Mezzanines
At Tecrostar we define the load evenly distributed per square metre. Therefore, the load capacity of mezzanines varies according to each model and its size. For detailed information on the load capacity of a particular mezzanine, we recommend consulting the corresponding technical datasheet.
In the case of some sturdier models, such as the XL Range, we also define the admissible concentrated point loads. These loads depend to a large extent on the board we use as the mezzanine floor, as it is the component that directly receives the load. Specific information on point loads can be found in the product description.
Steel parts such as frames, handrail posts and stair stringers are coated with an electrostatic polyester powder paint coating process for maximum adhesion, available in:
- White. Available from stock at no extra cost (RAL: 9016).
- Black. Available from stock at no extra cost (RAL: 9005).
- Any single-coat colour from the RAL range at additional cost and upon request. Please enquire about delivery times.
The mezzanines in the XL Range are available in:
- Yellow and black. Available from stock at no extra cost (RAL: 9005 and 1003).
- Any single-coat colour from the RAL range at an additional cost and upon request. Please enquire about delivery times.
This type of coating is perfect for indoor use. If you plan to install the mezzanine outdoors, we recommend consulting Can I install a Tecrostar mezzanine outdoors? This section contains information and recommendations to consider in order to improve its performance and durability.
Yes, the mezzanine floor is included.
For the S, M and L ranges we use 18 mm pine plywood structural panels, with tongue and groove joints on all four sides.
In the XL range, we use P5 HYDRO high-density particle board structural panels, with tongue and groove joints on all four sides and 35 mm thick.
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.
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.
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.
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.
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.
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.
Products with wooden components and load-bearing floors can be installed outdoors or in humid environments when a specific waterproofing treatment for wood is applied and maintenance is carried out on a regular basis.
It is not advisable to install products with electrical components outdoors.
If you want to install Tecrostar products outdoors or in humid environments, we recommend you to request the waterproof treatment that provides additional protection to the steel parts, increasing their durability against those atmospheric conditions that can cause corrosion.
Structural Calculation Considerations
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/
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.
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.
*The columns of the XL and L mezzanines are made of structural-quality materials. Consequently, they have a fabrication mark related to the traceability which indicates the heat number, steel type,…
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.
Yes, you can because the structure does not to be in full contact with the wall. When the walls are irregular or when you want to work around a fixed object, the boards can be finished off against the wall. These factors must be taken into account:
- When the distance between the mezzanine and the wall is less than 10 cm, you can cover that surface with the board.
- From 10 cm to 30 cm, it is necessary to use the board flight support. You should buy as many supports as necessary according to the length of the surface you want to cover.
- For gaps greater than 30 cm, please contact the technical department.
The total board surface included with the mezzanines only covers the maximum surface area of the mezzanine floor. You can add panels to cover this additional surface.
Yes, it is possible to reduce the height but not to increase the maximum position.
To reduce the height of S and M mezzanines, you can ask the technical department for a type of short column. With their use the telescopic and adjustable system is maintained, but the maximum and minimum positions of the structure are reduced.
Depending on how short the mezzanine needs to be, the customer may have to make a simple cut on these columns.
To reduce the height of L and XL mezzanines, a special cut must be made. You can order this cut from Tecrostar and we will send you a personalized quotation.
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.
You can make aesthetic modifications, but any structural modification non approved by Tecrostar will be under customer’s responsibility.
Yes. The columns can be moved to the corners up to 1/5 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.
Yes, you can. However, the maximum load capacity will be unaffected.
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.
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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
--
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.