Can a Mezzanine Floor Be Installed Without Disrupting Warehouse Operations?
One of the biggest concerns businesses have when considering a mezzanine floor is disruption.
If your warehouse is already busy with deliveries, picking, packing, production or distribution, closing areas for an extended period may simply not be practical. The additional space might be needed, but not at the expense of day-to-day operations.
The good news is that with careful planning, an experienced installation team and the right mezzanine system, disruption can often be kept to a minimum.
At Doity Engineering, we design mezzanine floors around both the building and the way the business operates, helping customers create the additional space they need while minimising the impact on their operations.
Can a Mezzanine Floor Be Installed While a Warehouse Is Operating?
Yes. In many cases, a mezzanine floor can be installed while the warehouse continues to operate. Careful planning, phased working areas, clear access routes and an efficient installation system can all help minimise disruption. The exact approach will depend on the warehouse layout, mezzanine design and operations taking place around the installation area.
Why Minimising Disruption Matters
For a busy warehouse, even relatively short periods of downtime can have consequences.
Installation work could potentially affect:
- Goods arriving and leaving the warehouse
- Picking and packing
- Forklift movements
- Access to stock
- Production areas
- Employee movement
- Customer orders
This is why installation should be considered during the mezzanine design process rather than once the structure is ready to be fitted.
Understanding how the warehouse operates allows the project to be planned around the business wherever practical.
Planning the Installation Around Your Warehouse
Every warehouse operates differently.
Before installation begins, it is important to understand where employees work, how goods move through the building and which areas need to remain accessible.
This can influence decisions such as:
- Where mezzanine components are stored before installation
- Which areas are temporarily restricted
- How installers access the site
- The order in which the mezzanine is assembled
- How forklift and pedestrian routes are maintained
Good planning can make a significant difference to the amount of disruption experienced during installation.
Can a Warehouse Stay Open During Mezzanine Installation?
Depending on the project and site conditions, it may be possible for other areas of the warehouse to continue operating while the mezzanine is installed.
This could involve temporarily separating the installation area from normal warehouse activities and carefully coordinating work around existing operations.
However, safety must always come first. Certain areas may need to be restricted at different stages of the installation, particularly where lifting or structural work is taking place.
The objective shouldn’t simply be to keep everything operating regardless of the circumstances. It should be to minimise unnecessary disruption while maintaining a safe working environment.
Faster Installation Can Reduce Disruption
The amount of time spent installing a mezzanine floor naturally affects the potential disruption to the business.
This is an area where the mezzanine system itself can make a considerable difference.
Doity Engineering’s Revlok mezzanine floor system can be installed up to 50% faster than traditional mezzanine systems.
Revlok uses an innovative keyhole locking system that enables structural components to be assembled quickly and efficiently on site.
A faster installation can mean:
- Less time with areas of the warehouse restricted
- Reduced interference with normal operations
- Faster access to the new floor space
- Less time required on site
- A quicker overall project
For busy warehouses where downtime needs to be kept to a minimum, installation speed can therefore be an important consideration when choosing a mezzanine floor.
Designing the Mezzanine to Reduce Operational Impact
Minimising disruption doesn’t begin when the installation team arrives. It begins during the design stage.
Column positions, staircases and access points can all be planned around existing warehouse operations.
For example, careful column positioning can help maintain:
- Forklift routes
- Picking aisles
- Production areas
- Loading areas
- Access to existing storage
A bespoke mezzanine design should work with the warehouse rather than forcing the warehouse to work around the mezzanine.
Preparing the Warehouse Before Installation
Businesses can also take practical steps before installation begins.
This may include temporarily moving stock away from the installation area, identifying alternative routes through the warehouse and ensuring employees understand which areas will be restricted.
Working closely with the mezzanine installer before work starts allows these arrangements to be planned in advance rather than dealt with once installation is underway.
How Long Does Mezzanine Floor Installation Take?
There isn’t one installation time that applies to every mezzanine floor.
The timescale will depend on factors including:
- The size of the mezzanine
- The complexity of the design
- Access to the installation area
- Site conditions
- Staircases and additional features
- The mezzanine system being installed
This is why businesses should discuss installation timescales early in the project, particularly where operational disruption is an important consideration.
Should Installation Speed Influence Your Choice of Mezzanine Supplier?
Price and design are naturally important when comparing mezzanine floor suppliers, but installation should also be part of the decision.
Businesses should ask potential suppliers:
- How long is the installation expected to take?
- How will disruption be managed?
- Which areas of the warehouse will need to be restricted?
- Can operations continue elsewhere during installation?
- How will the project be coordinated with the warehouse team?
Understanding this before choosing a supplier can help prevent unexpected disruption later.
Installing a Mezzanine Floor Around Your Business
Installing additional warehouse space doesn’t necessarily mean bringing your operations to a standstill.
With the right planning, mezzanine design and installation system, work can often be organised to minimise its impact on the rest of the warehouse.
At Doity Engineering, we design, manufacture and install mezzanine floors around the requirements of each business. Our Revlok mezzanine system can also be installed up to 50% faster than traditional systems, helping businesses create the space they need with less disruption.
If you’re considering a mezzanine floor but are concerned about how installation could affect your operations, speak to the Doity Engineering team about how the project could be planned around your warehouse.
Frequently Asked Questions
Can a warehouse remain operational while a mezzanine floor is installed?
In many cases, yes. Depending on the layout and project requirements, installation can often be planned so that other areas of the warehouse remain operational while work takes place.
How can disruption be reduced during mezzanine installation?
Disruption can be reduced through careful planning, clearly defined working areas, coordinated access routes, efficient installation methods and designing the mezzanine around existing warehouse operations.
How quickly can a mezzanine floor be installed?
Installation time depends on the size, design and complexity of the mezzanine. Doity Engineering’s Revlok system can be installed up to 50% faster than traditional mezzanine systems.
Will part of the warehouse need to be closed during installation?
Some areas may need to be temporarily restricted to allow installation work to be completed safely. The exact requirements depend on the mezzanine design, warehouse layout and site conditions.
Can mezzanine installation be planned around our working hours?
Installation requirements can be discussed during project planning so that the most appropriate approach can be considered around your operations, site access and safety requirements.
