When a business owner asks how long a mezzanine floor takes to install, the answer they usually want is the time on site. But the time on site is only the final stage of a process that starts weeks earlier. Understanding what happens between first contact and completed installation helps businesses plan properly, avoid surprises and ask the right questions of any installer they are considering.
Western Industrial, one of the UK’s leading mezzanine floor suppliers, has been managing mezzanine floor installations since 1979. This is how the process works, stage by stage.
Stage 1: Free site survey (week 1)
Every mezzanine floor project starts with a site survey. We visit the building, meet the client, measure the internal dimensions and ceiling height, check the ground floor slab condition, map the operational layout and identify any structural constraints that will affect the design.
The site survey is not a sales visit. It is a structural assessment. The outputs of a good site survey include: confirmed internal dimensions and ceiling height at all relevant points, slab condition and any areas where additional slab investigation may be needed, positions of existing structural columns or services that affect where mezzanine columns can go, fire exit positions and the travel distance calculation for escape route planning, and the operational constraints from vehicle routes, racking positions and production equipment.
We provide free site surveys across the whole of the UK, at no charge and with no obligation to proceed.
Stage 2: Structural design and drawings (weeks 1-2)
Following the site survey, our structural engineers produce the design for the mezzanine floor. This includes the column grid, primary and secondary beam layout, staircase position and specification, edge protection type and positions, pallet gate locations, and fire protection layout if required.
The drawings are produced in CAD and submitted to the client for review and approval before any Building Regulations application is made or materials ordered. This is the stage where column positions are confirmed against the ground floor operational layout, staircase positions are agreed, and any changes to the initial brief are incorporated.
Structural calculations are produced alongside the drawings. These confirm that the column sections, beam sizes and connections are adequate for the design loads. For industrial projects with complex dynamic loads or high load ratings, specialist calculation is carried out for point loads from racking uprights and machinery feet.
Stage 3: Building Regulations application (weeks 2-3)
Western Industrial submits the Building Regulations application to an approved private Building Control Inspector on behalf of every client. We manage all correspondence and documentation. In most cases, work on site can begin within 48 hours of the application being submitted.
The Building Regulations application includes the structural calculations, fire strategy drawings where fire protection is required, staircase dimensions and edge protection specification, and disabled access assessment where applicable. Building Control approve the design in principle at application stage and inspect the installation on site during and at completion.
Read more about Building Regulations for mezzanine floors here
Stage 4: Fabrication (weeks 3-5)
Once the design is approved and the Building Regulations application submitted, fabrication begins. All structural steelwork is manufactured as a prefabricated kit to the dimensions in the approved drawings. Column sections are cut to length, primary and secondary beams are fabricated with the correct connections, and all components are UKCA-marked in accordance with BS EN 1090.
Fabrication typically takes two to four weeks depending on the size and complexity of the project. During this period, ancillary components are also sourced and prepared: deck boards, staircase components, balustrade, pallet gates and access systems.
Read more about UKCA-marked steelwork here
Stage 5: On-site installation (days to weeks depending on scale)
Installation is a bolt-together process. There is no welding or heavy construction work inside the building. The prefabricated components arrive on site and are assembled using the approved drawings as the reference. Column base plates are fixed to the floor slab, primary beams are connected to column heads, secondary joists span between primary beams, and deck boards are laid and fixed across the joist grid.
Typical installation times:
- Storage mezzanine, 50m², no fire protection: 2-3 days
- Warehouse mezzanine, 100m², with pallet gates and staircase: 3-5 days
- Office mezzanine, 100m², with fire protection and full fit-out: 2-3 weeks
- Industrial mezzanine, 200m²+, phased installation around live production: 2-4 weeks
Installation programmes are designed around the operational requirements of the building. We use out-of-hours working, phased installation and defined exclusion zones to minimise disruption to the business throughout.
Stage 6: Building Control inspection and sign-off
The Building Control Inspector visits during installation and at completion. The on-site inspection confirms that the installation matches the approved drawings, that the structural connections are correctly made, and that any fire protection, staircase dimensions and edge protection meet the specified standards.
Following the final inspection and sign-off, we provide a completion certificate as part of the handover documentation.
Stage 7: Handover documentation
At project completion, we provide a full handover pack including: UKCA Declaration of Performance for all structural steelwork, structural certificates confirming the design loads, material traceability documentation, Building Regulations completion certificate, load plate fixed to the mezzanine structure, as-built drawings, and fire protection specification and test certificates where applicable.
This documentation is the permanent record of the installation. It is what an insurer, a future tenant or a commercial lender may request if the building changes hands or is refinanced.
How long does the whole process take?
From first site survey to completed installation, a straightforward storage mezzanine typically takes four to six weeks. An office mezzanine with fire protection and fit-out takes six to ten weeks. A complex industrial installation with CDM requirements and phased delivery around a live production schedule can take three to four months.
The longest stage is usually fabrication, not installation. The on-site time is a small proportion of the overall programme.
Contact us to discuss your project and get a realistic programme for your specific requirements.
Frequently asked questions about the mezzanine floor installation process
A standard storage mezzanine of around 50m² takes approximately two to three days on site. The full process from survey to handover typically takes four to six weeks. Larger floors with fire protection and fit-out take longer. We provide a clear programme at the quotation stage.
Yes. Mezzanine floors are assembled from prefabricated bolt-together kits with no welding or heavy construction inside the building. We design installation programmes around your operating hours, using out-of-hours working and phased installation where needed.
We measure the building, check the floor slab condition, map the operational layout, identify structural constraints, and assess the ceiling height and fire exit positions. The survey is free and takes one to two hours. It is the basis for the structural design and Building Regulations application.
Clear the area where the mezzanine will be installed as much as practicable. Confirm vehicle access to the building for materials delivery. Identify your main operational constraints (production schedule, trading hours, vehicle routes) so we can design the installation programme around them.
Western Industrial manages the full Building Regulations application on your behalf as a standard part of every project, at no additional charge. We submit the application, manage all correspondence with the Building Control Inspector, and provide the completion certificate at handover.
“Could not be more impressed by this company or David Moore. Extremely professional throughout. Access to great products and tradesmen that have totally transformed our office space. HIGHLY RECOMMENDED.”
— Google Review, 5★
“Western Industrial added a mezzanine floor to our warehouse, allowing us to make much better use of our space. Paul’s team were very reliable, and the mezzanine was constructed very quickly and to a high standard. Highly recommended!”
— Google Review, 5★
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Western Industrial | Designing, Supplying & Installing Mezzanine Floors since 1979
Established in 1979, Western Industrial Group have grown to a dedicated & professional workforce, delivering consistently high quality services across a range of projects, large & small.
From Mezzanine Floors to Warehouse Storage and Racking, Western Industrial Business Interiors design, supply, manage and install, to provide you with a complete office refurbishment package.
We supply and install Mezzanine Floors, Office Partitioning, Air Conditioning, Ventilation & Suspended Ceilings, through to all your Electrical & Mechanical requirements.
