Building an MS Mezzanine Inside a Running Factory in Noida's Sector 63 Belt

The garment, electronics, printing and warehousing units of Sectors 57, 58, 59, 63, 64 and 65 tend to run out of floor long before they run out of height. The area page sets out what decides a mezzanine's design. This page follows the build itself: what the deck is made of, how the columns meet an existing floor, and how the steel goes up without stopping the line below.

Choosing the deck

• Chequered steel plate takes trolleys and heavy point loads and shrugs off oil, which suits stores and assembly areas.
• Open grating lets light and air through to the floor below, but small parts fall through it.
• Boards on steel joists give a quieter, flatter surface for offices, sampling rooms and carton storage.

The deck choice changes the joist spacing and the steel weight, so it is settled before the frame is designed.

Where the columns land

Each column stands on a steel base plate anchored into the existing floor. Factory floors vary: some are thick slabs built for machines, others a thin screed over earth. The survey checks the floor, and where it is weak, larger plates spread the load or local footings are cast first. Columns also have to dodge drains, cable trenches and the forklift lanes that run under the deck, and the clear height below must still suit the people and machines working there.

Made outside, bolted in

Sections are cut, drilled and primed in the workshop, then bolted together on site. Bolting keeps hot work inside the unit to a minimum, which matters in a garment unit full of fabric, and it shortens the time the floor below is disturbed. Erection can be planned for a weekend or between shifts. Any welding that is unavoidable is done with fire precautions agreed with you. Joints that are welded badly can crack under vibration; see welding joint cracked, and a stair that moves underfoot, metal staircase wobbling.

Gates for the truck entrance

Plots in the belt usually have a wide entrance for trucks. A sliding gate keeps the yard clear for turning vehicles, and steel used outdoors lasts longer with hot-dip galvanising under the paint. The MS gate price guide explains what sets the cost.

Before the survey

• A rough layout of the shed with column positions, doors and machines.
• The load: what goes on the deck and how it is moved.
• Your production schedule, so erection fits a shutdown or shift gap.
• A word with your fire consultant on whether the added floor affects your approvals.

The ₹99 survey is usually arranged within 24–48 hours and set against the final bill. A free, all-inclusive written quote follows within about two hours, valid for 3 days, and fabrication starts on a 50% advance, with the balance on completion. Every steel job is on metal fabrication in Noida and in the metal fabrication catalogue; unit-level detail is on warehouses and factories in Noida. The Sector 63 belt page covers shutters and sheds, and Sector 62 is next door.