June 16, 2025 Building Up, Not Out with a Multistory Mezzanine

A Miami warehouse gets 7,000+ sq. ft. of code-compliant storage space with Panel Built’s modular mezzanine construction.

BLAIRSVILLE, GA — A Miami-based flower distributor had a problem familiar to many growing businesses: they were out of space. Their warehouse was reaching capacity, but expanding the building would have required a major investment and caused significant disruption to ongoing operations. With limited flexibility for downtime, a traditional build-out simply wasn’t practical.

Looking for a faster and less invasive solution, the company turned to Panel Built to design and deliver a two-story structural mezzanine that would maximize storage within their existing footprint.

A Modular Approach

Atlantic Rack, our trusted dealer, installed a 33′ x 110′ structural steel mezzanine using pre- engineered components manufactured by Panel Built. The new structure added more than 7,000 square feet of elevated storage above the warehouse floor.

Because the system was fabricated oV-site, installation moved quickly. The columns were anchored into the facility’s concrete slab to ensure long-term strength, and most components arrived ready to assemble. That meant less on-site labor and minimal disruption to operations.

“Our customer tasked Panel Built with providing a multi-level mezzanine to increase their production space for both cart traVic and storage,” explained Panel Built Sales Rep Seth Brinkman. “Working together to better understand their needs for eVicient workflow, we were able to deliver a design that exceeded their expectations and will continue to propel their growth into the future.”

See how the installation came together in this project overview video.

Installation & Site Coordination

Before components could be set, the crew core-drilled into the concrete slab at each column location. This ensured stable anchoring and proper load transfer across the full 110-foot span. Precise layout planning ensured accurate alignment and prevented installation errors.

The installation team coordinated with warehouse staff to stage materials and keep the project on schedule. Thanks to the modular system’s bolt-together design and rigorous pre-fabrication standards, the team completed the project with limited impact on the customer’s workflow.

Modular Benefits for Contractors

For contractors, modular mezzanines offer several clear advantages. Shifting much of the labor to the factory reduces hours on-site and shortens the overall construction timeline. With pre- engineered drawings and precision manufactured components, field crews can focus on assembly rather than improvisation.

This approach also streamlines inspections and reduces unexpected on-site delays. Everything from connection points to gate placement is accounted for in advance, making the job more predictable, especially in an occupied or time-sensitive facility.

Design Considerations

The mezzanine was engineered to match the client’s specific operational needs, balancing accessibility and durability. Key features included:

• 125 PSF Load Capacity for palletized and bulk inventory
• Hybrid resin and bar grate flooring for durability and drainage
• Eight 6-foot double swing gates for forklift-friendly access
• Powder-coated finish in yellow and gray for high-visibility
• IBC-compliant design for structural and safety assurance

Why It Matters

This project demonstrates how modular mezzanine construction can deliver big results with less disruption. By working with pre-engineered systems, installers were able to complete this high- capacity, code-compliant mezzanine on a tight timeline. For growing businesses with space constraints, and for contractors seeking labor-efficient solutions, modular systems like this one offer a smart, scalable path forward.

About the Author:
Clair Hartley is part of the marketing team at Panel Built, where she’s spent the past five years sharing the company’s modular solutions and finding creative ways to tell the Panel Built story.

Subscribe to Industry Today