Category: Case Studies

When a New Jersey (NJ) commercial printing company approached Mezzmaster by Westhead Associates for a new equipment platform, they brought a highly specific, non-negotiable structural requirement. The platform was being installed to support their incoming delivery of heavy-duty printing presses. This meant that maximizing floor space and ensuring machine clearance were absolutely critical to their daily operations.

In the commercial printing business, equipment integration leaves zero room for error. Standard, off-the-shelf mezzanine structures simply will not work for these facilities because traditional support column placements would block the exact paths needed to operate, load, and service the machinery.

The Structural Challenge: Eliminating Warehouse Floor Obstructions

To keep the operational paths completely clear for the new printing presses, our design team had to drastically limit the number of vertical steel columns on the shop floor. Standard platform layouts typically rely on a rigid grid of multiple columns to distribute weight safely. However, this specific machinery setup required a heavy-duty industrial structure that could support intense weight loads while leaving the ground space completely unobstructed.

The Mezzmaster Solution: A Custom Cantilevered Platform Design

Our structural steel engineering team developed a fully custom cantilevered platform utilizing only two structural columns.

To achieve the necessary clearance for the printing equipment, the column-to-column width was locked in at 3 feet 6 inches. From that final set of supports, we engineered a custom cantilevered span that extended an additional 4 feet out over the open floor. This unique steel overhang allowed the platform to fulfill its functional footprint requirements up top without intruding on the equipment pathways below.

To handle the weight distribution and rigorous structural demands of the printing facility, the platform deck was built utilizing heavy-duty B-deck and finished with robust steel diamond plate flooring. This specific material combination provides the rigid structural support, high capacity, and durable walking surface necessary for industrial manufacturing environments.

The Mezzmaster Advantage: Custom Steel Fabrication and Stamped Drawings

This project highlights exactly why industrial facilities partner with Mezzmaster by Westhead Associates for their space-saving needs. We do not force your warehouse operations to fit into a pre-packaged mezzanine kit. Every single equipment platform, industrial stair system, and mezzanine we deliver is engineered custom to your exact operational requirements, facility constraints, and machinery specifications.

Security and compliance are built into our workflow from day one. Every custom platform design meets all local and national building codes, complete with certified engineering stamped drawing approvals from the state to ensure total safety before installation even begins.

Looking for a Custom Industrial Real Estate Solution?

Do you have a challenging layout, tight clearances, or strict equipment constraints in your manufacturing facility? Contact the Mezzmaster team today to discuss how our custom structural steel fabrication and engineering services can maximize your vertical space.

In the world of industrial production, sometimes the biggest challenge isn’t what you’re making, but how you’re housing it. We recently completed a project for a client in New Jersey that required a specialized solution for their tank room, and the results are a perfect example of form meeting function.

The Challenge: Climate & Chaos

Our client needed to isolate their large production tanks from the rest of the facility. The goal was twofold:

1. Operational Separation: Keeping the high-traffic flow of production and deliveries away from sensitive equipment.
2. Climate Control: Maintaining a precise, controlled temperature within the tank area to ensure product integrity.

The Mezzmaster Solution: 4″ Insulated Metal Panels (IMP)

To achieve the R-value and structural integrity required, we utilized 4″ thick Insulated Metal Panels. These aren’t your standard partitions; they are high-performance building materials designed for superior thermal efficiency.

Key Project Specs:

• Seamless Integration: We installed the panels in a straight, single run from floor to ceiling.
• Soaring Heights: Each panel stands 30 feet high, providing a clean, vertical finish without the need for horizontal joints or complex framing.
• Total Isolation: The “box-in” design created a dedicated room-within-a-building, effectively shielding the tanks from the ambient temperature and dust of the loading docks.

Why This Matters for Production

By choosing 30-foot IMPs, the client gained a durable, easy-to-clean, and highly insulated environment. This enclosure doesn’t just look professional, it saves on energy costs and prevents temperature creep from the delivery bays, allowing the client to focus on their output rather than their thermostat.

Maximizing Production Space

In the competitive world of industrial printing, maximizing every square foot of your facility is essential for growth. We recently completed a high-profile project for a client in North Jersey who required an elevated workspace. This custom engineered mezzanine by Mezzmaster by Westhead Associates Inc. serves as a premier example of how structural steel can solve complex spatial challenges.

Strategic Engineering for Industrial Workflow

The primary goal for this North Jersey printing company was to create a specialized production area without sacrificing the valuable floor space below. Our team designed the structural platform with specific column spacing to ensure that the movement of forklifts and raw materials remained completely unobstructed. Because we aligned the support columns with existing traffic patterns, we maintained a seamless flow of operations on the ground level.

Creating a Controlled Printing Environment

To meet the high standards of a professional printing space, we enclosed the top of the platform using Insulated Metal Panels or IMPs. These panels are a superior choice for industrial cleanrooms because they provide a thermal barrier and a smooth surface that is easy to maintain. Furthermore, this enclosure protects sensitive printing equipment from warehouse dust and temperature fluctuations. This strategic addition effectively doubled the usable square footage of the facility.

Safety and Compliance with Dual Egress

Safety remains a core priority at Mezzmaster by Westhead Associates Inc. This North Jersey installation features two separate means of egress to ensure full compliance with building codes and provide efficient access for the crew. These heavy duty staircases allow for safe movement between levels. This accessibility is critical in a fast paced manufacturing environment where personnel must move quickly and securely.

Rapid Installation for Immediate ROI

One of the most impressive aspects of this project was the speed of the transition. Our modular design allowed for a quick and easy install that minimized downtime for the client. Consequently, the business owner in North Jersey now has a state of the art printing suite ready for high volume production. This project demonstrates how a rapid facility upgrade can lead to an immediate return on investment.

Contact Mezzmaster by Westhead Associates Inc. Today

If your warehouse or manufacturing plant needs more space, a custom mezzanine is the most cost effective solution available today. We specialize in designing and installing high quality platforms throughout the New Jersey, Pennsylvania, and New York area. Reach out to our team to discuss how we can optimize your facility with a custom engineered platform.

Unlocking Vertical Potential with VRC Lifts and Mezzanine Systems

At Mezzmaster by Westhead Associates Inc., we specialize in facility solutions that maximize space and cubic square footage. One of the most effective ways to unlock unused vertical space in a warehouse is through the strategic use of mezzanines paired with the right material handling equipment. A recent project featuring a PFlow Vertical Reciprocating Conveyor (VRC) serves as a perfect example of this synergy in action.

Project Overview: High Capacity VRC Lift for Mezzanine Storage

For this specific installation, our client required a safe and efficient way to move goods from the ground level to the top of their storage mezzanine. To meet this operational need, we installed a PFlow VRC lift with impressive dimensions of 10’ 0” W x 11’ 0” L x 24’ 6” H. This vertical material lift allows the client to transport products directly to their mezzanine level without using forklifts or ramps. Consequently, this system significantly improves both safety and workflow efficiency across the entire facility.

Why Choose a VRC Lift Over a Traditional Elevator?

A Vertical Reciprocating Conveyor is designed specifically for material handling rather than passenger transport. Compared to traditional freight elevators, VRCs offer several distinct advantages for industrial settings:

• Cost Effective Vertical Lifting: VRCs provide a much more affordable solution for moving goods between levels.
• Compact Footprint: These lifts are ideal for tight warehouse layouts where every square foot of floor space is valuable.
• Mezzanine Integration: Engineers design these systems specifically to integrate with mezzanine structures.
• Improved Workplace Safety: By reducing forklift traffic on upper levels, VRCs create a more secure environment for workers.
• Rapid Movement of Goods: These systems facilitate the swift transfer of inventory between floors to keep production on schedule.

The Benefits of a PFlow VRC System

PFlow Industries remains one of the most trusted manufacturers of VRC lifts in the industry. They are known for quality, reliability, and code compliant designs. Their VRC systems offer several high value features:

1. Safety Standards: Every unit is built to meet ASME safety standards for peace of mind.
2. Total Customization: These lifts are highly adaptable for different loads, sizes, and specific facility layouts.
3. Durability: The systems are famously durable and require very low maintenance over their lifespan.
4. Industrial Suitability: They are perfectly suited for the rigors of warehouse, manufacturing, and distribution facilities.

Maximizing Cubic Square Footage with Mezzmaster by Westhead Associates Inc.

At Mezzmaster by Westhead Associates Inc., we do not just install equipment. Instead, we design complete space optimization solutions. By combining mezzanines, VRC lifts, and material handling systems, we help our clients achieve several key goals.

First, we increase storage capacity without expanding the physical building footprint. Second, we improve workflow and overall operational efficiency. Finally, we enhance workplace safety and ensure that businesses get the most value possible from their existing facility. This PFlow VRC installation demonstrates how smart vertical design can transform a facility from a crowded warehouse into a streamlined operation.

Conclusion: It Is Time to Look Up

If your facility is running out of floor space, it may be time to utilize your vertical volume. Mezzmaster by Westhead Associates Inc. provides expert guidance, design, and installation for mezzanines and VRC lifts tailored to your operation.

Contact Mezzmaster by Westhead Associates Inc. today to learn how we can help you maximize your space and cubic square footage. We are ready to help you grow your business safely and efficiently.

At Mezzmaster, we specialize in creating smart, space-maximizing solutions for growing facilities. One of our recent projects perfectly highlights how a two-level modular office can transform workflow, improve logistics, and add valuable square footage—all with minimal downtime.

A Smarter Check-In Solution for Trucking Deliveries

Our client needed a centralized check-in point for incoming truck deliveries to streamline communication and improve visibility across their facility. Instead of building a costly traditional structure, they chose a modular office system, which allowed us to install a fully functional workspace quickly and efficiently.

The first level of the custom modular office now serves as the dedicated check-in station. Truck drivers can easily report, sign in, and receive instructions, helping the facility maintain smooth and organized operations.

Maximizing Space with an Upper-Level Office

The second level of the structure provides additional office space—a major advantage when floor space is limited. This elevated workspace offers privacy, visibility, and flexibility for administrative or supervisory staff, proving once again why mezzanines and modular offices are ideal for facilities that need to grow without expanding their footprint.

Fast Installation, Minimal Disruption

One of the biggest benefits of modular construction is speed. This two-level modular office was installed quickly and ready for use in just a few days, allowing the client to stay productive without lengthy construction delays. Our team ensured a clean, efficient installation process from start to finish.

Why Choose Mezzmaster for Modular Offices and Mezzanine Structures?

• Rapid installation with minimal downtime
• Custom designs tailored to your operational needs
• Cost-effective expansion solutions
• Durable, high-quality modular components
• Expertise in multi-level office and mezzanine builds

If your facility needs more space, better workflow organization, or a cost-effective way to expand, a two-level modular office may be the perfect solution.

Maximize Cubic Square Footage

At Mezzmaster by Westhead Associates Inc., we specialize in helping businesses maximize cubic square footage through custom-engineered mezzanines, equipment platforms, and modular office systems. Our recent project showcases how a well-designed mezzanine dramatically improves office functionality and facility efficiency without expanding the physical building footprint.

Industrial Project Overview: Vertical Space Optimization

Our client needed to create additional office space within their existing facility while maintaining flexibility for future growth. The goal was to utilize vertical height, ensure safe accessibility, and deliver a professional appearance.

To achieve this, our engineering and fabrication teams designed and installed a two-level mezzanine system. This project integrates modular offices on both levels, providing enclosed workspaces now and adaptable space for future expansion.

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Lower-Level Modular Office Design

The area beneath the mezzanine was enclosed using high-quality insulated modular wall panels. This created a quiet, climate-controlled office and operations area. These panels provide several key benefits:

• Superior Sound Insulation: Ideal for administrative or supervisory work.
• Temperature Control: Maintains a steady climate within the production environment.
• Flexible Access: The design includes multiple double-door entryways for smooth traffic flow and two independent stair systems for dual-side access.

Mezzanine Deck and Upper-Level Layout

The upper deck features a second modular office, offering elevated visibility and oversight of the production floor. To the right of this office, the mezzanine includes open floor space that can be adapted at any time. Whether the client needs to expand the office, add equipment storage, or create a production zone, the footprint is ready for growth.

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Key Results: Efficiency and Adaptability

By choosing a design-build solution from Mezzmaster by Westhead Associates Inc., the client achieved:

• Increased Cubic Footage: Gained usable space without the cost of new construction.
• Enhanced Workflow: Improved accessibility with dual stair access points.
• Professional Finish: A modern, integrated look using insulated modular wall systems.
• Future-Proofing: Built-in adaptability for office, storage, or production expansion.

Ready to Maximize Your Facility Space?

If you are looking to expand your office space or increase usable floor area without adding to your building footprint, we can help. Our in-house design, engineering, and installation teams deliver custom mezzanine and modular office systems tailored to your specific business goals.

Contact Mezzmaster by Westhead Associates Inc. today to start your facility transformation.

Mezzmaster by Westhead Associates Inc. recently completed a specialized mezzanine project in New Jersey for a client requiring a custom equipment platform to support incoming industrial press machines. This 2,200 square foot L-shaped mezzanine was engineered to fit seamlessly into the facility, spanning a slanted floor and extending across an existing ramp.

Engineering for Heavy Machinery: Hydraulic Press Support

What made this project unique was the requirement to install hydraulic presses both on top of the platform and on the ground level beneath it. To accommodate this, our design team carefully engineered the column layout to ensure the mezzanine structure would not interfere with the equipment footprint below.

Every column was positioned with precision to allow clear access and full functionality for both levels of machinery. This detail-oriented approach ensured the platform provided the necessary structural support above while avoiding any operational disruption on the facility floor.

Structural Integrity: I-Beam Steel and Bar Grating

To meet the heavy load requirements of hydraulic presses, the platform was constructed using:

• Heavy-Duty I-Beam Steel Framing: Providing the essential strength and long-term performance required for industrial applications.
• Bar Grating Deck: Chosen for its durability, safety, and ability to handle concentrated loads.

Every component was engineered to maximize usable space while maintaining the highest standards of structural integrity.

Coordinating Tight Installation Timelines

Timing was a critical factor for this project. The client had a fixed delivery date for their new hydraulic presses, making it essential for the mezzanine to be fully installed before the equipment arrived.

The Mezzmaster by Westhead Associates Inc. team coordinated closely with the client’s schedule to ensure the installation was completed without delays. This allowed the presses to be delivered and commissioned exactly on time.

Custom Mezzanines Built for Your Facility

This New Jersey equipment platform demonstrates how custom steel mezzanines can be tailored to solve complex facility layouts. Whether you are spanning over ramps, fitting irregular footprints, or supporting heavy industrial machines, we design and install systems that solve your specific operational challenges.

Ready to Optimize Your Floor Plan?

If your business needs to maximize space or support new equipment with a custom mezzanine, contact Mezzmaster by Westhead Associates Inc. today to learn more about our turnkey design and installation services.

High-Performance Modular Cold Storage

At Mezzmaster by Westhead Associates Inc., we specialize in creating high-performance cold storage rooms using our proven Insulated Metal Panel (IMP) solutions. Recently, we completed a modular cold storage project in New Jersey that illustrates our ability to deliver flexible, turnkey solutions in challenging environments.

The Challenge: Cold Storage in a Leased Facility

Our client required a state-of-the-art walk-in cooler within a leased building, making modular construction a top priority. A significant hurdle was the facility’s roof structure, which lacked the strength to support the load of an insulated metal panel ceiling. Our team engineered a creative, cost-effective solution that functioned independently of the existing building’s joints.

The Mezzmaster Advantage: Steel and IMP Contractors

While many contractors specialize in only one area, Mezzmaster by Westhead Associates Inc. brings multiple capabilities under one roof. In addition to being expert IMP contractors, we are experienced steel and mezzanine builders.

For this project, our team designed and built a freestanding steel support structure inside the facility to carry the load of the insulated metal panels. This eliminated the need for outside subcontractors and streamlined the entire build. The system featured:

• Perimeter Columns: Spaced strategically along the walls for maximum stability.
• Bar Joists: Integrated below the IMP ceiling to create a secure, durable framework.

Two Approaches, One Contractor

We provided our client with two distinct engineering options:

1. Building the IMP enclosure around the steel support structure.
2. Building the steel structure beneath the IMP ceiling.

For this New Jersey cold storage build, the client chose to place the steel support under the IMP. Our team handled every phase of construction from start to finish. This flexible approach allows businesses to expand or modify their facilities quickly without managing multiple vendors.

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Why Clients Choose Mezzmaster by Westhead Associates Inc.

• Turnkey Service: We are your single-source partner for IMP, steel, and mezzanine construction.
• Custom Engineering: Our designs are tailored to the unique footprint of your facility.
• Modular Flexibility: Ideal for leased buildings or spaces where future reconfiguration is expected.
• Operational Efficiency: Expand cold storage capacity without interrupting your daily operations.

Boosting Efficiency with Custom Cold Storage Solutions

We do more than build cold storage rooms; we engineer solutions that help clients increase operational efficiency and maximize their usable space. Whether you need a walk-in cooler, a freezer room, or a complete warehouse expansion, our insulated metal panels and steel support systems deliver performance and value.

Ready to Build Your Cold Storage Room? If your facility needs a modular cold storage solution or you are exploring options for insulated metal panel construction, let Mezzmaster by Westhead Associates Inc. be your partner.

Contact us today to discuss your project and discover how our IMP and steel solutions can transform your facility.

At Mezzmaster, we understand that in professional manufacturing environments, dust and debris are more than an inconvenience. They are a liability for your equipment and your workflow. We engineered a breakthrough solution to solve this problem. Our Patent Pending Closed Tubular Mezzanine System addresses particulate accumulation, which is one of the most common yet overlooked issues in facility design.

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The Problem with Traditional I Beam Systems

Standard mezzanine designs often make it difficult to maintain a clean workspace. Typical I beam systems, commonly found in warehouses and production facilities, are notorious for dust buildup. The flat angles and open ledges of these structures act as magnets for debris.

In many facilities, companies must pay employees to manually dust the framework frequently just to keep the area presentable and safe. These outdated systems feature exposed flanges and crevices that become prime traps for dust and buildup. This is a significant drawback for high standards in industries such as:

• Pharmaceutical manufacturing
• Aerospace and defense facilities
• Precision electronics plants
• Food and beverage processing centers

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The Mezzmaster Advantage: Closed Tubular Design

Our Closed Tubular Mezzanine System offers a revolutionary alternative. This design uses sealed, smooth tubular steel construction to eliminate the unnecessary angles and joints where dust typically collects.

Ultra Clean Finish

The system features no exposed horizontal flanges or shelf like surfaces. This virtually eliminates the need for frequent manual cleaning and significantly reduces the risk of dust falling onto production lines or sensitive equipment below.

Strength You Can Trust

We build every system from heavy duty tubular steel engineered for maximum load capacity and durability. Our patent pending closed system is both clean and incredibly stable.

Smart Design for Modern Manufacturing

This system is perfect for facilities focused on 5S standards or GMP compliance. We designed it for low maintenance operation in mission critical environments where keeping a clean floor is a top priority.

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Built for the Demands of Tomorrow

The Mezzmaster Tubular Mezzanine System is a long term solution for companies serious about maintaining an efficient and tidy workspace. Whether you are expanding a production floor or creating a new equipment platform, our system meets the highest standards for a clean mezzanine solution.

With our in house design and installation team, we support your project from concept to completion.

Ready to Upgrade? Contact Mezzmaster today to schedule a consultation and see how our tubular system can transform your facility. The difference in cleanliness and efficiency speaks for itself.

At Mezzmaster, we specialize in innovative facility construction solutions that turn underutilized space into efficient, productive environments. This older success story involved the design and installation of a custom 2-story modular office inside a military aircraft hangar—an ideal example of how our systems optimize even the most challenging spaces.

Creating Workspace Inside a Military Aircraft Hangar

Military hangars are built for size and strength, but rarely for interior workspace. Our client needed a secure, climate-controlled environment inside their large, open hangar—a space primarily used for aircraft storage and maintenance. Traditional construction wasn’t a practical or efficient option. That’s where Mezzmaster’s modular office systems came in.

We delivered a 2-level modular office structure right in the heart of the hangar. The new space offers enclosed offices, meeting rooms, and break areas—without compromising hangar functionality or footprint. This solution created usable workspace within a high-volume facility, all while maintaining operational efficiency and speed of deployment.

Built with Safety and Performance in Mind

Like all our modular builds, this project used Class A non-combustible panels, which offer superior fire resistance and meet strict safety standards. The system features:

• R-Value: R-11 for effective thermal insulation
  
• STC-31 sound rating for acoustic control
  
• Class “A” per ASTM-E84 for flame spread and smoke development
  

These features are especially critical in military and aerospace environments, where safety and durability are non-negotiable.

Fast, Flexible, and Future-Proof

One of the greatest advantages of our modular office construction is speed. Unlike traditional builds, modular systems are pre-engineered, allowing for rapid installation with minimal disruption to operations. They’re also reconfigurable and relocatable, which means your investment grows with your facility needs.

This project is a prime example of how 2-story modular offices can add functionality, safety, and comfort in unconventional environments—whether that’s inside a warehouse, distribution center, or a military aircraft hangar.

Why Choose Mezzmaster?

• Industry-leading experience in modular construction for industrial and military applications
  
• Tailored solutions for warehouse offices, mezzanine systems, and in-plant buildings
  
• Code-compliant materials and engineering that meets or exceeds local and federal standards
  
• Turnkey support from design through installation
  

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If your facility needs more space, smarter layout, or safer environments—Mezzmaster has the solution.