Rack Supported Mezzanine Floor Manufacturer in Delhi NCR
- Concept: Heavy-duty storage racks act as vertical structural support columns
- Floor capacity: 350 kg/m² to 1,000 kg/m² uniformly distributed floor load
- Cost savings: Saves 30% to 40% compared to structural column-beam mezzanines
- Features: Integrated catwalk walkways, industrial staircases, safety handrails & pallet gates
Star Labs
APT
Adani Defence and Aerospace
Globe Moving
Unilever Nepal Limited
Nepal Electricity Authority
Coca Cola
Mangalam Group
MAW Building Trust Through Service
CG Motors
Save the Children
USAID
Rack Supported Mezzanine Engineering & System Operation
What is Rack Supported Mezzanine? Rack-supported mezzanine floors use heavy-duty pallet racking or industrial shelving frames as the primary structural support columns for an overhead intermediate floor deck. By eliminating independent civil foundation posts, this system creates highly organized bin picking on the ground level while unlocking an expansive open floor above for secondary storage, packing lines, or administrative offices.
Where is it Used? E-commerce fulfillment centers, automotive spare parts hubs, garment picking warehouses, third-party logistics parks.
Key Benefits & Advantages:
• Doubles usable warehouse floor space on the exact same land footprint without civil construction.
• Integrates ground-level bin picking directly beneath an open upper storage or office deck.
• Available with chequered steel plate, galvanized mesh grating, or heavy particle board decking.
• Equipped with industrial staircases, safety handrails, kickplates, and forklift pallet gates.
How Vaishno Storage Solution Manufactures This System: Engineered from certified prime IS 2062 steel coils at our Mundka plant. Uprights, horizontal beams, and joist supports are CNC roll-formed and punched with millimeter accuracy. Treated through our 7-tank chemical pre-treatment and powder-coating line.
How We Install on Site: Baseplates are chemically anchored into the concrete slab, upright runs are tied with structural joists, and safety staircases with kickplates are erected with full load-deflection certification.
Recommended Applications & Operating Environments
E-commerce fulfillment centers, automotive spare parts hubs, garment picking warehouses, third-party logistics parks.
Request Factory Quote
Direct Mundka plant rates & 2D CAD layout.
| Parameter | Specification Details |
|---|---|
| Support Columns | Heavy-duty roll-formed pallet rack or shelving uprights (80x70 to 120x95 mm) |
| Floor Loading Capacity | 350 kg/m², 500 kg/m², 750 kg/m², 1,000 kg/m² UDL |
| Clear Heights | Under-mezzanine clear height: 2,400 mm to 3,200 mm; Upper level: 2,400 mm+ |
| Decking Options | Chequered steel plate (3-5 mm), galvanized steel grating, or 25 mm tongue-and-groove wood |
| Staircase Specification | Heavy structural steel stringers with anti-slip perforated treads and continuous handrail |
| Perimeter Handrails | 1,050 mm height with intermediate knee rail and 100 mm kick-plate toe guard |
| Safety Pallet Gate | Up-and-over safety pivot gate or bi-parting sliding gate for forklift loading |
| Steel Grade | IS 2062 Grade Prime High-Tensile Structural Steel |
Available Sizes & Variants
| Model / Size | Load Capacity | Recommended Application |
|---|---|---|
| 2-Tier Shelving Mezzanine (350 kg/m²) | 350 kg/m² floor load | Apparel picking, e-commerce order fulfillment & pharma bins |
| Heavy Pallet Mezzanine (750 kg/m²) | 750 kg/m² floor load | Automotive component buffers & medium industrial assembly |
| Heavy Industrial Mezzanine (1000 kg/m²) | 1,000 kg/m² floor load | Heavy manufacturing equipment, raw material coils & tool rooms |
Rack Supported Mezzanine B2B Price Benchmark
| Parameter | Vaishno (Factory Direct) | Trader Reseller |
|---|---|---|
| Price | ₹350 – ₹850 per square foot | +18% to +30% higher |
| Steel Grade | Prime IS 2062 Grade certified (Tata/JSW) | Re-rolled unverified |
| Paint Finish | 7-Tank + 80µ powder coat | Air-dry spray paint |
| CAD Layout | Free 2D/3D certified layout within 24h | Rough estimates |
| Rigging Crew | Factory-certified riggers with anchors | Unskilled labor |
Direct Fabrication & Testing
All upright columns, horizontal step beams, and steel deck panels are manufactured at our Mundka facility using automated multi-station roll-forming lines and precision CNC slot punching. Sourced exclusively from Tata Steel, JSW, and SAIL with verified Mill Test Certificates (MTC).
Fast Logistics & Turnkey Erection
Our structural installation crews serve warehouses across Delhi NCR, Haryana, UP, Rajasthan, and Punjab with on-site laser leveling, optical plumb inspection, and certified heavy-duty floor chemical anchoring.
How We Manufacture & Install Rack Supported Mezzanine
Manufacturing at Mundka Plant
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1
Prime Steel Profiling High tensile IS 2062 Grade E250 / E350 steel slitted and inspected for yield strength consistency.
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2
CNC Cold Roll-Forming Automated multi-stand cold roll forming lines produce continuous profiles with precise 50 mm pitch perforations.
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3
7-Tank Chemical Pre-Treatment Hot alkaline degreasing, derusting, water rinses, and zinc phosphating create superior powder bonding and rust resistance.
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4
Electrostatic Powder Coating Thermosetting epoxy-polyester powder applied at 70–80 microns and baked at 200°C for industrial scratch resistance.
On-Site Turnkey Installation
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1
Floor Slab & Laser Plumb Check Optical laser levels assess warehouse concrete floor flatness, expansion joints, and plumb lines prior to erection.
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2
Heavy Duty Chemical / Mechanical Anchoring Base plates secured with M12/M16 high-grade anchor bolts embedded into the industrial concrete floor slab.
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3
Safety Locks & Cross-Bracing Spring-loaded safety pins prevent accidental beam dislodgement from forklift contact, supplemented by horizontal and diagonal cross-ties.
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4
Load Testing & Signage Sign-Off Rigorous deflection checks under live weight followed by affixing certified UDL load capacity safety signboards.
How Rack Supported Mezzanine Compares
Factors Determining Rack Supported Mezzanine Cost
Where Rack Supported Mezzanine Has Been Installed
Real project installations delivered by our Mundka engineering plant.
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View Case Study →Rack Supported Mezzanine Frequently Asked Questions
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