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Custom-made mezzanine floors

Profielnorm supplies more dan 2,000 new mezzanine floors every year. To give you some examples, you will find Profielnorm case studies here. These mezzanine floors are built and delivered entirely based on the customer’s specification.


Dedicated system integration solution

Quick facts:

  • 70 x32 metre (4 levels)
  • Column pitch according to concrete pillars in the floor slab 5.4 x 5 metre
  • Up to 12,200 mm height
  • >10,000 m2 surface

What are the specialities of these projects?
  • The connection of the hanging garment system towards the profiles needed an additional row of holes in the purlins. In consultation with the customer, we engineered a dedicated solution.
  • A special design has been made in terms of simultaneous factor for the concrete floor to handle a four-tier mezzanine floor.
  • To secure a free running system on the mezzanine a special stability design has been implemented to give the customer a 100% free access and clear space. No blocking cross braces has been used in the mezzanine structure.
  • Project has been realized on time and in budget of the customer.
  • Customer was fully operational during the installation time of the project. No effective hinder was occurred by our installation team.


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Dedicated system integration solution

The main purpose for this steel construction is to support a hanging material handling system.

This mezzanine floor steel construction consists of one main steel tower with 4 levels and a smaller steel construction (1 level) above a concrete platform. For the main tower, the bottom three levels are equipped with wooden floors (top ‘natural’, underside white), kickplate, and handrails.

The top level is only for supporting the hanging equipment. The smaller steel construction is also only for supporting the hanging equipment and is not a floor.

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Large spans for a logistics hub

Quick facts:

  • Double-deck mezzanine flooring
  • Portalised construction
  • Optimised column grid and huge spans; Profielnorms’ core strength
  • Mezzanine surface: 31,000m2
  • Fire enclosures around stair towers

What are the specialities of these projects?
  • A huge column grid aligned with the building construction.
  • A very limited time slot to install the mezzanine.
  • Portalised construction to maintain a free flow under the mezzanine.


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Large spans for a logistics hub

For a huge retailing customer, we got the opportunity to step into the initial stages of the building design to come up with a totally sufficient solution for their new distribution centre.

A no nonsense approach, with the mix of looking for the best solution in relation to the building requirements and the budget we finally managed together to come up with a brilliant solution in terms of our customer’s logistic process.

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System integration mezzanine floors in 3 halls

Quick facts:

  • Surfaces: 3,500m2 (two mezzanines together), 180 m2, 380 m2, 2,120 m2 and 740 m2 
  • 6 mezzanine floors for system integration in 3 different halls for our customer
  • Total height of two of the mezzanine floors is 4,720 mm
  • Partly with chipboard and partly with grating, due to fire regulations

What are the specialities of these projects?
  • There is around eight kilometres of conveyors present in the building, these are attached and connected towards our steel structures.
  • A great Skywalk with a length of 20 metres, going above the sorter and hanging free for 9 meters to give access to a mezzanine in the building on a height of almost 8 meters.
  • For access reasons, a lot of step-overs and stairs are delivered and installed to make sure that all positions in the whole systems could be reached easily.
  • On and below the mezzanines there are workstations which are connected to the automated shuttle solution system.
  • This project is realised on time and in the customers budget, with no effective hinder of their ongoing operational process.


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System integration mezzanine floors in 3 halls

For a company in supply chain solutions, we delivered a lot of different constructions for a new, ultra-modern distribution centre, storing 150,000 different articles, predominantly perfumes.

The building has a surface of 38,000 m2. There is roughly eight kilometres of conveyors implemented in the building, going up and under our constructions.

Profielnorm delivered for this project 6 tailor-made system integration mezzanine floors. These mezzanine floors are installed in 3 different halls for our customer.

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Next level for Profielnorm

Quick facts:

  • Profielnorm’s highest built mezzanine with a height of 18,400 mm
  • Special column base due to the maximum column pressure
  • 41 x 29 metres (5 floors)
  • Special steel construction in the conveyor area

What are the specialities of these projects?
  • It was important for the customer that the height of the industrial building was optimally utilised with sufficient free space per floor.
  • The mezzanine floor bearing capacity had to be at least 500 kg/m2 distributed load, with no exceeding of the maximum allowed point load.
  • This mezzanine floor has a height of no less than 18,400 mm, an extra challenge for the designing, production, and construction of the mezzanine floor.
  • The different floors of the mezzanine floor are not only used for storage of goods, but also for conveyors with its particular forces.


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Next level for Profielnorm

One mezzanine floor is even larger and sometimes even more complex than the other This project is arguably our highest built mezzanine floor. The sky is the limit for Profielnorm.

Profielnorm had previously delivered a mezzanine floor to this end customer via one of our key accounts. The end customer already knew what he would get. That Profielnorm will be the right partner for his project.

This project of more than 5,000 m2 is not particularly large in terms of surface area, but the biggest challenge was to realise the desired height of more than 18,000 mm through a stable mezzanine floor construction.

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3 different projects, 1 mezzanine flooring solution

Quick facts:

  • Mezzanine surfaces: 5,235 m2 / 5,799 m2 / 9,265 m2
  • 300 kg/m2 (secondary beams are designed for 500 kg/m2)
  • Up to >9 metre
  • 2 mezzanine levels

What are the specialities of these projects?
  • Three different projects for different companies with the same Profielnorm mezzanine flooring solution.
  • We came up with a span in main beam direction of over 11 metres. Spans in other directions were up to six metres.
  • Another intelligent solution is the way how we integrated the sprinkler system in the mezzanine construction.
  • To maintain the unique spans of 11 metre we engineered a portalised solution which gives the customer free access in the 11-metre direction, without any blocking element.


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3 different projects, 1 mezzanine flooring solution

For these three customers, of which two are active in fashion logistics, and the other one in general third-party logistics we faced the same challenge.

All projects were on a greenfield, and all the stakeholders emphasised on a mezzanine with big spans. This has some huge advantages in their daily business.

In consultation with the customer and their respective consultants we came up with a span in main beam direction of over 11 metres. Spans in other directions were up to six metres. We had 1 mezzanine flooring solution for 3 different customers.

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Storage mezzanine floor with two levels

Quick facts:

  • Mezzanine floor area: 4,822 m2
  • Floor load of the mezzanine floor is 500 kg/m2
  • Large spans up to 9,500 mm
  • Two levels, with the second level having a height of 7,576 mm

What are the specialities of these projects?
  • The hall for which the mezzanine floor was planned is full of packing tables and roller conveyors. The necessary columns must be placed between them.
  • An additional challenge arose when it turned out that the concrete floor slab was not strong enough for the calculated column pressure.
  • It took about 10 weeks from the moment of order acknowledgement to the delivery of the mezzanine floor.
  • Assembly of the storage mezzanine floor took place at night between 24.00h and 7.00h, so that the customer’s work could continue undisturbed.
  • The mezzanine floor supplied is prepared for easy further expansion later.


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Storage mezzanine floor with two levels

The customer has opted for a significant expansion for their assortment and will also offer clothing in addition to their shoe portfolio. This requires a lot of extra storage space.

Profielnorm has ensured that a two-storey storage mezzanine floor has been produced and installed in a relatively short period of time.

To ensure that the customer’s operational e-commerce process could continue, the installation took place at night. The delivered mezzanine floor can easily be expanded further later if the customer can use even more extra storage space.

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Perfect combination: automation and more space

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: 40,000 m2

What are the specialities of these projects?
  • The mezzanines were part of a major turn-key warehouse automation project.
  • A cross sorter conveyor under the mezzanines, free standing weighing scale platforms, shelving, and conveyors on each level.
  • The overall realisation time of the entire project took less then 1 year from tender till completion.
  • The project was divided in phases according to the installation preferences and planning of the customer.


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Perfect combination: automation and more space

For one of our international customers, we supplied a double-deck mezzanine flooring for 2 major logistics halls with a total mezzanine surface of 40,000 m2.

The mezzanines were part of a major turn-key warehouse automation project with cross sorter conveyor under the mezzanines, free standing weighing scale platforms, shelving, and conveyors on each level.

From the start of the tendering phase Profielnorm was proactively advising the customer on the concept of the mezzanine in combination with the automation and shelving.

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Certification

NEN-EN 1090 and ISO 3834

Sustainability

CSR & Circulair building

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