Van Looy Group integrates frequently mezzanine floors into the design of a distribution center to increase the logistics handling spaces. To optimize the operational costs, logistics flows need to be adapted to the working on several levels. To reduce the investment costs, the design takes into account the latest techniques using cold rolled steel

A state of the art distribution center provides space for staging of pallets during inbound and outbound. The space above these areas can be of beneficial use. Traditionally, one chooses to install offices above the loading bays. They are structurally part of the building. They cover only part of the receiving and shipping area, which is often 25m deep.

The usage of standalone mezzanines provides a further solution. Standalone mezzanines can be more cost effective than mezzanines linked to the building. To obtain this advantage, the design shall take into account several aspects and constraints.

Goods flow
The usage of mezzanines implicates that the distribution center is organized in logistical zones. The goods flow between these zones merit full attention during the design. These flows can be automated (conveyor techniques, shuttles, AGV’s, overhead conveyors, vertical conveyors) or can remain manual. In that case, batching of internal transports and synchronization between the several areas play an important role.

People flow
Already at the beginning of the design, Van Looy Group gives a lot of attention to the people flow in the warehouse. Its importance is even bigger when using mezzanines. The people flow must be integrated in such a way that managing the floor teams can proceed seamless. In addition to that, a safety plan is elaborated to guarantee short escape routes.

Building design
Standalone mezzanines propagate considerable forces through their columns towards the floor. The floor must be designed to spread these forces. The floor is engineered to support the high point loads. In case of an existing floor, constructional reinforcements can sometimes lead to a solution.

Mezzanine design
An equilibrium needs to be found between a higher functionality when using less columns, and a reduced investment cost when using more columns. The engineering team of Van Looy Group is organized to implement innovative steel construction techniques into a cost effective design. The outcome is often a mixture of hot and cold rolled steel. Recent installations designed by Van Looy use e.g. sigma profiles (20.000m², column grid 5m x 6m, Courcelles) and corrugated plate profiles (6.000 m², column grid 12m x 12m, Beuningen).

Building equipment
Hand in hand with the design of the mezzanine and the material handling equipment, lighting, electricity, heating, cooling and sprinkler systems need to be integrated. Mainly with respect to the total investment cost, a conceptual installation plan for these equipments must be developed.

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