Mezzanine Decking

Decking provides the work surface of a mezzanine as well as providing the structural floor to carry the design load. There are three type of decking options. Solid, composite or open style. Each style has its own characteristics and features that influence performance and durability of a mezzanine floor.

Selection Factors:

1. Type and magnitude of loading.
A. Uniform
B. Concentrated
C. Dynamic

2. Types and extent of traffic.
A. Foot
B. Sliding (boxes, pallets, etc)
C. Rolling Wheels
D. Other

3. Environment (wet, corrosive, high or low temp. etc…)

4. Compliance with applicable local building, fire and safety codes.

5. Compatibility with existing structure and equipment.

6. Aesthetic preference.

7. Noise generation and transmission.

8. Cost

Solid Flooring Options

Solid flooring can be supplied in a variety of materials such as plywood, wood planking, steel floor plate, wood metal, composites, light weight concrete and metal planking. Sliding storage considerations as well as security, lighting, heating, ventilating, air conditioning, sound control and other concerns above or below the mezzanine may suggest the use of a solid deck surface. Walking and kneeling is more comfortable on a solid deck surface.

Plywood Flooring

Plywood may be applied directly to the joist framing members of the mezzanine provided the proper grade and thickness is selected. This type of floor will require closely spaced joist framing. Consideration should also be given to protection from abrasive or wheeled loads to guard against rolling shear and damage to the plywood.

Wood Plank Flooring

In this system the planking provides a working and wearing surface allows for somewhat greater spans than in the directly  applied plywood type flooring. The planks are applied directly to the joist framing members of the mezzanine. This type of flooring usually works well with heavy, concentrated or wheeled loads.

Wood/Metal Composite Floors

Composite flooring systems are built up using a subdeck underlayment of corrugated metal deck with the top deck working surface created from a variety of materials such as plywood or metal plate. The metal deck can provide structural strength to allow economical joist spacing and a good contact area for support of the top deck working surface.

The subdeck underlayment is available in a range of metal thicknesses and profiles for different loading and framing conditions. This product is visibly from the underside of the mezzanine and can offer excellent light reflectivity.

Plywood Over Corrugated Metal Deck

A very common type of flooring. It is solid, sturdy and may be suitable for many applications. Plywood of all grades and thickness is available and can include various specially laminated surfaces of metal, synthetics, or abrasives at additional cost.

Steel Floor Plate on Corrugated Metal Deck

This traditional system provides a heavy duty floor. It is appropriate for pallet jack operation and other applications that  require abrasion and/or skid resistance. These steel plates products are commonly referred to as diamond plate, checkered plate and flat plate.

Solid Metal Plank Flooring

These narrow (6″ to 12″ wide) formed metal sections provide an integrated surface. They are relatively lightweight for ease in installation and are available in longer lengths than most deck materials. Point or impact loading should be considered when selecting this deck type.

Open Deck Options

Open type decking can be used where light, sound, air or sprinkler water passage is required. This need has a traditionally been filled by various types of grating. In general, open rung or ventilated products may be less accommodating to wheeled traffic than solid floor types.

Formed Metal Plank Grating

This system has characteristics similar to the solid metal planking, except that the top surface is open in either a steel rung or reticulated hole pattern. Either opening type can be manufactured with a smooth or highly slip resistant surface.

Steel Bar Grating

This is an open rectangular steel bar grid system available in large panels. The grid dimensions and bar sizes may be varied to satisfy a wide range of use, span and loading conditions. Bar grating can offer good resistance to wear, and provides up to 80% open area for heat, light, and air transfer. It can be supplied in a painted or galvanized finish.

Mezzanines: Things to Consider

Height: Height is determined by importance of under-clearance and code restrictions. Is the distance from ground floor to the mezzanine deck surface or the mezzanine under-clearance more important? Headroom above the mezzanine deck should also be considered. Codes typically dictate minimums.

Loads: What types of load will be on the deck? Relative or concentrated?

Column Spacing: Will mezzanine columns be potential hazards for traffic and material flow. If this doesn’t matter Material Flow may be able to offer advice in configuring the most efficient column spacing.

Deck Surface: Many types of deck surfaces are available. Decking is an important aspect of mezzanines and should be carefully chosen considering the capacity required. Another factor to choosing decking is who will be using it, some workers may not feel comfortable working at heights on see-through mesh decking.

Interfaces: If the mezzanine is going to interface with conveyor, rack, shelving, offices and so on please let Material Flow know so we can help configure a mezzanine to work with this equipment.

Stairs and Railing: Stair and railing locations are established with the first concern  being user safety. Code requirements and efficiency of material and traffic flow are other important considerations.

Expansions: If the possibility of future vertical or horizontal expansion of the mezzanine is foreseen, it is important to inform Material Flow.

Guide to Mezzanines

Loading requirements, column spacing, flexibility of design, deflection, seismic considerations at the project location and supporting sub-structure must be considered regardless of the type of mezzanine.

Loading

A uniform load is one that is spread out evenly over the deck surface. A uniform load can be  determined by dividing the total load  [live applied] load plus dead weight. (decking, framing, sprinkering, lighting etc…) by the area of the deck surface.

Example: A load of 12,500 pounds is going to be spread equally over a 10′ x 10′ area. The uniform live load would be 125 lbs. per square foot: (12,500 lbs. / 100 sq. ft. = 125 PSF)

In this example the mezzanine would be designed for the 125 PSF load. Code considerations and future plans also need to be considered  in live load calculations.

Special loading conditions should also be taken into consideration during design. Pallet landing areas, heavy machinery, shelving, pallet rack or other items need to be identified during planning. These conditions may result in very heavy point (concentrated) loads under shelving, rack posts, or legs supporting machinery. Pallet loads tend to be uniform over a relatively small area and can result in a higher design load requirement in areas where they may be located. Any of these conditions may result in the requirement for heavier or supplementary framing under the load location.

Another type of load is dynamic loading which can be induced by rolling platform trucks, pallet jacks or carts.

Span

The distance between mezzanine column supports will affect the cost of the project, the amount of deflection, the depth of framing steel, the column load on he supporting floor and the degree of traffic movement under the mezzanine.

Deflection

Deflection, whether horizontal or vertical, should be controlled within acceptable limits determined by the intended use of the structure. Too much horizontal deflection can be give the sensation of the structure swaying. Excessive vertical deflection may result in a bouncy or springing sensation on the deck.

Horizontal deflection is usually controlled through the use of properly designed connections, knee braces, or increasing column and base plate sizes on small structures. Mass and weight will play a role in controlling horizontal deflection of larger projects.

Vertical deflection is determined by considering the actual load being applied together with the span, spacing and strength of the supports.

Flexibility

Design flexibility encompasses all aspects of the intended use of the structure. Will it be used for storage, offices, manufacturing, conveyor equipment support or a combination of uses? Is the loading  requirement uniform or concentrated? Are there obstructions or fixed building characteristics which must be considered in the design? Will the system size be increased late on?

Most mezzanines can be built using standard designs with little or no alterations. Some situations will require custom applications.

Material Flow can design and install custom and standard mezzanine systems.

Roach Conveyors

Roach Conveyor offers 100 models in 39,000 sizes which are available for 24 hour shipment from their facility in Northeasst Arkansas.

Here are just some of the models we have for 24 hour shipment.  A common myth is if you purchased one brand of conveyor you must keep buying  that brand for replacement parts, rollers or add on system components. So if you have purchased Hytrol, Rapistan,  Bushman, Alvey, Matthews, Versa, Interlake, Omni or any other conveyor and don’t like their delivery give Material Flow a call at 1-800-338-1382.

1. Trough Bed Belt Conveyor Model 250TB
2. Medium Duty Slider Bed Belt Conveyor – Model 350SB
3. Medium Duty Box Style Slider Bed Conveyor Model 350 BSB
4. Medium Duty Roller Bed Belt Conveyor Model 196 RB
5. Roller Bed Inclined Floor to Floor Conveyor – #196RBF
6. Slider Bed Inclined Floor to Floor Belt Conveyor #350SBF
7. Heavy Duty Roler Belt Conveyor #251RB
8. Medium Duty Belt Drive Live Roller Curve #196LRC
9. Medium Duty Curve Spur #196LRCS
10. Medium Duty Cam Adjusted Live Roller #196CALR
11. Medium Duty Cam Adjusted Live Roller #2251 CALR
12. Medium Duty Belt Drive Liver Roller #196LR
13. Medium Duty Variable Pressure Live Roller Accumulator
14. Line Shaft Driven Live Roller Conveyor #796LS
15. Line Shaft Driven Curve Module#796LSC
16. Line Shaft DrivenCrossover#796LSX
17. Heavy Duty Chain Driven Live Roller Conveyor #251CDLR
18. Power Accessories – Motors, Belting, Turning Wheels
19. Pneumatic Roller and Blade Stops
20. Take ups, center drives
21. End drives and take ups
22. Intermediate Bed Sections
23. Rail Wheel Conveyors
24. Replacement Skatwheels
25. Rail Wheel Conveyors
26. Gravity Wheel Conveyor – Steel and Aluminum Type
27. 1 3/8″ gravity roller conveyors – Steel and Aluminum Type
28. Roller Curve Sections – 90 and 45 Degree Curves
29. 1.9″ Diameter Roller Conveyors – Steel and Galvanized
30. 1.9″ Diameter Roller Covneyors – 12 Gauge, 9 Gauge, Straight and Curved
31. 2.5 Diameter Roller Conveyor 14 Gauge, 11 Gauge, Straight and Curved
32. 2 9/16″ Diameter x 7 Gauge
33. 3 1/2″ x 9 Gauge Roller Conveyors
34. 21 /2 Roller Conveyors
35. Ball Transfer Tables
36. Gravity Accessories
37.. Gate Sections & Conveyor Support Guardrails
38. Rollers (Replacement)

If you don’t see what you want call us at 1-800-338-1382, chances are we can help you with on of the other brands we represent.

Lyon Lockers. Single, Double, Triple and more…

Lyon Lockers are known for their extreme durability and attractive designs.  Lyon Lockers are available in single tier, double tier and multiple tier locker designs.

Single Tier Lockers

Model No. 5042-3SU

Lyon Single Tier lockers provide a convenient shelf as well as full length clothing storage. Designed to provide secure, private storage of personal effects and valuables.

Lyon  Double Tier or Triple Tier Lockers

Model No. 5283-3 Model No.  5222SU

The Lyon Double Tier and Triple Tier Lockers are the most widely used and practical lockers.  Accommodates twice as many people as single tier lockers in the same floor space, while still providing enough room for the outer wear and personal belongings.

Lyon Multiple Tier Lockers

Model No. 5332-3 Model No. 5332

Lyon Multiple Tier Lockers are great in classrooms, laboratories, gymnasiums, sports and recreational facilities, and more.  Doors with padlock attachments have door pulls – doors with built-in locks have no pulls.  One-point latching system.

Material Flow carries the full line of Lyon Lockers including: Lyon Designer Lockers,  Lyon All Welded Lockers,  Lyon Set-Up Lockers,  Lyon Expanded Metal Lockers, Lyon Healthcare Lockers, Lyon Collegiate Lockers. and many, many more.

For more information about Lyon Lockers please visit us at  Material Flow and Conveyors or call us at (800)338-1382

New Slip N’ Stik Aisle Sign Kit From Aigner

Create your own customized “Aisle Signs” at half the cost!

If it is a Warehouse, library or store room, sign posting starts in the aisle and there is no better system than our Slip ‘N Stik^TM Aisle Sign Kit.

For warehouse applications just snap it into the pallet rack assembly holes – snap out to re-locate, or for more permanent applications, a “self adhesive” option is available.

Print signs, in house, on Laser / Ink-Jet compatible paper which is included. Change a designation for only the cost of the paper!  This very original, clear plastic sign holder features a soft plastic hinge which allows the sign to flex when bumped, with no breakage. It can hold any type of paper stock or even plastic sign blanks up to .100″ thick.  Use two  holders for very large signs (11″ x 17″ or larger)

Ten holders along with twelve Laser / Inkjet sheets included with each box.  Kit enables you to make up to ten  5½” x 8½” (folded) double sided signs. Instructions included.  You can order by style and specific color.

To order please visit our website at Material Flow and Conveyors or give us a call at (800)338-1382

Horizontal Belt Conveyors

Horizontal Conveyors are usually designed for stationary use. They are also used as portable units when equipped with portable supports, ( in lengths up to 30 ft.).

The Horizontal Belt Conveyors design is such that they can be quickly installed, economically operated and easily maintained.  They lend themselves to many types of operations such as:

• Assembly Lines
• Inspection
• Packaging
• Testing
• Order packing
• Sorting
• Checking
• Transferring parts from one operation to the next
• Shipping
• Receiving

Because conveyor is horizontal,  a more economically affordable belt is used.  In most situations, black PVC belt is ideal.  Other     types of belts are available for special requirements such as food handling, higher temperatures, etc.

Material can be WIDER than the belt when packaged items with a flat solid bottom are moved.  However, because loose parts, odd shaped sub-assemblies, etc. are also handled on HORIZONTAL conveyors,  caution should be excercised that these items are not wider than belt, unless they are in trays, tote pans etc.

The Horizontal Belt Conveyors are availble in STEEL although the portable ALUMINUM units can be used horizontally if lengths suffice.  In such instances,  a smooth type belt should be used, usually ordered at a lower cost.

Permanent and adjustable supports are most frequently used for Horizontal units.  In some cases, hanger brackets are supplied to provide overhead support mounting.

For more information about  Conveyors please visit us at  Material Flow and Conveyors or give us a call at (800)338-1382/

How to Design a Storage Area

Design your storage system from the inside out or another way to put it is the function to the reality.

If you look at many warehouses the beams are all at the same levels and the aisles are 12′ to accomodate the lift trucks. Don’t buy your lift truck befor you determine what you are trying to accomplish. You must consider the following:

1. Do you have a new building? If so design your storage system before you build it. Most poeple go to architects which in turn design  the same old building. The column turn spacing can easily get in the way. Why not design your storage area and flow patteren and THEN tell the archictect to put the building columns where they are not in the way. In other words, plan and then do more planning. What you put in on the front end pays dividend laters.

2. Do you have an existing building? If so design similar to above and then adapt the building columns and any other obstructions.

For all your warehouse storage needs visit www.pallet-rack.net

Rack Supported Structures

If you need a massive storage system, a rack supported structure may be the way to go.  With a rack supported structure the rack frames support the roof and walls. This reduces cost as there is no expense for structural steel or footings. This also reduces the cost of professional services.

Time is another area where you will save with a rack supported structure. It simply takes less time to build a rack supported building than a conventional structure since the storage system is the support system for the building. You don’t have to build a building and a storage system.

Since every square foot of a rack supported structure is used for storage and handling it offers higher efficiency than a standard structure.

Rack supported structures may also offer special tax advantages since it is classified as equipment, not structure.

For all your racking needs visit www.pallet-rack.net

Incline Conveyors

Incline Belt Conveyors

1.Incline belt conveyors are also made up from pre-engineered standard sections, but designed for permanent installation only.    These standard sections are combined to make any length unit required.

2. Incline conveyors are normally equipped with NOSEOVER at the upper end.  This enables the conveyed product to level off to a   horizontal position before being discharged.  This is highly desirable for cartons carrying breakables.  The noseover eliminates a dropping action by the front of the carton when it reaches the top.

3. Incline conveyors can be used as independent units to move material from one level to another.  When used with gravity         conveyor, it provides continuous flow of material from one floor to another.

4. Because conveyor is used inclined, it is equipped with rough-top-belt.

5. Maximum recommended incline for is 25 degrees.

6. Material wider than belt can be moved on the conveyor adequately, if it has a flat solid bottom.  The general rule is,         carton should not exceed the overall width of conveyor.

7. Conveyed items on incline can be moved in two directions – both forward and back. Reversing applications require center        drive.

8. Incline conveyors are available in steel ONLY. However, the portable ALUMINUM type may be used if lengths suffice and if       NOSEOVER is not necessary.

9. Permanent supports are normally used for top and bottom of the conveyors when used as a floor-to-floor unit.

MAXIMUM INCLINES AND DECLINES: The maximum angle of incline or decline of a belt conveyor is function of:

1. Type of Belt being used.
2. The condition of the load. Some manufacturers claim that angles of 35 degrees to 45 degrees are possible.  This is possible if all conditions are perfect and this seldom is the case.

FOR EXAMPLE: A wooden box with a flat rough bottom might negotiate a 25 degree angle; a smooth oily tote pan will probably slide at 15 degrees on that same belt.  The weight of the load has little effect on the problem.  The condition of the bottom and the center of gravity are the most important.  For the uniform packed cartons, the center of gravity is close to the geometric center of the carton and can be located at the intersections of diagonal drawn between opposite corners.  THIS IS NOT TRUE FOR NON-UNIFORMLY LOADED CARTONS SUCH AS TV SETS, COMPUTERS, ETC…
The center of gravity for this type of package can be determined by balancing the load on each of its four bottom edges to note the angle of stability in each direction.

We know that under “static conditions” a load is most stable.  However, belt conveyors do not provide a static condition.  They must start and stop fast and a load must be able to absorb forces such as momentum and acceleration without rocking beyond its stability point and tumbling.

A short load is more vulnerable to toppling than a long load.

Acceleration and deceleration of higher speed belts add to the problem more severely than do slower belts.  Also, the use of magnetic brakes for stopping the conveyor will accentuate the problem associated with the tumbling due to deceleration.
The bottoms of most boxes are normally not flat, but slightly bulged.  This creates some swaying even on level belts.
The spacing of the load supporting roller in a live roller conveyors and also belt conveyors, affect the amount of “bobbling” or “rocking” in transit.  The closer the rollers are the smoother the travel.  Slider bed conveyors provide the smoothest action of all.

For more information on Incline Conveyors please visit our webiste at Material Flow and Conveyors or give us a call at (800)338-1382