Category: Case Studies

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 or industrial facility is through the strategic use of mezzanines paired with the right material handling equipment. A recent project featuring a PFlow Vertical Reciprocating Conveyor (VRC) is a perfect example.

Project Overview: VRC Lift for Mezzanine Storage

For this installation, our client needed a safe and efficient way to move goods from the ground level to the top of their storage mezzanine. To meet this need, we installed a PFlow VRC lift sized at:

• 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, improving both safety and workflow efficiency.

Why Use a VRC Lift Instead of an Elevator?

A Vertical Reciprocating Conveyor (VRC) is designed specifically for material handling—not passengers. Compared to traditional freight elevators, VRCs offer several advantages:

• Cost-effective vertical lifting solution
• Smaller footprint, ideal for tight warehouse layouts
• Designed to integrate with mezzanine systems
• Improved safety by reducing forklift traffic on upper levels
• Efficient movement of goods between floors

For facilities looking to maximize vertical storage space, VRC lifts are often the smartest and most practical solution.

Why We Chose a PFlow VRC

PFlow Industries is one of the most trusted manufacturers of VRC lifts in the industry, known for quality, reliability, and code-compliant designs. Their VRC systems are:

• Built to ASME safety standards
• Highly customizable for different loads, sizes, and layouts
• Durable and low maintenance
• Well-suited for warehouse, manufacturing, and distribution facilities

For this project, the PFlow VRC was the perfect match for the client’s mezzanine storage needs, providing smooth, dependable vertical material movement while supporting long-term operational growth.

Maximizing Cubic Square Footage with Mezzmaster

At Mezzmaster, we don’t just install equipment—we design complete space-optimization solutions. By combining mezzanines, VRC lifts, and material handling systems, we help clients:

• Increase storage capacity without expanding their footprint
• Improve workflow and operational efficiency
• Enhance workplace safety
• Get more value from their existing facility

This PFlow VRC installation is a great example of how smart vertical design can transform a facility.

Looking to Optimize Your Facility?

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

Contact us today to learn how we can help you maximize your space and cubic square footage—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.

At Mezzmaster, we specialize in helping businesses maximize their cubic square footage through custom-engineered mezzanines, equipment platforms, and modular office systems. Our recent project showcases how a well-designed mezzanine can dramatically improve office functionality and facility efficiency — all without expanding the building footprint.

Project Overview

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

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

Lower-Level Modular Office

The area beneath the mezzanine was fully enclosed using high-quality insulated modular wall panels, creating a quiet, climate-controlled office and operations area. These modular panels provide superior sound insulation, temperature control, and a professional finish, ideal for administrative or supervisory workspaces.

The design includes multiple double-door entryways for smooth traffic flow and two independent stair systems leading to the mezzanine deck from either side. The modular system also allows the client to easily reconfigure or expand the space as their needs evolve.

Mezzanine Deck and Upper-Level Layout

On the upper deck, we constructed another modular office offering elevated visibility and oversight of the production floor. To the right of this office, the mezzanine includes open, unused floor space that can be adapted at any time — whether to expand the office area, add equipment storage, or create a dedicated production zone as operations grow.

This flexibility allows the client to plan for future needs while benefiting from immediate operational improvements.

The Results

• Maximized cubic square footage without new construction
• Improved workflow and accessibility with dual stair access
• Modern, integrated appearance using insulated modular wall systems
• Built-in adaptability for future office, storage, or production expansion

This project demonstrates Mezzmaster’s design-build expertise and commitment to delivering smart, flexible, and space-efficient solutions tailored to each client’s goals.

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Ready to Maximize Your Facility Space?

If you’re looking to expand your office space or increase usable floor area without adding to your building footprint, Mezzmaster can help. Our in-house design, engineering, and installation teams deliver custom mezzanine and modular office systems that grow with your business.

Mezzmaster recently completed a mezzanine project in New Jersey for a client who needed a custom equipment platform to support incoming press machines. This 2,200 square foot L-shaped mezzanine was designed to fit seamlessly into their facility, spanning over a slanted floor and carrying across an existing ramp.

Hydraulic Press Support Above and Below

What made this project especially unique was the client’s plan to install hydraulic presses both on top of the new platform and below it. That requirement meant our design team had to carefully plan the column layout so the footprint of the mezzanine structure would not interfere with the presses located underneath. Every column was positioned with precision to allow clear access and functionality for both levels of equipment. This attention to detail ensured that the mezzanine provided the necessary support above while avoiding any disruption below.

Durable I-Beam Steel Construction with Bar Grating Deck

The platform was built using strong I-beam steel framing and a bar grating deck to ensure safety, strength, and long-term performance. Because the mezzanine needed to support heavy hydraulic presses, structural integrity was the highest priority. Every detail was engineered to handle the load requirements while maximizing usable space in the facility.

Meeting Tight Installation Timelines

Timing was another critical factor on this project. Our client had a scheduled delivery date for their new hydraulic presses, and it was essential that the mezzanine be completed before the equipment arrived. The Mezzmaster team coordinated closely with the client to ensure installation was completed without delays, allowing the presses to be delivered and installed on schedule.

Custom Mezzanines Built for Your Facility

This New Jersey mezzanine project demonstrates how a custom steel equipment platform can be tailored to meet unique facility layouts and operational needs. Whether spanning over ramps, fitting into irregular spaces, or supporting heavy industrial machines, Mezzmaster designs and installs mezzanines that solve complex challenges.

If your business is looking to maximize space and support new equipment with a custom mezzanine, contact Mezzmaster today to learn more about our turnkey mezzanine solutions.

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 perfectly illustrates our ability to deliver flexible, turnkey solutions—even in challenging environments.

The Challenge: Cold Storage in a Leased Facility

Our client needed a state-of-the-art walk-in cooler but didn’t own the building. This meant modular construction was a top priority. Because the facility’s roof structure wasn’t strong enough to support the load of the insulated metal panel ceiling, our team had to engineer a creative, cost-effective solution without relying on the existing building’s joints.

The Mezzmaster Advantage: Steel + IMP Contractors

Unlike many contractors who 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 also 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—eliminating the need for outside subcontractors.

The system featured columns spaced along the perimeter walls and bar joists running across the top below the IMP ceiling, creating a secure and durable framework for the cold storage room.

Two Approaches—One Contractor

We gave our client two options:

1. Build the IMP around the steel support structure
2. Build 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, and our team handled every phase of construction from start to finish.

This flexible approach allows businesses to expand or modify their facilities quickly without needing multiple contractors. Mezzmaster is your single-source partner for insulated metal panels, steel structures, and mezzanines.

Why Clients Choose Mezzmaster

• Turnkey service: One contractor for IMP, steel, and mezzanine construction
• Custom engineering: Every facility’s footprint is unique—our designs are tailored to your needs
• Modular flexibility: Ideal for leased buildings or spaces where future changes are expected
• Increased efficiency: Expand cold storage capacity without interrupting operations

Boosting Efficiency with Custom Cold Storage Solutions

At Mezzmaster, we don’t just build cold storage rooms—we engineer solutions that help our clients increase operational efficiency and maximize their 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, flexibility, and value.

Ready to Build Your Cold Storage Room?

If your facility needs a modular cold storage solution or you’re exploring options for insulated metal panel construction, let Mezzmaster by Westhead Associates Inc. be your partner. We bring the expertise, flexibility, and engineering know-how to deliver your project on time and on budget.

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 clean-controlled manufacturing environments, dust and debris aren’t just an inconvenience—they’re a liability. That’s why we’ve engineered a breakthrough solution: our Patent-Pending Closed Tubular Mezzanine System, specifically designed to address one of the most common yet overlooked issues in facility design—particulate accumulation.

Out With the Old: Traditional I-Beam Systems Invite Contamination

Take a look at the image to the left: this is your typical I-beam mezzanine system, commonly found in older warehouses and production facilities. Notice the dust buildup collecting on the flat angles and open ledges of the structure. In fact, this image shows a paid employee manually dusting the framework—a task that needs to be done frequently just to keep contamination under control.

These outdated systems come with exposed flanges and crevices that are prime traps for dust, mold, and debris, especially in sensitive environments like:

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

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In With the New: The Tubular Mezzanine System Advantage

Now look to the right: our Closed Tubular Mezzanine System. This revolutionary design uses sealed, smooth tubular steel construction, eliminating unnecessary angles, joints, and crevices where dust can collect. The result?

Ultra-Clean Finish

• No exposed horizontal flanges or shelf-like surfaces.
• Virtually eliminates the need for frequent manual cleaning.
• Reduces contamination risk in sensitive areas.

Strength You Can Trust

• Built from heavy-duty tubular steel engineered for load capacity and durability.
• Patent-pending closed system is not just clean—it’s strong and stable.

Smart Design for Modern Manufacturing

• Perfect for facilities focused on 5S standards, GMP compliance, or ISO cleanroom classifications.
• Designed for low-maintenance operation in mission-critical environments.

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Built for the Demands of Tomorrow’s Facilities

Mezzmaster’s Tubular Mezzanine System isn’t just a product—it’s a long-term solution for companies who are serious about maintaining a clean and efficient workspace. Whether you’re expanding your production floor, creating a new equipment platform, or designing a cleanroom-compliant structure, our system checks all the boxes.

And with our in-house design and installation team, we’re with you every step of the way—from concept to completion.

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Ready to Upgrade? Let’s Talk.

Want to see how the Mezzmaster Tubular Mezzanine System can transform your facility? Contact us today to schedule a consultation. And don’t forget to explore the image comparison above—the difference 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.

At Westhead Associates Inc. by Mezzmaster, we’re committed to delivering custom mezzanine solutions that help industrial businesses maximize space and efficiency. Our latest project took us back to New Jersey, where we partnered with a manufacturer of electrical components looking to optimize their facility footprint—without interrupting core operations.

The Challenge: Freeing Up Indoor Floor Space

The client was facing a familiar challenge: limited indoor floor space due to large, frequently used equipment that had no designated storage area. With production space at a premium, the company needed a way to relocate and store this equipment—while still keeping it accessible for ongoing operations.

The solution had to be durable, weather-resistant, and efficient. Moving the equipment outside seemed logical, but it required proper protection and structural planning to ensure long-term usability.

The Solution: Exterior Mezzanine with Canopy Roof

Our team at Westhead Associates Inc. by Mezzmaster designed and constructed a custom exterior mezzanine system, purpose-built to handle the client’s storage and accessibility needs.

Outdoor Equipment Storage: The mezzanine created a secure elevated platform outside the facility, offering reliable storage for heavy-duty equipment.

Durable Canopy Roof: We added a weather-protective canopy roof to shield stored items from rain, snow, and UV exposure—ensuring long-term durability and minimizing maintenance costs.

Efficient Space Utilization: By lifting equipment storage off the indoor floor and moving it outdoors, the client was able to reclaim valuable production space inside their facility.

Seamless Operational Flow: The mezzanine’s design allows equipment to be quickly lifted and relocated between indoor and outdoor spaces as needed, supporting smooth day-to-day operations without downtime.

Expanding Space Beyond Four Walls

This project showcases how exterior mezzanine systems can be a game-changer for manufacturers looking to expand storage capacity without expanding their building footprint. For this New Jersey-based electrical manufacturer, the results were immediate:

• Improved floor space management
• Protected equipment storage
• Maintained production flow
• Cost-effective facility optimization

At Westhead Associates Inc. by Mezzmaster, we help manufacturers think vertically. Whether it’s indoor clean-room mezzanines or rugged outdoor storage platforms, our engineered systems are designed to grow with your operation.

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Need to Expand Without Building Out?

If your facility is running out of room and you need a reliable way to increase storage or workflow space, contact Westhead Associates Inc. by Mezzmaster. We specialize in mezzanine systems for manufacturing, warehousing, food processing, and clean environments—tailored to your exact operational needs.

At Westhead Associates Inc. by Mezzmaster, we specialize in designing and building innovative mezzanine solutions for industrial and manufacturing facilities across the U.S. Recently, we partnered with a leading candy manufacturing company in New Jersey to help them solve a crucial challenge: maximizing cubic square footage without disrupting their production flow.

The Challenge: Expand Space Without Halting Production

Our client needed to increase their facility’s usable space to support growth and new processes. However, shutting down operations wasn’t an option. They also required the new mezzanine areas to be fully encapsulated using Insulated Metal Panels (IMP) to maintain strict environmental controls necessary in food manufacturing.

Beyond adding square footage, it was essential to preserve the flow of goods, materials, and personnel traffic underneath the mezzanine. This project demanded a solution that was not only structurally sound but also designed for clean manufacturing environments.

The Solution: A Clean, Efficient Mezzanine System

Our team designed and installed a custom mezzanine system that delivered on every requirement:

Increased Usable Space: The mezzanine added significant cubic square footage, transforming unused overhead space into valuable production and storage areas.

Clean Manufacturing Design: We utilized our patent-pending closed tubular system, engineered to prevent the accumulation of dust and debris. This design is perfect for food and candy manufacturing facilities, where hygiene and cleanliness are critical.

Insulated Metal Panel (IMP) Enclosures: The mezzanine’s new areas were encapsulated with IMP walls on both sides. This ensured environmental control, helping maintain temperature, humidity, and cleanliness standards essential for candy production.

Uninterrupted Production Flow: The space beneath the mezzanine now serves as a perfect corridor alley, allowing smooth and efficient movement of people, materials, and goods. The structure was designed to integrate seamlessly into the existing facility layout, preserving workflow efficiency.

A Win-Win for Manufacturing Facilities

This project is a perfect example of how mezzanine systems can help manufacturers maximize facility square footage while supporting operational efficiency and clean manufacturing standards. For our candy manufacturing client, the new mezzanine is a win-win solution, delivering:

• Increased production capacity
• Improved facility organization
• Enhanced environmental control
• Continued operational flow without disruption

If you operate in food, candy, or any clean manufacturing industry and need to expand your space without sacrificing efficiency, Westhead Associates Inc. by Mezzmaster can help. Our mezzanine solutions are custom-designed to fit your unique production needs, compliance requirements, and budget.

Contact us today to discuss how we can transform your facility and help your business grow!

At Mezzmaster by Westhead Associates Inc., we specialize in transforming industrial spaces into high-functioning, efficient environments. Our latest mezzanine installation for a New Jersey-based manufacturing company is a perfect example of how smart design and custom engineering can help maximize both floor space and vertical clearance without compromising productivity.

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Project Overview: Maximizing Cubic Space in a High-Performance Manufacturing Facility

The client came to us with a clear objective: they needed to build a dedicated control room for their operations while maintaining the ability to run full-scale production underneath the structure. Floor space was limited, and productivity could not be interrupted — making our custom mezzanine system the ideal solution.

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Mezzanine Platform with Custom Stair Integration

We designed and installed a mezzanine platform complete with safety handrails and a space-saving custom stair system. Unlike standard staircase configurations, this application was built to minimize the square footage required on the facility floor. The staircase hugs the mezzanine footprint tightly, preserving valuable workspace for production activities, material movement, and storage.

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Encapsulated Control Room with Insulated Metal Panels (IMP)

The mezzanine platform connects seamlessly to a larger second-tier mezzanine, which we enclosed using Insulated Metal Panels (IMP). These panels provide thermal insulation and environmental separation, making the space ideal for housing critical control equipment. The encapsulated mezzanine serves as a temperature-controlled control room, essential for maintaining the client’s operational standards.

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Full Utilization of Vertical & Horizontal Space

One of the most impressive aspects of this installation is how it supports production activity underneath the structure, allowing the facility to utilize every cubic foot. The open ground level beneath the mezzanine remains fully functional, giving the client the ability to maintain a smooth flow of goods and operations — all while keeping critical equipment protected and isolated above.

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Serving Manufacturers in New Jersey and Across the U.S.

Located in New Jersey (NJ), this manufacturing client now benefits from a custom-built, high-capacity mezzanine system that enhances both production flow and space efficiency. At Mezzmaster, we proudly serve clients across NJ, PA, and all 50 U.S. states, delivering modular and custom steel mezzanine systems built for real-world manufacturing demands.

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Key Benefits of This Mezzmaster Project:

• Custom-engineered mezzanine and stair layout for maximum space usage
• Encapsulated control room with Insulated Metal Panels (IMP)
• Safe, durable platform with OSHA-compliant handrails and access
• Supports active production underneath to maximize throughput
• Designed for clean, controlled, and efficient operations

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Ready to Maximize Your Facility’s Potential?

Whether you need a modular control room, an elevated work platform, or a full-scale production mezzanine, Mezzmaster by Westhead Associates Inc. can deliver a solution tailored to your space, workflow, and compliance needs.