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 challenge:

The client needed to significantly expand their usable space without disrupting ongoing operations. The goal: design and install a four-tier mezzanine that could support a suspended material handling system and allow for a fully unobstructed, free-running layout—no interruptions, no downtime.

Our solution:

We engineered a custom mezzanine with a unique stability concept that eliminated the need for cross braces, ensuring 100% open access and maximum flexibility beneath the structure. Our experienced installation team carried out the entire build with minimal disruption, allowing the client to maintain full operational continuity throughout the process.

No Down Time

For the customer it was of utmost importance that they could stay operational during the installation of the mezzanine floor. Thanks to our teams and professional installation, we have built their new mezzanine floor while they could continue their business. A big project and there was no down time for the client.

- Johan Bazen,

CCO

Supporting a Hanging Material Handling System with a Custom Steel Structure

Our client required a structural system to support a complex hanging garment system—without compromising their operational floor space or causing downtime during installation. The solution needed to include multiple levels, allow for unrestricted movement of equipment, and integrate seamlessly with an existing concrete platform.

Profielnorm engineered a bespoke mezzanine floor structure consisting of two parts:

Main Steel Tower: A four-level structure, with the bottom three levels equipped with wooden flooring (natural top finish, white underside), kickplates, and safety handrails. The fourth level was specifically designed to carry the load of the hanging equipment—no flooring needed.

Secondary Steel Frame: A one-level structure placed above a concrete platform, solely for supporting additional hanging equipment.

To accommodate the specific requirements of the garment system, our engineering team developed a dedicated solution by modifying the purlins with an extra row of holes for custom connection points. We also addressed load distribution by implementing a special simultaneous load factor design on the concrete base—ensuring safe, stable support for the new multi-tiered structure.

One of the project's standout features was its unobstructed layout. Our team designed a unique stability system that eliminated the need for traditional cross bracing, enabling free movement across the mezzanine without structural interference. This allowed for 100% clear space beneath the platform—essential for the client's operations.

Meeting the client's timeline and budget was a priority—but so was ensuring their operations continued smoothly. Our experienced installation team completed the project efficiently, allowing the customer to remain fully operational throughout the build. Installation was completed without causing any disruption to daily business activities.

Explore the photos below to see how Profielnorm transformed this space with a tailor-made steel structure.

Looking for a custom solution for your business? Get in touch for expert advice or request a quote directly online. At Profielnorm, we create more space for your success—designed around your needs.

Profielnorm mezzanine floor case studies

Project gallery

Are you interested in more photos of different projects? Have a look at our project gallery! We will show you more photos of recently realised projects in this sector and other sectors.

Custom-made mezzanines

Multi-Level Steel Structure for Advanced Material Handling

No Down Time

Supporting a Hanging Material Handling System with a Custom Steel Structure

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