Composite concrete decking – heavy-duty performance for your mezzanine

Composite concrete flooring is ideal for companies installing a mezzanine to carry a heavy load, and suits sectors as diverse as food production and car manufacture.

It has extensive benefits. Cast onto high-grade galvanised steel, its durability and strength makes it suitable for industrial environments with heavy-duty machinery, as well as warehouses and logistics premises.

Strong, waterproof and fire resistant

The galvanised steel’s ridge-cut design allows it to withstand higher loads and provide stronger structural support than other mezzanine decking options: loadings can be up to 3000 kg/m2.

composite concrete diagram

Strength is not its only asset, however. Composite concrete decking is waterproof and moisture resistant, perfect for food production sites where the concrete provides a hygienic, extremely easy-to-clean surface. In these settings timber flooring is unsuitable because areas are frequently washed down, and there can be no risk of splinters getting into food.

These qualities made composite concrete flooring the right solution for snack box maker Graze, and Hi-Level Mezzanines was delighted to install it at the company’s premises in Hayes, Middlesex.

Another example is our mezzanine floor installation for Jaguar Land Rover as it expanded its pre-production line in Coventry. For its new laboratory the carmaker wanted a stiffer floor that could take heavier loads with minimum vibration. Composite concrete also offers water resistance, soundproofing and fire protection.

The brief required a bespoke design to provide a mezzanine over a single level that was future proofed to produce additional storage for the parts department. It was particularly important to provide clear areas on the ground floor so that production equipment could be brought in and positioned where required.

Unique solution

Hi-Level’s creative approach and previous success in providing mezzanine floors to fulfil highly specific requirements was invaluable, as composite concrete decking needs advanced engineering skills. In this case we had to take into account:

  • Decking to take very high point loads across the entire area
  • Clear areas to the ground floor for maximum flexibility
  • Positioning on the existing low-capacity floor slab

Hi-Level engineers always calculate whether foundations are needed to carry the load, as composite concrete flooring can be as heavy as the weight it is carrying.

Our 30 years of engineering expertise explain why we are uniquely able to offer this solution.

In the case of Jaguar Land Rover,a wide-span structure was required to provide clear space beneath the mezzanine, which meant markedly fewer ground floor columns than usual with consequently higher column loads for the slab to cope with.

Our solution was to design and supply pile foundations beneath the column baseplates, creating a seamless integration into the existing slab.

“This was a project where Hi-Level’s expert engineers produced a design that was greatly beneficial to JLR’s productivity and overall logistical performance. We ensured that we met all the specific requirements Jaguar Land Rover had set out with minimal disruption to their operations. Both Hi-Level and our client were delighted with the finished product.”

Hi-Level Project Manager

Thanks to galvanised steel’s high quality and long product life, our concrete flooring system is highly durable and has fantastic longevity, meaning the benefits will last for many years to come.

Benefits of our composite concrete flooring for mezzanine decking

composite concrete flooring
  • Very high loading up to 3000 kg/m2
  • Extremely durable and strong
  • Fire and sound resistant
  • Waterproof
  • Minimal vibration
  • Reduced wear
  • Anti-slip

Uses of composite concrete flooring for mezzanine decking

mezzanine with composite concrete decking
  • Warehouse and Logistics
  • Industrial Floors
  • Automation and Manufacturing
  • Commercial Buildings

All our floors are designed bespoke to the requirements of each customer.

Hi-Level Mezzanines has the expertise for the longevity, durability and safety of mezzanine solutions to fit your requirements.

For more information on how to optimise your space with a mezzanine solution, please contact us at or call 01730 237 190.

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