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Mezzanine projects

Custom-made mezzanines

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Each year, Profielnorm designs and delivers over 2,000 custom mezzanines, tailored to meet the unique needs of our clients. Curious how we make it happen? Dive into our case studies below to see real-world examples of our bespoke solutions in action!


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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Mezzanines for automation success

Collaboration Success in Cold Storage

Profielnorm was approached by a U.S. division specializing in roller conveyors and automation, operating within a larger industrial group. They were in search of a dependable partner for the design and manufacture of custom mezzanines—both in Europe and the United States.


The inquiry involved a large-scale mezzanine spanning approximately 16,000 square feet, designed to support conveyor systems within a deep-freeze mega warehouse in the U.S. After visiting our headquarters in Tholen, the Netherlands, the client chose Profielnorm to bring the project to life.

The result? A robust, high-performance mezzanine system engineered to meet the unique demands of a cutting-edge cold storage facility. Take a closer look at this impressive international collaboration in industrial design and manufacturing!

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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.
  • Zero-Obstruction Layout: To maintain a completely clear and accessible mezzanine level, we implemented an advanced stability solution—eliminating the need for cross braces and ensuring 100% unblocked floor space for smooth operations.
  • On-Time, On-Budget Delivery: The project was successfully completed within the agreed timeline and budget, demonstrating our commitment to reliability and consistency.
  • 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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Mezzanine flooring specialist

Multi-Level Steel Structure for Advanced Material Handling

Profielnorm engineered a custom steel mezzanine solution designed specifically to support a high-performance, hanging material handling system—where strength and precision were key.

At the heart of the project is a robust steel tower featuring four levels. The first three levels are fully outfitted with wooden flooring (natural finish on top, white underside), complete with safety kickplates and handrails for secure access and use. These floors are built to handle both foot traffic and system integration.

The fourth and highest level of the tower, along with a secondary single-level steel structure mounted on a concrete platform, serve a different purpose: they're dedicated solely to carrying the weight of the suspended material handling equipment.

This project showcases our ability to tailor structural solutions to highly specialized industrial needs. It's not just a mezzanine—it's precision-built infrastructure for automation at scale.

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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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Mezzanine flooring specialist

Built for Flow: Large-Span Mezzanine Powers Logistics Hub

For a major retail client, we had the opportunity to contribute from the earliest stages of their new distribution center's design.

By taking a practical, no-nonsense approach—and closely aligning our solutions with both the building requirements and budget—we collaboratively developed a highly effective structural concept. The result? A smart, efficient system that perfectly supports the customer's logistical processes and sets a strong foundation for their operational success.

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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.
  • Optimized Access Infrastructure: Numerous step-overs and staircases were strategically placed throughout the system to ensure safe and easy access to all operational areas, supporting both maintenance and day-to-day use.
  • Integrated Workstations: Workstations were positioned both on and beneath the mezzanines, fully integrated with the automated shuttle solution system to streamline workflows and maximize space utilization.
  • On-Time, On-Budget Delivery: The project was successfully completed within the agreed timeframe and budget, without causing any disruption to the client's ongoing operations.


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Customised mezzanine floors for system integration

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

For a leading supply chain solutions provider, Profielnorm delivered a series of advanced structural systems for a new, ultra-modern distribution center handling over 150,000 unique SKUs.

Covering approximately 400,000 square feet, the facility features around 5 miles of conveyor systems—strategically routed above and below our mezzanine structures to support smooth, uninterrupted logistics operations.

Profielnorm engineered and installed six fully custom system integration mezzanine floors, located across three different halls. Each floor was designed to integrate seamlessly with the automation systems and building layout, optimizing space and ensuring long-term operational efficiency.

This project highlights Profielnorm's ability to deliver complex, large-scale mezzanine solutions tailored to the demands of high-volume, fast-paced distribution environments.

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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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Next level mezzanine

Next level for Profielnorm

At Profielnorm, no project is too high to handle—literally. This installation stands out as one of our tallest mezzanine floors ever built, proving once again that the sky is the limit.

The end customer, already familiar with Profielnorm through a previous project, knew exactly what to expect: a reliable, expert solution. That trust led to this ambitious new build.

While the mezzanine spans over 53,800 square feet, what truly sets it apart is the height—soaring to more than 60 feet. Achieving this height safely and securely was the main challenge, requiring precise engineering and a highly stable structure.

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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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Mezzanine floor staircases

One Smart Mezzanine Solution, Three Unique Logistics Spaces

Three customers. Three greenfield projects. One shared challenge: creating mezzanine systems with wide, open spans to support fast, flexible logistics operations.

Two of these clients operate in fashion logistics; the third is a major player in general third-party logistics. Despite their different sectors, they all needed the same thing—maximum usable space beneath the mezzanine for smooth daily operations.

Working closely with each customer and their consultants, we engineered a solution that delivered main beam spans of over 36 feet, with secondary spans stretching up to 20 feet. The result? A streamlined, high-performance mezzanine that met the operational demands of all three facilities—without compromise.

Profielnorm was proud to deliver one versatile mezzanine design proved ideal for three very different logistics environments.

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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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Mezzanine floor steel construction

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-storey 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, offering a flexible solution that grows with the business.

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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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Built to Move: Mezzanines Powering Automation

For a key international client, Profielnorm successfully delivered a double-deck mezzanine flooring solution across two major logistics halls, covering a total surface area of approximately 430,500 square feet.

This installation formed a vital part of a comprehensive, turn-key warehouse automation project. The mezzanine structures were engineered to integrate seamlessly with advanced logistics systems, including cross sorter conveyors located beneath the decks, as well as free-standing weighing platforms, shelving, and conveyors installed on both levels.

From the early stages of the bid process, Profielnorm took a proactive, consultative approach—offering expert guidance on the mezzanine design to ensure smooth integration with automation systems and storage solutions. This collaborative planning helped maximize operational efficiency and space optimization throughout the facility.

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Certification

NEN-EN 1090 & ISO 3834

Sustainability

CSR & Circulair building

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