Specifying an MS Mezzanine Floor and Plant Steelwork in IMT Manesar

Plants in IMT Manesar were mostly built as single-storey sheds with high roofs, laid out when production volumes were lower. As lines are added, floor area runs out long before roof height does, and a steel mezzanine is the usual way to win space: for component storage, a packing area, a canteen or an office above the line. In Manesar, Gurugram district, the questions that decide a mezzanine are engineering ones, and they are easier to answer before the site visit than during it.

Five things to tell us before the visit

Decking choices

The deck surface follows the use. Chequered steel plate is tough and suits trolleys and heavy storage. Open steel grating lets light and sprinkler water through, which a fire officer may prefer over storage areas. Boarding over a steel deck suits offices and canteens where people walk in normal shoes. Each changes the weight the beams carry and so the MS mezzanine floor sections themselves.

Stairs, guards and gates

Every mezzanine needs safe access and safe edges. A straight steel stair with a staircase railing on both sides suits daily foot traffic; an MS spiral staircase saves floor space for occasional access to a store. Open edges need a guard rail with a toe board so nothing gets kicked onto the line below. Where a forklift loads pallets up, a pallet gate opens one side while the other stays closed. A stair that flexes underfoot after a year is covered under metal staircase wobbling.

Bolted or welded

Welding on site inside a running plant needs a hot-work permit and fire watch. A bolted mild steel mezzanine is cut, drilled and painted in the workshop, then assembled on site with little or no welding, which suits most plants here and allows it to be moved later.

Boundary gates and yard steel

Plot boundaries along the IMT sector roads take trucks all day. A wide MS sliding gate with sealed wheels on a concrete-set track handles that better than swing leaves, and a gate that drops or scrapes is covered under gate sagging and dragging. For yards exposed to rain, hot-dip galvanising under paint lasts far longer than paint alone.

How the job runs

The ₹99 site visit, usually within 24 to 48 hours of booking and adjusted against the bill, walks the bay with your team. The written quotation, valid for 3 days, follows within about two hours of the visit for simple work, or after the briefing points are settled for larger mezzanines. Fabrication starts after the 50% advance, and erection is planned around shift breaks or a shutdown.

See the IMT Manesar page, metal fabrication in Gurgaon, the metal fabrication catalogue and work for warehouses and factories. Our guide to comparing fabrication quotes helps when tenders come in. Older industrial units in Udyog Vihar raise similar questions.