Warehouse Mezzanine Stair Compliance in NSW: Performance Solutions Without Major Rebuilds

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Warehouse Mezzanine Stair Compliance in NSW: Performance Solutions Without Major Rebuilds

Published: February 2026 By Sydney Access Consultants – Accredited Access Consultants, NSW

Warehouse owners and facility managers in Sydney and across NSW frequently face the same challenge: a building certifier identifies non-compliances on mezzanine stairs in a Class 7b storage facility—unequal riser heights, reduced landing widths, excessive riser dimensions, or openable balustrade gaps—and the initial reaction is often “this will cost a fortune to fix”.

The good news? In most cases, especially for non-occupiable storage mezzanines with trained staff-only access, you don’t need a full rebuild. A well-prepared performance solution under NCC 2022 Volume One can resolve the issues cost-effectively, maintain safe movement, and often improve usability for everyone who uses the stairs.

Here’s a real-world example from a recent project we completed at a warehouse in Greenacre, NSW. We used a performance-based approach to address multiple stair and barrier departures without major structural changes.

The Typical Mezzanine Stair Issues We See

In Class 7b warehouses, mezzanines are almost always used for storage only. Access is occasional, limited to trained staff retrieving stock, carrying out maintenance, or supervising deliveries. Public access is excluded.

Common certifier comments include:

• Riser heights exceeding 190 mm (e.g., 195–197 mm)
• Riser variations within a flight exceeding 5 mm adjacent or 10 mm overall (e.g., 14–15 mm at the top riser)
• Landing unobstructed widths below 1.0 m (e.g., 765–877 mm due to handrail extensions or structural columns)
• Openable balustrade sections without a lower rail, allowing a 150 mm sphere to pass through a ~550 mm gap

These departures breach NCC 2022 Volume One Deemed-to-Satisfy provisions (D3D14 for stair geometry, D3D15 for landings, D3D19 for barriers), but they are often manageable in low-exposure industrial settings.

Key Standards and Important Exemptions

Premises Standards Exemption The Disability (Access to Premises – Buildings) Standards 2010 (which sit under the Disability Discrimination Act 1992 and are referenced in NCC Part D4) do not require accessible path of travel—including lifts, ramps, or full AS 1428.1 compliance—to non-occupiable upper levels or mezzanines used solely for storage in Class 7b buildings.

This exemption applies particularly where the space is not normally used by occupants, is not open to the public, and vertical access would impose unjustifiable hardship. In short: no wheelchair-accessible features are mandated for the mezzanine in this type of warehouse.

AS 1657:2018 – The Right Standard for Industrial Access For mezzanine stairs, platforms, and guardrails in warehouses, AS 1657:2018 Fixed platforms, walkways, stairways and ladders is the primary reference. It is specifically written for industrial environments with infrequent, authorised access.

Relevant provisions include:

• Riser uniformity within ±5 mm tolerance
• Riser heights 115–190 mm
• Guardrail height 900–1100 mm with mid-rails or infill to limit gaps
• Functional openings (e.g., for deliveries) allowed when mitigated
• Slip-resistant treads and clear visibility of edges

Because usage is low-frequency and users are trained, AS 1657 supports more practical tolerances than public-access standards like AS 1428.1.

Our Performance Solution in Action – Greenacre Warehouse Case Study

We prepared a consolidated performance solution report and design brief for the client. The solution demonstrated equivalence to DP4 (safe movement) and DP1 (limited application due to exemptions) using layered, low-cost mitigations.

Key Remedial Works Implemented

• Slip-resistant luminance contrast strips applied to all stair nosings (full tread width, ≥30% contrast, R10 slip rating) – improves edge detection and reduces trip risk, especially helpful when staff are carrying boxes or navigating in variable light.
• Warning signs installed at the base and top of each flight: “CAUTION: UNEQUAL RISER HEIGHTS – Watch Your Step and Hold Handrail” Clear, high-contrast signage promotes safe behaviour without needing to rebuild.
• Emergency evacuation lighting upgraded to AS/NZS 2293.1:2018 standards – ensures treads, nosings, handrails, and signage remain visible during power failure, critical for safe egress in an emergency.
• Removable lower rail or lockable chain added to openable balustrade sections – closes the gap to prevent a 125 mm sphere passing when not in use for deliveries.
• Handrail continuity confirmed/upgraded where practicable, plus staff training reinforcement on handrail use and slow negotiation.

Estimated Cost: $2,000–$5,000 (versus tens of thousands for full reconstruction).

Why This Approach Works So Well for Warehouses

In storage mezzanines with staff-only access:

• Exposure is very low → even small variations or gaps pose minimal real-world risk when mitigated.
• Premises Standards exemptions avoid the need for full accessibility upgrades.
• AS 1657:2018 provides sensible industrial tolerances and supports performance-based fixes.
• Practical improvements (contrast nosings, emergency lighting, signage) not only satisfy the certifier but genuinely make stairs safer and easier to use for trained staff—especially those carrying loads or working in low light.

Ready to Resolve Your Mezzanine Compliance Issues?

If your warehouse in Sydney, NSW, or elsewhere has mezzanine stair non-compliances flagged by a certifier, you don’t necessarily need expensive structural changes. A targeted performance solution can deliver compliance, safety, and better usability at a fraction of the cost.

At Sydney Access Consultants, we specialise in warehouse and industrial access audits, performance solutions, and NCC-compliant designs that work in the real world.

Contact us today for a no-obligation discussion or site visit. We’ll review your certifier comments and advise on the most practical, cost-effective path forward.

Phone: [Your Phone Number] Email: [Your Email] Website: sydneyaccessconsultants.com.au

Let’s make your mezzanine stairs compliant, safe, and user-friendly—without breaking the budget.

Sydney Access Consultants – Advocating for sensible, inclusive access solutions across NSW and beyond.