Pakistan 4-Tier Longspan Shelving Racks for 30x20x10m Warehouse 700kg per Shelf Mezzanine Project

Project Overview

A Pakistan-based distribution company approached our engineering team with a clear challenge: a newly constructed warehouse measuring 30 meters long, 20 meters wide and 10 meters high that needed far more usable storage than a single ground floor could offer. Rather than pouring expensive concrete mezzanine slabs, the client wanted to convert the building's generous height into storage by dividing it into four evenly spaced tiers, each one fitted with steel longspan panel shelving. The result is a high-density, cost-efficient multi-level storage system that multiplies the original floor area without altering the building structure.

Client Requirements

Every design decision was driven by the client's detailed specification, which we captured precisely before engineering began:

• Divide the 30 x 20 x 10 m warehouse into four evenly divided tiers.
• Use steel panel shelving (longspan shelving) on every tier instead of concrete mezzanine floors.
• Each shelf level sized at D 1000 mm x L 2400 mm x H 500-600 mm.
• Load capacity of 700 kg per shelf level.
• Provide one staircase for each tier to guarantee safe, quick operator access.
• Reserve a dedicated zone in the center of the building for a future elevator.
• Keep the upper-tier aisles wide enough for manual pallet trucks to travel through.
• The bottom level of each tier must stand directly on the ground, with no floor slab.
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Our Solution

We engineered a four-tier steel longspan shelving system built around the client's exact footprint. Each tier is constructed from heavy-gauge cold-rolled steel uprights and step beams, forming a rigid, fully bolted structure that carries the shelf loads directly to the floor without any suspended concrete slab. The ground-supported design keeps the load path simple, reduces civil work and shortens the project timeline.

The shelf levels use durable steel panels, giving a smooth, flat surface that protects cartons and packaged goods while making picking fast and comfortable. Upright frames and beams are powder-coated for corrosion and rust resistance, which is essential in Pakistan's hot, dusty warehouse conditions.

Accessibility and safe circulation were treated as first-class requirements. Each tier is served by its own staircase, so operators can move between levels without returning to a single central stair. The center of the building is left clear as an elevator zone, giving the client the flexibility to install a lift later as throughput grows. Aisle widths on the upper tiers were dimensioned to let manual pallet trucks roll freely, ensuring smooth put-away and order picking on every level.

Technical Specifications

Design Highlights

• Four-tier density: Turns a single-floor building into four usable storage levels, maximizing cubic space.
• No concrete mezzanine: Ground-supported shelving avoids costly slabs and simplifies installation.
• 700 kg shelf load: Engineered beams and uprights safely handle heavy cartons and packaged stock.
• Tier-by-tier staircases: Direct access on each level improves safety and picking speed.
• Future elevator-ready: A reserved central zone keeps expansion options open.
• Manual pallet truck aisles: Comfortable working widths on every upper level.

Project Outcome

By combining longspan shelving with a smart multi-tier layout, the Pakistan client gained a storage system that dramatically increases pallet and carton capacity within the same 30 x 20 m footprint, all without a heavy concrete investment. The modular design also means the configuration can be adjusted, extended or relocated as the client's business evolves.

Looking for a similar multi-tier shelving or mezzanine project? Contact our engineering team for a tailored solution and a fast quotation.