Column Based Mezzanine system.

Work Method Statement (WMS)

‘Column Based Mezzanine System’

1
 Column Based Mezzanine system.

Document Changes
Revision Amended on Description
R0 March 2019 New Document
R1 April 2023 Points to be noted

2
 Column Based Mezzanine system.

Contents

1. Introduction............................................................................................................................... 4
2. Installation considerations ......................................................................................................... 5
3. Check list before start of Installation ........................................................................................ 6
3.1. Layout and Elevation Drawings ............................................................................................6
3.2. Area Demarcation ...............................................................................................................6
3.3. Site Survey and Floor Marking .............................................................................................6
3.4. Unloading & Materials Count ..............................................................................................7
3.5. Stacking Norms ...................................................................................................................7
4. Installation Procedures ............................................................................................................. 9
4.1. Point to be noted ................................................................................................................9
4.2. Measurement and Site Marking ..........................................................................................9
4.3. Tool Box Meeting ................................................................................................................9
4.4. Column Based Mezzanine ................................................................................................. 10
4.4.1. Column / Upright and Beam assembly ...................................................................... 10
4.4.2. Inter Beam Fixing ...................................................................................................... 12
4.4.3. Inter Inter Beam Fixing ............................................................................................. 14
4.4.4. Catwalk panels fixing ................................................................................................ 15
4.4.5. Tubular Knee Bracings............................................................................................... 16
4.5. Hand Rail Fixing ................................................................................................................ 17
4.6. Tie rod & Turn Buckle fixing .............................................................................................. 20
4.7. Stair case Assembly .......................................................................................................... 21
4.8. Grouting the Columns / Uprights ...................................................................................... 22
4.9. Accessories ...................................................................................................................... 22
5. Check point during Installation ................................................................................................. 23
5.1. Floor Marking ................................................................................................................... 23
5.2. Column / Upright and Beam Assembly .............................................................................. 23
5.3. Column Erection & Beam Fixing ........................................................................................ 23
5.4. Stability Members Fixing .................................................................................................. 23
5.5. Grouting .......................................................................................................................... 23
6. Reporting................................................................................................................................. 24
7. Inspection ................................................................................................................................ 25

3
 Column Based Mezzanine system.

8. System Installation Tolerance .................................................................................................... 27

9. Tools Required ......................................................................................................................... 28
10. Manpower Planning ................................................................................................................. 29
11. Handover ................................................................................................................................. 30

4
 Column based mezzanine system.

1. Introduction
This manual has been prepared as a step-by-step guide or installation of the Column Based Mezzanine system. This manual
covers the installation process to be followed at site, fixity of standard components used in Column Based Mezzanine
system and standard operating procedure to be followed during the installation. The success of the installation ultimately
depends on the experience and skills of the installation crew.

5
 Column based mezzanine system.
2. Installation considerations

• First Aid: Provision of a suitable First Aid Box at site

• Emergency Exit: Awareness to all workers on Emergency Exits and procedures. An emergency response
team shall be prepared and their name and contact numbers must be displayed at site. Once the customer
briefs its emergencyresponse procedures to the racking staffs, the workers will be provided a training on
the same.

• Risk Assessments: For every task of installation, identify the Risk involved and the necessary steps taken to
reduce the same to acceptable levels as per the Hazard Identification & Risk Assessment (HIRA) Sheet.

• Responsibilities:

▪ Project Head/Manager
➢ Supervising and overseeing the direction of the project, ensuring that the client’s
specifications and requirements are met, reviewing progress and maintaining the project
within the budget.
➢ Checking and preparing site reports, designs and drawings.
➢ Finding ways to prevent the problems and to solve the problem, if any, in short period of
time.
➢ Inspecting workplace to understand work progress and ensuring safety at site.

▪ Site Engineer/Site supervisor

➢ To ensure the work progresses as per the schedule.
➢ Is responsible in maintaining the quality of work.
➢ Reporting to project manager about the work progress.
➢ Responsible for maintaining the work environment secure, safe &healthy.
➢ To ensure and fulfil the needs of the workers.
➢ Maintaining weekly & monthly work progress report.

▪ Safety Officer/Supervisor
➢ To ensure the effective implementation WMS & HIRA.
➢ To ensure that all hand tools & portable power tools shall be of good condition and with
inspection labels, inspected by HSE in charge before the commencement of work
execution.
➢ To ensure that all workers are following the safety rules and wearing PPEs at site.
➢ Issuing the work permit after inspecting the site to ensure it is hazard free environment.
➢ Conducts toolbox meetings.
➢ To review and approve all relevant work permits.
➢ Promotes safe practices at the job site.
➢ Enforces safety guidelines

▪ Workers
➢ Comply with safety rules and regulations.
➢ Work safely and shall not do anything that can cause injury to himself.
➢ Ensure work tools, materials, and/or equipment including Personal Protective Equipment
(PPE) are used correctly and maintained in good serviceable conditions.
➢ Report any unusual occurrences and all defects of plant and equipment to your immediate
supervisor.
➢ Attend all Tool Box Meetings, other meetings and/or training relating the safety.
➢ Observe all written and verbal safety instructions issued from time to time by Safety
Manager and/or Safety Supervisor.
➢ Observe and obey all safety signs/notices.
➢ Keep work place clean and tidy.
6
 Column based mezzanine system.
➢ Seek medical assistance for all injuries
➢ Report to the medical Centre

• Safety Policy

7
 Column based mezzanine system.
• Waste Management Plan:
➢ Plastics, cardboards and railing pipe(metal) cut pieces shall be generated as scraps during execution
of the project.
➢ Earmark the scrap areas for different types of wastes after consultation with the customer.
➢ Appropriate signage to be displayed at scrap storage area.
➢ Make schedule for collection and disposal of wastes. Arrange a local vendor in removing scraps from
scrap yard on every alternate day of the week.
➢ All employees at site shall be informed and make aware of the waste disposal system.

• Work at height:
➢ All work at height above 2 meters from ground level without complete platforms, handrails and other
related fall protection shall require a work permit in the prescribed form. This shall require approval
by the competent authority.
➢ The Safety officer shall follow controls being mentioned in HIRA rigorously by physically verifying the
condition of the work area before recommending for approval.

▪ Mobile Scaffolds:
➢ Scaffolds shall be inspected for a safe use by a competent person.
➢ Scaffolding may be assembled, dismantled or significantly altered only under the supervision
of a competent supervisor and by persons who have received appropriate and specific
training in the operations envisaged which addresses specific risks which the operations may
entail and precautions to be taken, and more particularly in understanding of the plan for the
assembly, dismantling or alteration of the scaffolding concerned and safety during the
assembly, dismantling or alteration of the scaffolding concerned.
➢ The altered scaffold also to be checked thoroughly by safety person before taken for the use
of the scaffolds.
➢ Ensure Inspection and load test stability certificate of the mobile scaffold.
➢ Scaffold fittings and other connections should be securely tightened.
➢ Ensure tagging of the scaffold at regular intervals not exceeding seven days since the last
inspection.
➢ Guard-rail fitted to the work platform.
➢ Tower must not be overloaded.
➢ Wheels should be locked when the tower is in use.
➢ Care should be taken to avoid overheads when the tower is moved.

• Fire Prevention Plan:

➢ All should obey by ’No Naked Flame’ & ‘No Smoking’ policy.
➢ Area where Hot work activities are carried out (mainly cutting of railing pipes by grinding machine)
above working spot, a GI / fire-resistant non-asbestos sheet or suitable material shall be placed to
prevent the fall of hot sparks.
➢ A suitable type fire extinguisher shall be kept nearby while doing hot work.
➢ Hot work shall be preferably carried out in a designated area. The designated area shall have fire
extinguishers.
➢ All flammable material shall be kept away from hot work area.
➢ Tarpaulin/ plastic sheet/ any other inflammable material shall not be used for windshield for any hot
work.
➢ The fire extinguishers shall be inspected regularly for its availability and validity.
➢ Emergency telephone number to be displayed at all conspicuous place in site.
➢ All workers should be training on “safe hot work operations” and “usage of fire extinguisher”.

8
 Column based mezzanine system.

• Personal Protective Equipment: This includes the following but not limited to

❖ Helmets

❖ Safety Shoes

❖ Gloves

❖ Reflective Jackets

❖ Double Harness Safety Belts for Height work more than 2 mtrs

❖ Safety Goggles if required

❖ Hearing Protection

• Site Handling tools / Equipment: This includes the following but not limited to

❖ Measuring Tape

❖ Rubber Mallet

❖ Socket Drilling Machines with M12 Drill bits

❖ Hand Pallet Trucks

❖ Mobile scaffold

❖ Farana for Frame/Column Lifting

❖ Impact Wrenches with M6, M8, M10 & M12 – Hex Head

❖ Ring Spanners

❖ Trolleys

❖ LASER Measurement instrument

9
 Column based mezzanine system.

3. Check list before start of Installation

3.1. Layout and Elevation Drawings
The final layout and Elevation drawings of the system should be discussed with the Client as per Site conditions. The
Client must approve the Final drawings before start of the installation.

3.2. Area Demarcation

The installation Area and the assembly area must be identified for the smooth flow of installation and that area should be
clearly marked with warning that “Work is in progress”. The racking installation area must be hard barricaded by the
customer.

3.3. Site Survey and Floor Marking

Check for all sides of the warehouse & roof are in closed condition before start of the installation. If any of the sides are in
open condition, do not start the installation.

The flooring of the warehouse would be checked for flatness and waviness using Leveling instrument. The assembly of
Column / Uprights on irregular floor surfaces can pose a Safety Hazard for employees and materials stored.

The clear height availability needs to be checked before installing the system.

The system needs to be installed on a concrete slab and minimum floor slab thickness should be 150 mm to support the
grouting of columns/uprights. Floor level variation should not be more than ±5 mm.

Note: Customer should verify the thickness of floor slab with Landlord based on total designed load and responsible for
providing proper cement floor with adequate strength for installation

Marking of start point as per drawing with reference to Wall / Pillars. Marking of total Layout with Storage in floor using
permanent markers

Inspect the layout area to verify the Positioning of Civil pillars and distance between civil pillars as per drawing. Loss of
storage space and Aisle interference will be informed to customer and will take necessary approvals in prior before start
of work. Interference of Piping, Electrical Panels, trenches, ducts, lighting, Emergency Exit etc. will be checked and find
deviations if any.

10
 Column based mezzanine system.

3.1. Typical Photos of Floor Marking

3.1. Typical Photos of Floor Marking

Marking is done by using a thin strong thread / Wire (Line Dori) by stretching it between the end points
marked. This line is marked on the floor & a transparent tape is stuck over it on the floor to ensure
retention of marking on the floor.

SAFETY CHECK: Need to ensure that all workmen are wearing Safety Helmet, Safety Jacket and Safety
Shoes as basic PPEs for entering the site.

3.4. Unloading & Materials Count

Site Accessibility: The approach roads for Vehicles to reach the site will be cross checked for receipt
of Materials.

Review and count all mezzanine materials while unloading and compare them with the BOM / delivery
challan to make sure receipt of correct materials at site. Shortages if any will be informed to plant for
necessary replenishment. Inspect the materials to check the damages in transit and necessary actions
will be initiated for replacement if any.
SAFETY CHECK: Need to ensure the proper approach road for vehicle to reach unloading point. The
dock areas should be cleared for material unloading.

3.5. Stacking Norms

The materials which are getting stored in site should be stacked in the below manner:

Columns - Should be stored on runners / Plates in well stacked manner to avoid falling. It can be
stacked in the vertical height for Maximum 600mm.
Panels – Should be stored on runners / Plates in well stacked (Zig Zag) manner to avoid falling. It can
be stacked in the vertical height for Maximum 1500mm.
All other materials should be stored in a well stacked manner to avoid falling. It can be stacked in the
vertical height for maximum 1200mm. However, stability of the stack to be ascertained by the
supervisor & ensured.

11
 Column based mezzanine system.

Note: Attached Pics for references

3.2. Stacked Panels and Beams.

12
 Column based mezzanine system.

4. Installation Procedures
Point to be noted
➢ Ensure Medical Fitness certificate of each racking crew before undergoing safety induction training. Skilled
workers who are supposed to work at height must possess ‘Vertigo Test Certificate’. Use BOCW form XI
during medical check-up. Ensure ‘Fit for working at height ‘must be mentioned on medical certificate for
skilled workers & ‘Fit for work’ on other medical certificates.
➢ A certified electrician shall be present at site for doing proper electrical connections as well as checking
of power hand tools.
➢ An electricity supply source shall be provided by the customer either in the vicinity of barricaded (Hard)
racking installation area or nearby the area and electrical connections with industrial plug-sockets shall be
taken from the source. Ensure the electrical connections must be provided through 30 mA RCCB as well as
routing of electric cable to avoid trip hazard and in accordance with the customer requirement. Industrial
plug- sockets shall always be used in doing electrical connections or providing power to power hand tools.
No distribution board shall be carried to site by the racking crew. Electrical cable must be over headed by
insulated hook wherever possible.
➢ Use material handling equipment like HPT wherever possible.
➢ Overhead clearance of at least 12m is required for Farana operation during mezzanine installation work. A
designated parking area must be provided by the customer.
➢ Ensure TPI certificate of all lifting tools and tackles.
➢ All plastics and other scraps shall be kept in a designated scrap yard on daily basis with proper
segregation. The removal of scraps from site premises should be done regularly as per customer’s
instructions.
➢ Always use PPEs as required.
➢ Do not climb the system without suitable harness.
➢ Project Supervisor or engineer must ensure that the workers thoroughly understand how components
should be handled and assembled. If necessary, checklists to be used.
➢ Inspection, monitoring & supervision of site engineer and safety personnel must be available at
site during mezzanine installation.
➢ 20 -25 workers will be worked at site in general shift only for at least 30 days. If reqd. for any
extension, then team will intimate the customer in advance.
➢ Conduct daily Toolbox Talk (TBT) meeting in morning before start of work.
➢ Do abide by customer’s PTW requirements.
➢ Site engineer and safety person must be present at site during installation.

➢ Measurement and Site Marking

This should be undertaken at each phase of Erection using datums provided on the installation Layout. Measurement
of complete layout in the building and ensure all Columns / Uprights fit in as per the drawing. Each Column needs to
be marked on floor.
Uneven floors must be determined by laser level or tube level at the points where the system will
be installed. The measured results are entered in the installation drawing. It is useful for using the
shim plates after erecting the columns / Uprights.
The floor level variation should be checked before installing the system. The floor level variation
should be within ±5mm. If it exceeds the limit, customer has to do rework on the floor to maintain the
floor variation within the limit.

13
 Column based mezzanine system.

Toolbox Talk Meeting

Toolbox meeting will be conducted by Safety Supervisors and Shift supervisors before start of work in
each shift. Daily Activity plan, Manpower requirements and target for the day will be briefed to all
workers. Site supervisor will explain the Risks involved in activities planned for the day based on
Hazard Identification and Risk Assessment (HIRA) chart prepared for the specific site and Safe working
methodologies to ensure safe working.

1.1. Toolbox Talk Meeting at site

Column Based Mezzanine

14
 Column based mezzanine system.

4.4.1. Column / Upright and Beam assembly

4.3. Beam Main

Main Beam (length - 5.8 m, weight – 32 kg approx.) is fixed with two columns (length – 8.4 m, weight – 85 kg approx.), on
the ground using M10x30 Bolt & Nut with Serrated spring washers.

15
 Column based mezzanine system.

M10x30 Bolt & M10 Nut, with

M10 Serrated Spring Washers

Column Main Beam

4.3. Main Beam assembly with column

4.5. Frame/Column lifting using Farana.

The frames (weight – 160 kg approx.) can be lifted by farana and placed on it’s marked
(cemented padding) area and grout the columns. After erection a single frame, it has to be
supported with persons standing on mobile scaffold or against a Strong structure or held by
suitable equipment till the inter beams were connected. The safety person must ensure all
checkpoints, All lifting tools and tackles must have been inspected, tested by certified

16
 Column based mezzanine system.

authority and possess load and functional test certificates. Only trained and certified operator
will be allowed to operate Farana and scissor lift. Be sure to conduct pre-operation inspection
of Farana. Farana movement area shall be barricaded to restrict unauthorized access.
Mandatory PPEs should be provided and worn by all.

4.4.2 Inter Beam Fixing

4.6. Inter Beam

The Inter Beam (4.5 m; weight – 35 kg) is mounted on the column using Nos. of M10x30 Bolts & Nuts with
M10Spring washers by the workers standing on Mobile scaffold (approx. 4m height)/ Step – ladders with
compliance of all safety norms.

Main Beam
M10x30 Bolt & M10
Nut, with M10 Serrated
Spring Washers

Inter Beam Column

14
 Column based mezzanine system.

4.7. Inter Beam assembly with column.

4.8. Inter beam fixing

4.4.3 Inter Inter Beam Fixing

4.9. Inter Inter Beam

Inter Inter beam (5.6 m; weight – 40 kg) is the member transferring load from the mezzanine
floor. The inter interbeam is mounted between two main beams using M10x30 Bolt & Nut.
Workers can use mobile scaffold/step ladder in fixing inter inter beam.

15
 Column based mezzanine system.

Inter Beam Inter inter beams Main Beam

4.10. Inter Inter Beam fixing with Main Beam

4.4.4. Catwalk panels fixing
Catwalk Panel

Main Beam Inter Beam

4.11. Catwalk Panel fixing

The decking panels has to be fitted to the inter beams with M8x25 Bolts & Nuts as shown in
the fig. 4.12. The decking panels are connected each other using M8x25 Bolts & Nuts. Workers
can use mobile scaffold in fixing catwalk panel, workers must be worn and anchored FBH
properly. Ensure the provision of area barricading and lifeline before starting decking panel
fixing. Ensure there is no floor opening prevails after decking panel fixing at the end of each
working day. If there is, then safety person must barricade the openings. First floor decking

16
 Column based mezzanine system.

must be completed before engaging workers in laying of decking panels at 2nd floor.

Panel interconnected
using M8x20 Bolt & Nut
. 4.12. Interconnecting panels

4.4.5 Tubular Knee Bracings

4.13. Tubular Knee Bracings

M10x30 Bolt &

M10 Nuts with
Spring Washer

17
 Column based mezzanine system.

4.14. Tubular Knee bracing fixing with column & Main Beam

The knee bracing is connected with Main beam and column / Uprights using M10x30 Bolts & Nuts

NOTE:

After completing a module, the plumb and level has to be checked. After checking the
plumbs, the other modules were erected by taking reference from that module.
If it was a multi-tier system, some modules at each floor left without fixing inter inter beams
for the supply of wooden boards for wooden flooring (if required).

4.5. Hand Rail Fixing

Railings are fitted around the mezzanine decking and Gangways for Protection and safety of
the personnel who work on the floor. Hand Rail components
1. Railing pipe
2. Corner Rail joining pipe
3. Railing post
4. Rear Mesh
5. Kick plate
6. Clamps for Railing pipes
7. Holding plate

Railing pipes Railing Posts Railing Clamps

4.15. Hand and rail components

Kick Plates

Insert the holding plate in the Main / inter beam and place the Rail post in the respective place and bolt it
with the holding plate using M8x20 Bolt & Nut with washer in between the plate and Rail post.

18
 Column based mezzanine system.

M8x20 Bolt
& Nut

4.16. Holding plate fixing for hand railing post.

After that the Railing Clamps are fixed at the Rail post to hold the railing pipes. Rail joining Pipes are used
to interconnect two Railing pipes. It is connected using M8x20 Bolt & Nut.

Railing Pipes

Rail Joining Pipe

4.17. Rail Joining Pipe

The Corner Rail joining pipes are used to connect two Railing pipes at the corner of the Hand rail system. It
is connected by M8x20 Bolt & Nut.

19
 Column based mezzanine system.

4.18. Corner Rail joining Pipe

4.19. Rear Mesh fixing

• Rear Mesh frame cladding (W1797 × H1195-2.5mm dia) are fixed between two
railing posts by Hex bolt M8 × 60 and nut M8 zinc blue. The mesh shall be shifted
manually by using rope-pulley. Ensure the provision of area barricading and
mandatory PPEs should be provided and worn by all, workers must be worn and
anchored FBH properly.

20
 Column based mezzanine system.

• Kick plates are connected at the edge of the decking panels to prevent accidents & material
fall. It is connected to the decking panels using M5x25 self-tapping screw.

4.20. Kick Plate

Splice plates are used to connect two kick plates.

Splice plate connected

with M8x20 Bolt and Nuts

4.21. Kick plate with splice

4.6. Tie rod & Turn Buckle fixing

M12x40 Bolt & Nut

21
 Column based mezzanine system.

4.22. Turn Buckle

4.23. Tie Rod

M12 x 40
Bolt & Nut

Tie Rod

Turn Buckle

4.24. Turn Buckle & Tie Rod Assembly

The diagonal between the two columns / Uprights are corrected by adjusting the turn buckles.

4.7. Stair case Assembly

22
 Column based mezzanine system.

Landing Platform

Railing Assembly

Step Panel

Main Channel

4.25. Staircase Assembly

railing The assembly is a welded structure with top rail, middle rail and railing post. It is welded with
main channel.

The step panels are rested on top of the step support angle, which is mounted / welded to the main
channel sideways.

Generally single tier Staircase has single landing platform and multi-tier staircase has minimum
two landing platforms.

4.8. Grouting the Columns / Uprights

Only after alignment and leveling, you can start with proper anchoring. It is important that all the
Columns / Uprights have to be grouted for the proper functioning of the system.

Drill the anchor holes through the base plates. The holes have to be drilled in accordance with
manufacturers instruction of the anchor bolt manufacturer and to be cleaned thoroughly.

23
 Column based mezzanine system.

4.26. Anchor fixing Procedure

Divide the layout in to multiple grids and do alignment & plumbing of the modules before firmly
grouting to the floor. Align& grout smaller grids & then proceed for further correction. Do not wait for
full erection to be completed to start grouting.

The procedure to be followed is to

a) Mark & align the Column / Upright as per marking on floor.

b) Ensure the columns are all square to each other to ensure aesthetics & avoid twist in
uprights.
c) Once aligned mark the position of the holes to be drilled for grouting & drill holes to the
required depth.
d) Clean the hole for the dust.
e) Insert the expansion fastener in the reverse direction & locate the columns / Uprights
properly.
f) After location, check the plumb of the Column / upright, adjust by shimming & reverse the
bolt, insert correctly and grout.

4.9. Accessories

Fixing of Stability, Safety members and accessories considered in the drawing as per locations specified
in Installation drawings like, Safety Signages etc.

4. Check point during Installation

5.1. Floor Marking

❖ Check whether reference has been taken from the longest wall in site for marking
the longest side in the layout.
❖ Check whether the dimensions of the columns/modules marked on the floor are
correct. Check whether o/o marking dimensions matches with that of o/o
dimensions in the layout. Check whether the boxes are square by checking their
diagonals.
❖ Is there any obstruction like pillars, trenches, etc. to the floor marking which was
not captured earlier.
❖ Check whether the floor level variation is within the limit.

5.2. Column / Upright and Beam Assembly

❖ Check whether washers are used inside along with M10X25 bolts-nuts for fixing
Main beams, Inter beams, Inter Inter beams & Knee Bracings.
❖ Check the diagonal of the first module and proceed.
❖ Check whether all fasteners are tightened fully (using a torque wrench) & then
the bolts are marked with a line running across the bolt and upright to ensure

24
 Column based mezzanine system.

visible checking of tightening.

5.3. Column Erection & Beam Fixing

❖ Check whether Inter beams & Inter Inter beams are fixed correctly in its place as
per elevation drawing.
❖ Check span, height, type & weld position.
❖ Check whether the module is square in elevation by checking their diagonals in
horizontal plane. Check whether the module is square in plan view & if there is
difference, adjust to ensure squareness.
❖ Check whether the unit is in plumb in both planes (X & Z Planes). Check whether
the modules are leveled properly.

5.4. Stability Members Fixing

❖ Check whether Knee Bracings are fixed as per design. Check whether washers are
used along with M12X40 bolts-nuts for fixing Knee Bracings.
❖ Check whether tie beam’s locations are correct as per drawing. Check the turn
buckles are tightened.

5.5. Grouting

❖ Check whether all the columns / Uprights are in one horizontal plane (zero-zero).

❖ Check alignment before starting grouting.

❖ Check whether the columns / Uprights are twisted before grouting, ensure they
are made straight before grouting.
❖ Check whether drilling is done to required depth and diameter. It should not be
either excess or short.
❖ Check whether the dirt is removed fully from the hole before the bolt is
hammered. In case of Pin type of expansion bolts, check whether the pin is just
above the bolt.
❖ Ensure that the columns / Uprights are located as per alignment before the shims
are placed properly. No protrusions.
❖ Shims should not be stacked higher than 25mm.
❖ Is the bolt projection after tightening should not be more than 15mm (for
mechanical anchors) & 20mm (for chemical anchors) above base plate.
❖ In case of Chemical bolts, Check whether the bolt is rotating after curing. If yes,
then grouting is improper.
❖ Check whether the nuts are tightened after grouting.

25
 Column based mezzanine system.

6. Reporting
The reporting will include

❖ Materials Dispatch / Truck details

❖ Dispatch updates BOM vs. Actual Vs Pending Materials Daily status
summarizing the progress achieved.
❖ Key planned activities for next 2 days Brief on schedule
❖ Open / site issues to be addressed if any
The Daily reports shall be issued to Customer project team every day Morning. This is expected that
in the event of any open issue requiring decision by customer, the same will be taken on fast track to
Godrej project team to keep the project on time.

7. Inspection
The correct fitting of the components has to be checked before the racks are loaded. The racks may
be loaded only after the end of installation. Sample Check list for Mezzanine System Installation Audit
is given below.

26
 Column based mezzanine system.

Check List for Mezzanine System Installation Review :-

Customer: Branch:

1. The System is installed as per the layout, which has been

YES NO
approved by design department

2. Any Damage to the Uprights YES NO

3. Is the system properly grouted ? YES NO

a) Are all the Grouting Bolts of upright in Place YES NO

b) Are all the Grouting Bolts fully tightened YES NO

c) Is the Pins of all the Grouting Bolts hammered properly YES NO

4. The Nuts & Bolts are in the place for the

YES NO

b) Main Beams YES NO

c) Inter Beams YES NO

YES NO

YES NO

f) Tie Rod YES NO

5. Any visible damage on the components :

YES NO

b) Main Beams YES NO

c) Inter Beams YES NO

YES NO

YES NO

f) Hor. Tie Rod YES NO

g) Ver. Tie Rod YES NO

6. Check the vertical alignment of the Frames YES NO

27
 Column based mezzanine system.

7. Check the Horizontal alignment of the units

8. Check the Skew ness of the system

9. The Flooring is in good shape. There is no visible signs of

any cracks, uneveness etc…

10. The uprights are not on Underground trenches / Ducts

11. The uprights are not Grouted with excessive shimming.

13. Your observations :

28
 Column based mezzanine system.

8. System Installation Tolerance

• The Column / Upright straightness Cx is checked using plumb. The maximum variation
allowed is ±10 mm.

Cx

• The Maximum variation in the diagonal of a single module should not exceed more than
5mm.

29
 Column based mezzanine system.

• The maximum variation ‘x’ between the two base plates should not exceed ± 5 mm.

9. Tools Required
• Spanner Set -16/17, 18/19, 20/21, 12/13, 11/10, 9/8.
• Measuring Tape- 5 mtrs & Measuring Tape- 25 mtrs
• Heavy Duty Nylon Hammer.
• Drilling Machine for Grouting
• Grouting Drill BitsM12
• Pulley with Hooks
• ¼” Cotton/Nylon Rope (length 10-15mtrs minimum)
• U -Clamps for tightening the ropes
• Helmets (to be provided to all men working at site)
• Safety Belts
• Gloves (cotton)
• Safety Shoes
• Tool Box (For safe keeping of above tools at site)
• Shims
• Screw Driver
• ½” inch Half Round Rough File
• Needle File
• Torque Wrench (if available Power Torque wrench)
• Plumb Line
• Thick Cotton Twain

30
 Column based mezzanine system.

• Spirit Level
• Marker
• Adjustable Stools/ Ladders (For installation of Main Beams/Inter Beams)
• The quantity of the tools can be ascertained according to the team size
• Working on the project.

10. Handover
After inspection is carried out, need to obtain the clients authorized signature in the Completion
Certificate and need to take the customer feedback.

Completion Certificate format

31
 Column based mezzanine system.

Customer Feedback Form

32