Double Your Floor Area.Without Extending the Building.

A structural steel mezzanine floor is an intermediate floor level inserted within an existing single-storey building — such as a factory, warehouse, or retail unit — to create additional floor space without extending the building's footprint or height. It consists of a primary steel beam framework supported on columns, a decking surface, perimeter safety railings, and an access staircase. Mezzanines are widely used to maximise the utility of existing warehouse and factory floor area.

Load capacity is determined by the structural design and depends on the use. Typical design loads are: office mezzanines 300–400 kg/sqm; production/assembly floors 500–750 kg/sqm; and heavy racking or pallet storage 750–1,000 kg/sqm. Point load capacity for heavy machinery is specified separately. Our structural engineers size the beams, deck thickness, and column sections specifically for your stated load requirement. Overloading a mezzanine beyond its design load is a safety risk — accurate load information is essential at design stage.

In most cases, an internal freestanding mezzanine structure does not require planning permission as it is considered a change of use fit-out within an existing building. However, requirements vary by state, local authority, and building use. If the mezzanine increases the building's fire compartment size, increases occupancy load, or affects escape routes, a building authority approval or fire NOC may be required. We advise clients to confirm with their local authority before installation. We provide the structural drawings and load information required for any approval submission.

A typical 500–1,000 sq m mezzanine is installed in 5–7 days by a 6–8 person installation team. Smaller mezzanines (100–300 sq m) take 2–4 days. All structural components are shop-fabricated and arrive pre-cut, pre-drilled, and pre-painted. Assembly uses bolted connections with no on-site welding required. Operations in the affected area of the building are typically paused for 1–3 days at peak installation, then resumed as sections are completed.

Usually yes, with careful planning. We work with the facility manager to sequence installation in zones — installing one section of the mezzanine at a time while the rest of the warehouse continues to operate. Specific aisles or bays are vacated during column and beam installation in that zone. This requires advance planning and clear staging areas, but in most cases, a warehouse remains operational throughout installation, with only partial restrictions in active zones.

Three main decking types are available: solid mild steel deck (4–6 mm plate) — the most common, suitable for offices, production, and storage; steel bar grating — allows light, ventilation, and fire suppression water penetration to the floor below, commonly used in production mezzanines; and composite deck (steel profiled deck with cast concrete or screed) — for heavier loads, a more floor-like surface, and superior acoustic isolation. Decking choice depends on load, use, maintenance requirements, and whether seeing or sprinkler coverage of the floor below is required.

Yes. Because our mezzanines are bolted (not welded) assemblies, they can be disassembled, transported, and re-erected at a new location. This is a realistic option for businesses on leased premises or organisations that plan to move facilities. Disassembly typically takes 2–3 days; the components are inspected, any damaged elements are replaced, and the structure is re-erected at the new site. We recommend periodic structural inspection after any relocation.

Standard safety features on all Poojary Prefab mezzanines include: perimeter safety railings to IS 4759 (minimum 1,050 mm height with mid-rail and toe board); access staircase with anti-slip chequered plate treads, handrails on both sides, and appropriate staircase angle (typically 42–45 degrees); and pallet gates or hinged sections at goods-loading points to allow forklift or crane loading while providing fall protection when not in use. Additional features such as safety netting under the mezzanine deck (below-level protection) and edge protection at floor openings are available.

A freestanding mezzanine is supported entirely by its own column and base plate system bearing on the existing building's concrete floor slab. It does not transfer any load to the building's walls or roof structure. Column base reactions are provided by our structural engineers so that the existing slab can be checked for bearing capacity. In most warehouses and factories with standard industrial floor slabs (150–200 mm thick), freestanding mezzanine column loads are within slab capacity — but confirmation from a structural engineer is required for each project.

Standard treatment is shot-blasted steel with epoxy primer and polyurethane topcoat in your choice of colour. For food processing, pharmaceutical, or coastal environments, hot-dip galvanisation is available on structural members. Deck plate is typically painted; open bar grating is left in hot-dip galvanised finish. We provide a full surface treatment specification on request, and colour samples for topcoat selection.