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Custom-made mezzanine floors

Profielnorm supplies more than 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.

Mezzanine case studies

Efficient mezzanine structure with multifunctional use Efficient mezzanine structure with multifunctional use Efficient mezzanine structure with multifunctional use Efficient mezzanine structure with multifunctional use Efficient mezzanine structure with multifunctional use Efficient mezzanine structure with multifunctional use Efficient mezzanine structure with multifunctional use Efficient mezzanine structure with multifunctional use
77 m2
350 kg/m2
RAL 7016
Germany

Efficient mezzanine structure with multifunctional use

Profielnorm was engaged in a new construction project to create a mezzanine floor designed for dual-purpose use—offices on the ground floor and storage facilities above.

The key challenge was to design a load-bearing steel structure using as few columns as possible. This was essential because the area beneath was planned for office units, where minimising obtrusive supports was critical. At the same time, the upper level needed to offer robust load capacity to accommodate storage requirements.
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Efficient mezzanine structure with multifunctional use

Quick facts:

  • Office and storage space in one;
  • Sufficient load-bearing capacity;
  • Large spans.
 
What are the specialties of this project?
  • Seamlessly integrating ground-floor office space with an upper-level storage area.
  • Precision-engineered steel components for fast on-site assembly and reduced build time.
  • Upper floor designed with a reinforced system to meet industrial load requirements.

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Mezzanine floor for system integrators Mezzanine floor for system integrators Mezzanine floor for system integrators Mezzanine floor for system integrators Mezzanine floor for system integrators Mezzanine floor for system integrators Mezzanine floor for system integrators Mezzanine floor for system integrators
1,347 m2
350 kg/m2
RAL 7035
Germany

Complex mezzanine design for tight spaces

Profielnorm was contacted by a system integrator for a challenging project in Germany. The goal was to design, manufacture, and install two interconnected mezzanines to support conveyors and control cabinets.

The biggest challenge in this project was a closed concrete shaft that needed four levels of mezzanines with spiral conveyors through them. All levels needed to be attached to the concrete walls of the shaft and no columns should be used. Have a look at this complex mezzanine project completed by Profielnorm.
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Complex mezzanine design for tight spaces

Quick facts:

  • 4 mezzanine levels with spiral conveyors through them
  • 957m2 chipboard and 390m2 grating in the concrete shaft
  • Load capacity up to 350 kg/m2

What are the specialities of these projects?
  • Four levels in the shaft all built without columns, attached to the walls.
  • Mezzanines engineered to support conveyors and control cabinets effectively.
  • Two interconnected mezzanines designed for optimal support.
  • Innovative engineering solutions and meticulous execution.

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Installation of a mezzanine floor Warehouse mezzanine by Profielnorm Profielnorm mezzanine floor Multi-tier mezzanine floor Custom-made mezzanine solutions by Profielnorm Warehouse mezzanine Multi-tier mezzanine floor Mezzanine solutions by Profielnorm
25,967 m2
350 kg/m2
RAL 7035
The Netherlands

Streamlining operations to meet surging orders

A leading online clothing retailer sought to revolutionise its warehouse operations. With customer demand surging, they faced the challenge of efficiently managing and swiftly dispatching thousands of clothing items on a daily basis.

We embarked on a collaborative journey to transform their warehouse into a hub of efficiency and safety with our mezzanine solutions. Have a look at the progress and result in this case study!
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Streamlining operations to meet surging orders

Quick facts:

  • A sprawling 25,967m2 mezzanine across four towering floors
  • Reaching heights exceeding 13 metres
  • 30-minute fire-resistant staircase towers
  • A state-of-the-art sprinkler system on each mezzanine level

What are the specialities of these projects?
  • A challenging project we navigated with precision and innovation.
  • Advanced hanging clothing sorters are integrated to streamline operations.
  • A mezzanine project meeting and exceeding regulatory requirements.
  • A portal design without bracing.

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Innovative mezzanine solutions by Profielnorm Innovative mezzanine solutions by Profielnorm Innovative mezzanine solutions by Profielnorm Innovative mezzanine solutions by Profielnorm Innovative mezzanine solutions by Profielnorm Innovative mezzanine solutions by Profielnorm Innovative mezzanine solutions by Profielnorm Innovative mezzanine solutions by Profielnorm
3,550 m2
250 kg/m2
RAL 7016
Germany

Enhancing operational efficiency for a supermarket chain

Profielnorm partnered with a top supermarket chain to develop a state-of-the-art distribution centre, focusing on advanced automated palletising and depalletizing processes.

This ambitious project demanded sophisticated mezzanine floor solutions seamlessly integrated with high-tech automation systems. It’s a prime example of how Profielnorm collaborates with industry leaders to drive innovation and elevate operational efficiency.
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Enhancing operational efficiency for a supermarket chain

Quick facts:

  • A mezzanine design to support heavy pallet conveyors and automated systems
  • Integration of 4 catwalks spanning 26 metres each
  • Equipped with 12 cage ladders for safe access

What are the specialties of this project?
  • Design, production, and installation of specialised mezzanine floors tailored for heavy-duty automation systems.
  • 1,500m2 of chipboard and 2,100m2 of grating mezzanine floors.
  • Incorporation of lifts through the mezzanines and shuttle systems on top.

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Mezzanine solution Mezzanine solution Mezzanine solution Mezzanine solution Mezzanine solution Mezzanine solution Mezzanine solution Mezzanine solution Mezzanine solution Mezzanine solution Mezzanine solution Mezzanine solution
43,200 m2
200 kg/m2
RAL 7016
Germany

Mezzanine solution for an international clothing brand

In collaboration with a system integrator and a shelving supplier, we had the great opportunity to contribute to the construction of a major distribution centre.

This prominent international clothing brand is located in Germany. Our specific role involved supplying mezzanines, a critical component of the overall infrastructure. We worked in close cooperation with our partners to ensure seamless integration.
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Mezzanine solution for an international clothing brand

Quick facts:

  • Four halls with each four mezzanine floors
  • Nearly 2.5 kilometres of railing were incorporated
  • Columns stacked over 11 metres high

What are the specialties of this project?
  • Seamless integration with the shelving and sorting systems, enabling smooth operations and easy access for maintenance.
  • Top-down construction.
  • Precision engineering ensured all breakthroughs and structural accommodations were precisely aligned with the sorter system’s requirements.

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Mezzanine floors for units Mezzanine floors for units Mezzanine floors for units Mezzanine floor Profielnorm Mezzanine floors for units Mezzanine floors for units Mezzanine floors for units
387 m2
500 kg/m2
RAL 9002
The Netherlands

Mezzanine floors for units

A small, large, simple or complex mezzanine floor?
It's all possible: the sky is the limit!
 
The main aim of this project is to provide a solution that meets all the customer's requirements. Together with the customer, we ensured that seven units with double square metres could be rented out.

Thanks to Profielnorm’s fully customised mezzanine floors, everything was designed, manufactured and installed as expected for the customer.
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Mezzanine floors for units

Quick facts:

  • 387m2 in total
  • Load capacity up to 500 kg/m2
  • Mezzanine floors for seven different units
  • Powder coated in RAL 9002

What are the specialities of this project?
 
  • Low height due to low-hanging beams
  • Consideration of water drainage for the toilets
  • Make the square metres of seven units as attractive as possible to potential tenants
 
 

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Dedicated system integration solution Dedicated system integration solution Dedicated system integration solution Dedicated system integration solution Dedicated system integration solution Dedicated system integration solution Dedicated system integration solution Dedicated system integration solution
10,000 m2
250 kg/m2
RAL 7016
The Netherlands

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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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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Large spans for a logistics hub Large spans for a logistics hub Large spans for a logistics hub Large spans for a logistics hub Large spans for a logistics hub Large spans for a logistics hub Large spans for a logistics hub Large spans for a logistics hub
31,000 m2
500 kg/m2
RAL 7035
The Netherlands

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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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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System integration mezzanine floor System integration mezzanine floor Make the most of your space with a mezzanine floor Installing a mezzanine floor Walkway for your mezzanine floor Custom-made mezzanine floor System integration solutions Custom-made mezzanine floors
3,109 m2
750 / 350 kg/m2
RAL 9017
Germany

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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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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Highest built mezzanine floor Mezzanine floor with five levels More space with a mezzanine floor High mezzanine floor Mezzanine floor for your business Floor finish for your mezzanine floor More space with a mezzanine floor
5,720 m2
500 kg/m2
RAL 5010
Germany

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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Next level for Profielnorm

Quick facts:

  • An impressive project with a height of 18,400mm
  • 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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Warehouse mezzanine floor Mezzanine floor in your warehouse Mezzanine floor More space in your warehouse Mezzanine floor with two levels Mezzanine Profielnorm Mezzanine floor pallet gate Profielnorm Mezzanine floor staircases
20,299 m2
300 kg/m2
RAL 7016
The Netherlands

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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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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Steel mezzanine floor Steel mezzanine floor construction Mezzanine project by Profielnorm Mezzanine construction
4,822 m2
500 kg/m2
RAL 9005
The Netherlands

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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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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Mezzanine with orange columns Mezzanine floor in company colours Profielnorm mezzanine floor Mezzanine floor construction Installing a mezzanine floor Mezzanine floor with orange columns Installation of a mezzanine floor New mezzanine floor
40,000 m2
600 kg/m2
RAL 2003
Ukraine

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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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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