment budget while meeting the load-bearing requirements of the goods.

        (3) The shelving is connected as a main frame and a secondary frame, and can be wirelessly connected according to the site conditions.

        Load capacity: Because the shelves are placed on the beams, the span is small, and the load-bearing capacity is high. Each layer can hold 200-500kg of small and medium-sized items, suitable for manual handling.

        Common specifications: L (1500-2000) * W (300*1000) * H (1500-3000) mm

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