Apex Mezzanines has refined our Design process to ensure we provide cost-effective &
efficient Mezzanine Systems that are built tough.
Mezzanine Spans are generally dictated by the load capacity requirement of the Mezzanine Floor.
If you require a smaller load capacity, bigger spans are possible whereas with a higher load capacity, spans are generally restricted. In saying that, every Mezzanine Floor design is unique, and we adjust the Bearer (beam supporting the Mezzanine) according to the project requirements.
For example: You may require 6000mm openings with a 5kPa Load Capacity but can have as many posts as required along the sides. This means we have bearers at closer intervals which would allow this to work.
We recommend not getting too caught up in spans, once we establish what you are trying to achieve, we can change our Bearer from a C Purlin up to a PFC (parallel flange channel) or UB (universal beam) to meet the requirements.
Load Capacity is assessed at the beginning of the design process.
kPa is the equivalent kilograms per square metre – For Example: 3kPa is 300kg per square metre.
kN is the point load requirement – This is relevant when placing heavy shelving or moving pallet jacks around the Mezzanine Floor where the loads are distributed onto specific points.
C Purlins, Universal Beams (UB), Parallel Flange Channels (PFC), Square hollow sections (SHS), Circular Hollow Sections (CHS) and Rectangular Hollow Sections (RHS) are what make up a Mezzanine Floor design. Once we establish the design requirements such as Load Capacity and Spans required, this defines what Steel is used in the Mezzanine Floor.
Bearers are either back-to-back C Purlins which is the most cost-effective solution or if required we will step up to a UB or PFC.
Joists are C Purlins and spaced at 300, 400, 450 or 600mm centres depending on the design.
Posts are made up of SHS that is welded to a Baseplate for fixing to the concrete slab and a Top Plate that is fixed to the bearer.
Stair Stringers are made of RHS or PFC and fabricated to suit the specific Floor height to ensure compliance to the Australian Standards AS1657 or AS1428.1.
Handrail is designed with CHS welded to a baseplate and then steel handrail fittings are installed onto this to create a continuous rail around the Mezzanine Floor.
There are two options for joist layout – The first being Joists In-Line.
This means the joist is fixed to the bearer at the same height via a bolted or welded cleat. This is the best solution for Mezzanine Floors where minimal headroom is available as it saves on space.
The other option for a joist layout is Joists Over Bearer.
This is when the joists run over the top of the bearer and are fixed via bolting from flange to flange or by using a bracket that is bolted or screwed depending on the application.
Joists Over Bearer will take up some headroom but this can be a good solution if you need to cantilever your joists to work around obstructions like building columns or electrical switchboards etc.
If the Floor level doesn’t need to match an existing Mezzanine or structure, we use prefabricated stair stringers that have 175mm risers. The benefit of these is they are available off the shelf and are cost-effective.
If a specific Floor Level is required or the stair footprint needs to be reduced then we fabricate the stair stringers accordingly using PFC or RHS sections of steel.
Generally we will use Aluminium Step Treads but we can also provide hardwood or other materials if required.
Handrails and Gates are provided by Kwikclamp Systems – www.kwikclamp.com.au who are based in Brisbane and Melbourne. They provide a range of fittings to suit every design required for Mezzanines and Staircases. They also provide an option for Sliding Gates and Up & Over Style gates that allow for Pallet or product access to the Mezzanine Floor.
The Flooring sheets vary per load capacity and design however generally we use:
The kN point loading dictates the Flooring required, particularly with the 3kPa Light Industrial and 5kPa General Industrial. You will notice the Flooring for these are the same even the load capacity is different – That is because both have the same point loading requirements.
We provide services in South East Queensland ie Brisbane, Gold Coast and Sunshine Coast.
