Case Studies

16,000 sq. ft.

125 lb/sq.ft.

Storage

Collaboration Success in Cold Storage

Profielnorm was approached by a U.S. division specializing in roller conveyors, seeking a partner for custom mezzanine design in Europe and the U.S. The 16,000 sq ft mezzanine supports conveyors in a deep-freeze warehouse. After visiting our Dutch HQ, the client chose Profielnorm. The result: a durable, high-performance mezzanine built for the demands of advanced cold storage.

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Collaboration Success in Cold Storage

Quick facts:

A 16,000 sq. ft. mezzanine to support conveyors
Grating decking finish and 125lb/sq.ft. load capacity
Columns in blue: RAL 5005
Railings in yellow: RAL 1033
This mezzanine includes 13 cage ladders

The key features of this project:

Our mezzanine is made with European components meeting the American standards.
Our mezzanine supports the client's mission to serve every customer with accurate orders as quickly and efficiently as possible.
This new distribution center was festively opened by the Dutch King and Queen!

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Profielnorm mezzanine floor case studies

107,600 sq. ft.

51.2 lbs/sq.ft.

Material Handling

Multi-Level Steel Structure for Advanced Material Handling

Profielnorm engineered a custom steel mezzanine to support a high-performance hanging material handling system. The four-level steel tower features wooden floors on the first three levels with safety kickplates and handrails, while the top level and an adjacent single-level structure carry the suspended equipment. A precision-built solution tailored for industrial automation at scale.

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Multi-Level Steel Structure for Advanced Material Handling

Quick facts:

230 ft × 100 ft (4 levels)
Column Pitch: 18 ft × 16.5 ft (aligned with concrete floor slab pillars)
Height: Up to 40 ft
Surface Area: Over 107,600 sq. ft.

The key features of this project:

Custom-Engineered Compatibility: To support the hanging garment system, we added an extra row of precision-cut holes in the purlins—tailored in close collaboration with the client for a seamless integration.
Heavy-Duty Floor Design: A specialized structural approach was developed to account for the simultaneous load factor of a four-tier mezzanine on a concrete floor—ensuring safety, stability, and longevity.
No Downtime, No Disruption: Installation was carried out while the client remained fully operational. Our team ensured zero disruption to ongoing business activities—minimal impact, maximum efficiency.

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333,000 sq.ft.

102 lbs/sq.ft.

Logisitcs

Built for Flow: Large-Span Mezzanine Powers Logistics Hub

Profielnorm partnered with a major retail client to shape the design of their new distribution center from the ground up. By aligning practical solutions with building needs and budget, we developed an efficient structural concept that supports their logistics and lays a strong foundation for operational success.

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Built for Flow: Large-Span Mezzanine Powers Logistics Hub

Quick facts:

Two tier mezzanine
Portal bracing construction
Optimised column grid and huge spans; Profielnorm’s core strength
Mezzanine surface: 333,000 sq.ft.
Fire enclosures around stair towers

The key features of this project:

A huge column grid aligned with the building construction.
A very tight timeline to install the mezzanine.
Portal bracing construction to maintain a free flow under the mezzanine.

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Make the most of your space with a mezzanine floor

400,000 sq.ft.

71.7/153.6 lbs/sq.ft.

System Integration

Seamless Integration – Mezzanine Solutions for a High-Performance Distribution Center

For a leading supply chain solutions provider, Profielnorm delivered advanced mezzanine systems for a 400,000 sq ft distribution center handling 150,000+ SKUs. Six custom mezzanine floors across three halls integrate seamlessly with 5 miles of conveyors, optimizing space and ensuring efficient, uninterrupted operations in a high-volume, fast-paced environment.

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Seamless Integration – Mezzanine Solutions for a High-Performance Distribution Center

Quick facts:

Approximately 400,000 square feet of mezzanine surfaces area
Complex mezzanine system in 3 separate halls to optimize system integration
Mezzanine height 15.5 feet
Mixed decking materials (chipboard and grating) due to fire regulations

The key features of this project:

Extensive Conveyor Network: Approximately 5 miles of conveyors were installed throughout the facility, seamlessly integrated with our steel support structures to ensure operational efficiency and structural stability.
Impressive Skywalk Installation: A 66-foot-long elevated skywalk was constructed above the sorter, featuring a 30-foot unsupported span. This innovative design provides direct access to a mezzanine level located nearly 26 feet above ground, enhancing internal mobility without obstructing equipment below.

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53,800 sq.ft.

100 lb/sq.ft.

System Integration

Next level for Profielnorm

At Profielnorm, no project is too high to handle. This mezzanine, one of our tallest ever, spans 53,800 sq ft and soars over 60 ft high. A repeat client trusted us to deliver a reliable, expert solution. Achieving this height safely required precise engineering and a highly stable structure, showcasing our ability to tackle ambitious, large-scale projects.

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Next level for Profielnorm

Quick facts:

An impressive project with a height of over 60 feet
Special column baseplates due to the high column loads
134 feet x 95 feet (5 levels)
Reinforced framing to support the conveyors

The key features of this project:

The customer needed to fully utilize the height of their industrial building while maintaining open, usable space on each level.
The mezzanine reaches an impressive height of 60 feet, one of the tallest we've ever built.
Engineered to support a distributed load of at least 100 lbs/ft² without exceeding maximum point load limits.
Each floor supports not only goods but also conveyors—bringing additional forces and complexity to the design.
The height, load requirements, and multi-functional use made this a major challenge in design, production, and construction—perfectly handled by Profielnorm.

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218,000 sq.ft.

61/102 lb/sq.ft.

Storage

One Smart Mezzanine Solution, Three Unique Logistics Spaces

Three greenfield projects, three clients, one challenge: creating mezzanines with wide spans for flexible logistics. Serving fashion and general 3PL sectors, each needed maximum usable space below. Profielnorm engineered main spans over 36 ft and secondary spans up to 20 ft, delivering a high-performance mezzanine that met all operational demands across these diverse facilities.

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One Smart Mezzanine Solution, Three Unique Logistics Spaces

Quick facts:

Mezzanine surfaces: 56,000 ft² / 62,000 ft² / 100,000 ft²
61 lb/ft² load capacity (secondary beams are designed for 102 lb/ft²)
Mezzanine height up to 30 feet
2 mezzanine levels

The key features of this project:

One solution: three projects: A single Profielnorm mezzanine system used across three distinct logistics facilities.
Long, clear spans: Main beam spans over 36 ft; secondary spans up to 20 ft for maximum floor space.
Integrated sprinkler system: Fire safety seamlessly built into the customized mezzanine structure.
To maintain the unique spans of 36 ft, Profielnorm developed a customized portal bracing construction, eliminating the need for any blocking element.

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52,000 sq.ft.

102 lb/sq.ft.

Storage

Making Space: A Smarter Warehouse Upgrade

To support a significant expansion of their product range—from shoes to apparel—a leading footwear company needed additional storage space. Profielnorm provided a custom two-story mezzanine floor, designed and installed in a short timeframe. To avoid disruption to the customer’s ongoing e-commerce operations, installation was carried out overnight. The modular design also allows for future expansion.

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Making Space: A Smarter Warehouse Upgrade

Quick facts:

Mezzanine floor area: 52,000 sq.ft.
Floor load of the mezzanine floor is 102 lb/sq.ft.
Large spans up to 31 ft.
Two levels, with the second level having a height of 25 ft.

The key features of this project:

The mezzanine was designed for a hall densely packed with packing tables and roller conveyors, requiring precise placement of columns between existing equipment.
The concrete floor slab’s limited load capacity posed a challenge, necessitating special considerations for column pressure.
The entire project—from order confirmation to delivery—was completed within approximately 10 weeks.
Installation was carried out overnight (12:00 AM to 7:00 AM) to ensure uninterrupted customer operations.
The mezzanine structure was engineered for straightforward future expansion, allowing the customer to easily increase storage capacity as needed.

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430,500 sq.ft.

123 lbs/sq.ft.

Automation

Built to Move: Mezzanines Powering Automation

For a key international client, Profielnorm delivered a double-deck mezzanine across two logistics halls, totaling 430,500 sq ft. Engineered for seamless integration with conveyors, weighing platforms, and shelving, the structures were planned collaboratively from the start, maximizing space and operational efficiency as part of a turn-key warehouse automation project.

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Built to Move: Mezzanines Powering Automation

Quick facts:

Double-deck mezzanine flooring
Cross sorter conveyor under the mezzanines
Free standing weighing scale platforms, shelving, and conveyors on each level
Mezzanine surface: 430,500 sq.ft.

The key features of this project:

Mezzanines integrated into a fully automated warehouse system.
Equipped with conveyors, shelving, and weighing platforms across both levels—plus a cross sorter below.
Completed in under 12 months from tender to handover.
Executed in stages to align with the client’s timeline and operational needs.

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Custom-made mezzanines

Collaboration Success in Cold Storage

Collaboration Success in Cold Storage

Multi-Level Steel Structure for Advanced Material Handling

Multi-Level Steel Structure for Advanced Material Handling

Built for Flow: Large-Span Mezzanine Powers Logistics Hub

Built for Flow: Large-Span Mezzanine Powers Logistics Hub

Seamless Integration – Mezzanine Solutions for a High-Performance Distribution Center

Seamless Integration – Mezzanine Solutions for a High-Performance Distribution Center

Next level for Profielnorm

Next level for Profielnorm

One Smart Mezzanine Solution, Three Unique Logistics Spaces

One Smart Mezzanine Solution, Three Unique Logistics Spaces

Making Space: A Smarter Warehouse Upgrade

Making Space: A Smarter Warehouse Upgrade

Built to Move: Mezzanines Powering Automation

Built to Move: Mezzanines Powering Automation

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