Mezzanines

What load do the mezzanines support?

The metallic Tecrostar mezzanines of the S, M and L ranges support a uniformly distributed load of 200 kg/m² (that means that you can place a 200 kg distributed load on each square meter). This is the live load for residential uses according to the international regulations. The total maximum load will be 200 kg by the square meters of the mezzanine.

The XL mezzanines support higher loads, 500 kg/m² (considered as medium storage) and their usage is more industrial. However, they can also have a domestic use when more resistance and rigidity is required. The bearing board included in the XL kits is thicker, more resistant and allows point loads (pallet truck, racks) as well. Ask Tecrostar the permissible values of these point loads.


What are the available colours and finishes for the mezzanines?

The steel pieces of the structures, railing posts and stringers of the stairs are available in:

  • Black and white. Available in stock without additional costs.

  • Any RAL monolayer colour. The personalized colour has an additional cost formed by two different parts: a unique and fixed cost of 95 € that is specified after adding the items to the cart, and a percentage cost that is specified in the price of each product when choosing RAL colour option.

The delivery time of the personalized colour option is longer than usual, so it is recommended to ask the Customer Service Department about the delivery times.

In both cases the paint is a lacquer with maximum adhesion applied by electrostatic process with polyester powder paint, suitable for outdoors.


Does the kit include the flooring boards?

Yes, it does. They are structural boards made of 18mm thick european radiata pine plywood. They have tongue-and-groove joints in their four sides.

Length: 2335 mm

Width: 610 mm

Thickness: 18 mm


Is the floor tailored? How does it fit to my dimensions?

The kit includes as many boards as needed to install the mezzanine in its maximum dimensions. To install the mezzanine in smaller dimensions, it is necessary to cut the boards as it is explained in the installation manual included in the mezzanine kit. Cutting the boards is really easy and all the required tools are available at our online store as well.


Is there any other alternative to the wooden floor?

No. Tecrostar does not have a different flooring alternative. However, it is possible to personalize the finish of the floor by adding some accessories on the boards (carpet, platform,...). Check our floor finishes in accessories section. If the customer installs a different floor from the boards provided, it is their responsibility to ensure the resistance of the full mezzanine, since the floor contributes to the stability of the whole.


Can I close the mezzanine with plasterboards?

Plasterboard is a low density material, so you can make a closing wall on top of the mezzanine. You can also close the lower part of the mezzanine when mezzanine is indoors. When this closing wall is made in mezzanines installed in the exterior, you should consult tecrostar, since lateral wind load can cause the structure needs stability kits.


Can I have two heights?

No, you can’t. At the moment, our mezzanines are available just for a single height although some customers install them on another existing mezzanine. In that case, the resistance of the existing one should be checked.


What load can support the beams if I hang something from them? (E.g. a punching bag)

It depends on the beam type, we need to calculate the corresponding surface load. For example, a secondary beam TM15 supports around 560 kg. You should take into account that if we apply additional loads, a part of the bearing capacity of the beam is being consumed.

If you have any doubt about important additional loads, contact our technical department.


Can I install a Tecrostar mezzanine outdoors?

TecroStar products can be installed outdoors (in the open), provided that the following considerations are taken into account, which define the structural, environmental and material maintenance calculation conditions.

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Structural Calculation Considerations

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Outdoor installation involves forces due to snow and wind, which depend on the geographical location, altitude of the site, etc. These actions have been taken into account in the calculation, with certain maximum values that must be compared with those of the area where it is installed, to ensure that these limits are not exceeded.

The value of the snow load corresponding to the zone must be subtracted from the use overload supported by the mezzanine to the dimensions that have been installed. As a guide value, TecroStar structures can be considered to withstand a minimum use overload of 200 kg/m², and therefore the load of snow that a mezzanine can withstand outdoors is very high.

The mezzanine can be installed as a canopy outdoors by installing the stability kit, contemplating the case of a complete obstruction when it is placed against a façade, or free if it allows air to pass through its lower part. A wind speed of 100 km/h is taken as a reference. The regulations of each locality must be consulted to check that these limits are not exceeded.

Under no circumstances should the sides of the building be closed, as this implies greater horizontal forces that are not included in the calculation.

The columns of the mezzanine must be fixed to a solid base that resists the actions transmitted by the mezzanine. TecroStar offers guidance as to the type of footing or foundation required under the columns, but it is the customer's responsibility to check the final strength of the terrain.

When the mezzanine is required to be placed on a grass or soil type surface, some type of footing will be necessary. The modular foundation system shown below may be a good solution, although it is up to the client to check it through the technician responsible for the project https://piloedre.es/

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Environmental conditions and performance of materials

The metallic steel pieces are lacquered with paints suitable for exteriors. TecroStar structures have a thermosetting polyester polymerised powder coating, with a coating thickness between 60 and 80 microns.

Corrosivity category C2 has been obtained, of medium durability, when submitting the pieces to the tests, according to the criteria of the European Norm EN ISO 12944 of May 1998: "Protection of steel structures against corrosion by means of protective painting systems". Examples of typical environments for corrosivity category C2:

● Interiors: buildings without heating where can be condensations (warehouses, sports centres,…)

● Outdoor: atmospheres with low pollution levels. Mostly, rural regions.

The medium durability of the lacquer covers a period of 5 to 15 years. The standard states that durability is NOT a "warranty period". Durability is a technical consideration that can help the owner establish a maintenance programme. That is, tests are performed for a specified number of hours under uniform conditions applied to smooth surfaces. The reality is that climatic and environmental conditions are very variable.

It is to be expected that after some time the structure requires retouches of painting on small zones, like edges or corners that can present beginning of oxidation and loss of the brightness. It is recommended to polish these areas to remove the rust and then apply the paint. The edges of steel parts are the parts most prone to corrosion and where rust first appears, in fact, these areas are not evaluated in salt spray tests, as the standard does not contemplate them.

TecroStar does not advise the use of metallic parts painted in white for exteriors, since the appearance of rust is appreciated much earlier than in black.

When the visual inspection indicates that paint retouching is required, careful attention should be paid to all edges or corners that may show signs of oxidation and loss of gloss. It is recommended to polish these areas to remove the rust and then apply the paint.

If the mezzanine is to be installed outdoors in a marine or coastal environment, maintenance recommendations should be carried out more frequently, due to the corrosive power produced by the existence of salt and moisture. Try to control the oxidation process to avoid further deterioration. In this case, it is recommended to polish the affected areas to remove the rust and then apply the paint.

The aluminium handrails of the rails do not require any special maintenance, as all of them are subjected to surface treatments that guarantee their outdoor performance (anodised silver, black lacquer or with a wood effect).

The load-bearing floor of TecroStar mezzanines consists of structural plywood panels. It is intended for indoor use in a humid or protected outdoor environment in accordance with EN 636-1-S. The customer must apply a lasur* or specific waterproofing treatment for wood to the floor and to the exposed edges, which protects the surface and prevents water from penetrating into the tongue and groove joints of the panels and affecting the edges.

Likewise, all wood pieces (steps, wooden strips, etc.) must be treated with some type of water-resistant paint or varnish to prevent moisture from penetrating and the material from cracking, and therefore losing its mechanical and aesthetic characteristics.

The wood pieces should also be maintained, checking that the applied surface protections (varnishes or paints) have not deteriorated, and treating them if necessary.

The presence of water in puddles or “ponds” on the mezzanine should be avoided. To that end, the mezzanine should be installed with a slight slope to facilitate the water evacuation and to avoid its accumulation (approximately 2%). This unevenness can be achieved by installing levelling plates under the highest pillars of the structure. Drains can also be created for the same purpose.

 * It is a product for outdoor uses that is more appropriate than varnish because it offers a high resistance, does not create a layer on the surface it is applied, controls humidity, gives a waxy finish and provides a wide range of finishes.



Can the mezzanine be installed without columns or removing a column? Attached to walls

No, our mezzanines are sold with columns by default. We cannot guarantee the resistance of walls or corbels and the customer will be responsible if the product is modified in these cases.


What is the diameter of the columns and measurements of the bases?

Pilars

The columns of the XL and L mezzanines are square shaped and are made of structural-quality materials. Consequently, they have a fabrication mark related to the traceability which indicates the heat number, steel type,…


Can I install the mezzanine in a sloped floor?

Yes. Provided that the inclination is small, we can use a wedge under the mezzanine columns to level it. If the inclination is too small it might be not necessary at all and the slope might be imperceptible.


Can I install it in a room with trapezoidal or irregular walls?
Yes, you can, because the structure does not need to be in total contact with the wall.

You can adjust the structural floor, working around architectural barriers or irregular surfaces.

When the walls are irregular or when you want to work around a fixed object, the decking can be finished off against the wall

Adjustment from below:

Adjustment from above:


Can I install the mezzanine at a lower or higher height than indicated?

It is possible at lower height but it requires to cut the columns and drill again though. At higher height is not possible. The cut of the columns can be done by the customer or you can order Tecrostar to do it upon request for a quote.


Can it be installed as an extension to an existing mezzanine?

Yes. This is quite common and the results are very good. The telescopic system of the columns enables the height to be adjusted every 6 cm.


Can I install a mezzanine making modifications of it?

You can make aesthetic modifications, but any structural modification non approved by Tecrostar will be under customer’s responsibility.


Can the columns be installed moved to the corners?
Yes. The columns can be moved to the corners up to ¼ of the total length of the structure. This feature allows you to work around the walls, switches or furniture you have on site without compromising safety.

Can I add extra columns to distribute the weight?

Yes, you can. However, the maximum load capacity will be unaffected.


Waterproof treatment of Steel

This treatment provides the steel pieces an additional protection that increases their durability in weather conditions that cause corrosion.

It consists of a cold-dip galvanizing or electrolytic zinc coating, whereby the steel pieces are covered with a thin zinc layer, between 8 and 15 um, in a low temperature bath. Subsequently, it is added a passivation using chromium that increases the protection and, finally, a sealing is made.

This zinc coating process differs from cold-dip galvanizing and avoids the pieces from deformation by heat and their holes from blockage, providing a much softer and more appropriate finish for the use of Tecrostar products.

After applying the zinc coating, the pieces are lacquered with the high-quality standard process typical of Tecrostar, with powder-coating paint, to obtain a perfect finish in the colour desired by the customer, also increasing the corrosion protection by creating a barrier (steel + zinc plating + lacquering).

With the TecroStar waterproof steel treatment, a high level of protection is achieved on steel parts, obtaining the following rating:

  • Corrosivity category C4 with Low durability.

  • Corrosivity category C3 with Medium durability

  • Corrosivity category C2 with High durability

Durability is obtained by testing the parts according to the criteria of the European Standard EN ISO 12944. The standard indicates that durability is NOT a "warranty period". Durability is a technical consideration that can help the owner to establish a maintenance programme. That is, tests are performed for a given number of hours under uniform conditions applied to smooth surfaces. The reality is that climatic and environmental conditions are highly variable.

Durability

Period

Low

2 to 5 years

Medium

5 to 15 years

High

More than 15 years

It should be taken into consideration that the guarantee of our treatments is given on the basis of laboratory conditions, which are the hours without rust appearing in a salt fog chamber, but every real location may imply a different kind of exposure. Therefore, we provide an extract from the European standard EN ISO 12944 of May 1998 "Protection of steel structures against corrosion by means of protective paint systems", where you can see some examples of typical environments.


Corrosivity Categories

Examples of typical environments in a warm weather (informative)

Exterior

Interior

C1

Very Low

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Heated buildings with clean atmospheres, e.g.  offices, shops, schools, hotels 

C2

Low

Atmospheres with low level of pollution: mostly rural areas

Unheated buildings where condensation can occur, e.g., depots, sports halls

C3

Medium

Urban and industrial atmospheres, moderate sulfur dioxide pollution; coastal areas with low salinity

Production rooms with high humidity and some air pollution, e.g., food-processing plants, laundries, breweries, dairies

C4

High

Industrial areas and coastal areas with moderate salinity

Chemical plants, swimming pools, coastal ship- and boatyards

C5-I

Very High

(Industrial)

Industrial areas with high humidity and aggressive atmosphere

Buildings or areas with almost permanent condensation and with high pollution

When visual inspection indicates that touch-up painting is required, close attention should be paid to any edges or corners that may show the beginnings of rust and loss of gloss. It is recommended to polish these areas to remove the rust and then apply the paint. The edges of steel parts are most prone parts to corrosion and where rust first appears, in fact, these areas are not evaluated in the salt fog tests, as they are not covered by the standard.