Built for Flow: Large-Span Mezzanine Powers Logistics Hub

Quick facts:

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

The challenge:

As part of a major new central logistics hub, our client needed mezzanine floors designed to support the flow of large packages. Because these packages are bulky, the floor structure had to span wide distances—minimizing obstructions and keeping driveways open and accessible for smooth operations. But with so much open space underneath the mezzanine, two key challenges quickly emerged:
No cross bracing allowed—the open space had to remain completely clear for movement and equipment.
High point loads—with fewer columns, the weight concentrated heavily on the concrete floor below.

Our solution:

Collaborating closely with the consulting engineers, we developed a smart structural layout using a sequence of uneven spans: nine spans of 23 feet (7 meters), followed by seven spans of 23 feet, and secondary beams spanning 20 feet (6 meters) across. This layout aligned perfectly with both the building's column grid and the logistics hub’s need for wide, unobstructed driveways—delivering the open, efficient space the client required without compromising on structural integrity.

“During the tender process, it quickly became clear that Profielnorm was the best partner to meet our needs.”

Profielnorm’s expertise in large-span mezzanines truly stood out in this project. The client had a strict timeline, and being awarded the contract at an early stage allowed us the necessary preparation time to ensure a smooth and efficient execution.

In hindsight, it was a technically sound decision for the client to move forward when they did. The collaboration was both productive and enjoyable, and we’re grateful for the trust they placed in us. It’s rewarding to see such a large mezzanine successfully completed—exactly the kind of project where Profielnorm excels.

- Philip van der Harst,

Area Sales Manager

Smart Design for a 333,000 sq.ft. warehouse mezzanine floor

Profielnorm had the opportunity to join the project right from the early design phase of a large-scale distribution center for a major retail client. By being involved from the outset, we were able to deliver a smart, practical solution that balanced structural requirements, logistics, and budget—resulting in an optimized design tailored to the client’s operational needs.

With a straightforward, no-nonsense approach, we worked closely with the customer to evaluate column loads and navigate the necessary approval process for building permits. A key engineering challenge was creating a bracing-free structure in the main beam direction to maintain open, obstruction-free spaces critical to the client's logistics.

Our team designed portal bracing connections at each column level, allowing us to eliminate cross bracing in one direction. Strategic cross bracing was still used in the secondary direction—only in areas designated for storage—ensuring that warehouse operations remained completely unhindered. In the fully operational facility, there are no obstacles affecting movement or workflow.

Another essential requirement was safe evacuation in case of emergency. To meet fire safety standards, we engineered enclosed stair towers capable of withstanding fire conditions for at least 20 minutes, providing safe and reliable evacuation routes throughout the building.

Have a look at the photos of this project in the photos below. Feel free to contact us for more information about a warehouse mezzanine floor.

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Built for Flow: Large-Span Mezzanine Powers Logistics Hub

Smart Design for a 333,000 sq.ft. warehouse mezzanine floor

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