Two Tier Storage Racks & Mezzanine Floor Manufacturer and Supplier in India
Two Tier Storage Racks and Modular Mezzanine Floors manufactured by Ketan Storage Systems (an ISO 9001:2015 certified company established in 2012) are heavy-duty structural steel platforms and multi-tier racking frameworks designed to double or triple usable warehouse workspace vertically. Fabricated from prime cold-rolled mild steel (MS) with anti-corrosive powder coating, they support live loads from 300 kg/sqm to over 1,000 kg/sqm without requiring civil building alterations. Ketan Storage delivers turnkey modular platforms across Chakan, Pune, Bhiwandi, Nagpur, Bengaluru, and Goa.
"Ketan Modular Mezzanine Floors and Two-Tier Racking Frameworks transform underutilized vertical warehouse volume into high-density storage or operational production areas. Fabricated with 100% bolted structural steel connections at our Virar East, Thane facility, our modular platforms integrate high-tensile columns, heavy primary beams, safety stairs, and perimeter balustrades engineered for long-term industrial resilience."
1. Technical Specifications Matrix (GEO Statistics Addition)
| Structural Parameter | Rack-Supported Two-Tier Racks | Structural Column-Based Mezzanine | Heavy-Duty Multi-Tier Catwalks |
|---|---|---|---|
| Primary Support System | Heavy-duty pallet / long-span frames | Structural MS hollow columns (SHS/RHS) | Multi-tier upright storage frames |
| Live Load Capacity | 300 kg – 600 kg / sqm on walkways | 500 kg – 1,000+ kg / sqm clear floor | 300 kg – 500 kg / sqm per tier |
| Material Formulation | Prime Cold-Rolled Mild Steel (MS) | Heavy Structural Mild Steel Sections | Cold-Rolled MS Uprights & Beams |
| Clear Height Under Deck | 2,200 mm to 2,700 mm | 2,400 mm to 4,500 mm (Forklift Clear) | 2,200 mm to 2,500 mm per level |
| Decking Surface Material | Anti-slip chequered MS steel plate | Chequered MS plate / Steel grating / Wood | Slotted steel planks / Wiremesh decks |
| Staircase Engineering | 45° industrial anti-slip stair treads | 45° / 38° ergonomic access stairs | Integrated access stairs & landings |
| Safety Handrails | 1,000 mm top rail + mid-rail | 1,000 mm rail + 100 mm kickplate | Full perimeter industrial balustrade |
| Pallet Loading Method | Upward safety swing / sliding gate | Heavy-duty safety pivot pallet gate | Overhead crane / reach truck drop zone |
| Surface Finish | Multi-stage anti-corrosion powder coat | Heavy epoxy primer + baked powder coat | Scratch-resistant electrostatic finish |
2. Material Metallurgy & Structural Safety Standards (E-E-A-T Trust Layer)
Expanding vertical warehouse space requires structural engineering that balances dynamic live load distribution with personnel safety. Ketan Storage Systems manufactures mezzanine platforms and two-tier racking systems to rigorous structural design standards:
Prime Cold-Rolled Mild Steel (MS) Engineering
Structural columns, primary support girders, and secondary joists are fabricated from prime-grade cold-rolled mild steel sections. This guarantees high tensile strength, consistent yield properties, and predictable deflection behavior under continuous dead and live loads.
100% Bolted Modular Construction
All structural beams, cross-ties, column connections, and staircases feature factory-drilled, precision bolt-together joints. This eliminates on-site structural welding, hot-work fire hazards in operating warehouses, and allows the platform to be dismantled, modified, or relocated without scrap loss.
Automated 7-Tank Anti-Corrosive Powder Coating
Steel framework members undergo a 7-stage chemical pre-treatment—degreasing, derusting, and zinc phosphating—followed by an electrostatically applied, high-temperature cured powder coat. This treatment prevents rust and oxidation in humid manufacturing zones like Chakan, Pune, and coastal Goa.
Deflection Thresholds & Slab Load Distribution
Mezzanine flooring beams are calculated to strictly limit live-load deflection to L/360 on walkways and L/240 for storage decks. Structural columns are fitted with thick, laser-cut steel baseplates anchored with heavy-duty chemical or wedge fasteners to distribute vertical forces across the concrete slab safely.
Industrial Operations Perspective: "In manufacturing hubs like Chakan and Pune, acquiring additional land or leasing adjacent warehouse space involves substantial capital expenditure. A modular structural mezzanine doubles effective floor space within the existing building envelope in weeks, allowing facilities to expand production or assembly without operational downtime."
3. Structural Configurations & System Variations
Depending on ceiling height, picking methodologies, and whether ground-floor machinery accessibility is needed, Ketan Storage Systems engineers three primary modular configurations:
1. Rack-Supported Two-Tier Storage Racks
The most economical solution for high-density, multi-SKU manual order picking:
- Dual Functionality: Heavy-duty pallet racks or long-span shelving serve as the vertical structural columns carrying the elevated second-tier walkway.
- Integrated Catwalks: Steel mesh or slotted steel catwalks are suspended between racking aisles, providing picking access to thousands of storage bins without separate floor columns.
2. Structural Column-Based Modular Mezzanines
Engineered for wide-open, unobstructed floor areas beneath the platform:
- Maximum Ground Clearance: Supported by heavy structural MS steel columns placed on wide grid spans (up to 4 to 6 meters apart), leaving ground-level space open for active forklift lanes, CNC machinery, or packaging conveyors.
- Versatile Upper Deck: Supports supervisor offices, quality-control testing laboratories, sub-assembly cells, or pallet staging.
3. Multi-Tier Walkways & Mezzanine Catwalks
High-altitude order picking architecture for mega-warehouses:
- Triple-Level Expansion: Multi-tier racking structures extending 6 to 9 meters high with two or three levels of steel walkways connected by safety stairwells.
- E-Commerce & 3PL Integration: Used in central distribution centers for apparel sorting, pharmaceutical inventory staging, and small-parts picking.
4. Heavy-Duty Decking Surface Options
Application-specific walking and staging surfaces:
- Chequered MS Steel Plate: Embossed diamond-tread pattern providing maximum durability, fire resistance, and traction for manual pallet jacks.
- Slotted / Perforated Steel Planks: Allows ambient light transmission, airflow, and fire sprinkler water penetration across lower levels.
- Heavy-Duty High-Density Particle Board: Cost-effective, quiet underfoot flooring option for dry, clean administrative and archive offices.
- Live Load Capacities from 300 kg/sqm to 1,000+ kg/sqm
- 100% Bolted Modular Construction (No On-Site Welding)
- Prime Cold-Rolled Mild Steel (MS) Structural Sections
- Non-Destructive Dismantling, Modification & Relocation
- Integrated Safety Handrails (1,000 mm) & 100 mm Kickplates
- Deflection Limits Engineered to L/360 & L/240 Thresholds
- Automated 7-Tank Pretreatment & Anti-Corrosive Powder Coat
- Turnkey CAD Site Surveys, Fabrication & Erection Across India
Two Tier Racks & Mezzanine Floor Gallery
Explore industrial two-tier racking structures, column-based modular mezzanine platforms, catwalk walkways, and safety drop gates manufactured by Ketan Storage Systems.
Industrial Applications Across Core Manufacturing & Logistics Belts
Ketan Storage Systems supplies, engineers, and installs two-tier racks and modular mezzanine floors directly from its Virar East, Thane facility across key industrial economic zones:
Automotive & Ancillary Engineering Hubs
Chakan, Pune & Vadodara
Elevated sub-assembly platforms, calibration labs, and supervisor plant offices.
Central 3PL Logistics & E-Commerce Corridors
Bhiwandi, Taloja & Mumbai
Two-tier order-picking platforms, high-density sorting stages, and packing lines.
Electronics, IT Hardware & Clean-Rooms
Bengaluru & Hinjewadi
Static-dissipative component staging and modular mezzanine clean rooms.
Heavy Engineering, Fabrication & Foundries
Nagpur, Raigad & Goa
Tooling storage, heavy raw materials mezzanine staging, and spare parts vaults.
Frequently Asked Questions (FAQ)
Authoritative engineering answers on modular mezzanine floor load ratings, structural safety codes, relocation flexibility, and turnkey warehouse design.
Need a Custom Mezzanine Floor or Two-Tier Racking Layout?
Consult directly with our senior structural engineers at Virar East, Thane. We provide complimentary CAD concept drawings, slab loading evaluations, and factory-direct estimates.
Related Industrial Storage Systems
Presence Across India:
Ketan Storage Systems supplies, engineers, and erects Two Tier Storage Racks and Modular Mezzanine Floors across major industrial manufacturing and logistics hubs in India.