512 Sq. Ft. Mezzanine with Integrated In-Plant Office & Lab Space | Texas

Challenge

Bravo Ordnance, a defense industry manufacturer in Texas, needed additional operational and lab space inside an active manufacturing environment. The facility required clearly defined work zones for testing, technical tasks, and administrative functions, but expanding the building footprint was not an option. The solution also needed to support industrial equipment loads, maintain workflow across departments, and provide a more controlled interior environment for day-to-day operations. The Safety Source LLC and dealer representative J. Eastom partnered with Panel Built to develop a fully integrated space solution.

Solution

Panel Built delivered a custom 512 square foot steel mezzanine combined with enclosed modular office and lab spaces to maximize vertical space within the facility. The freestanding mezzanine was engineered with a 125 psf live load capacity and finished with durable ResinDek decking over steel construction for long-term performance. The elevated structure includes dual stair access, OSHA-compliant handrails, kick plates, and a sliding safety gate for safe employee movement.

Along with the mezzanine, Panel Built installed a fully enclosed 20' x 20' office and lab area, an additional 8' x 11' enclosed office, and a 60-foot dividing wall system to separate production and lab operations. Class A fire-rated insulated wall panels, suspended acoustic ceilings, integrated windows, and prewired electrical systems created a more controlled and organized workspace suited for technical operations and daily administration.

Key Features

• Steel Mezzanine System: 16' x 30' elevated platform adding 512 sq. ft. of usable space.
• Heavy-Duty Capacity: Engineered for a 125 psf live load to support lab and operational equipment.
• Integrated Office & Lab Areas: Enclosed 20' x 20' modular lab space plus an 8' x 11' office.
• Safety Systems: Dual stair access, OSHA-compliant handrails, kick plates, and sliding safety gate.
• Controlled Work Environment: Class A fire-rated wall panels and suspended acoustic ceiling system.
• Electrical Infrastructure: Prewired lighting, duplex outlets, and dedicated 125 AMP service panel.
• Operational Visibility: Integrated windows and vision panels overlooking production areas.

Conclusion

By combining a structural mezzanine with modular office and lab construction, Panel Built helped Bravo Ordnance create a more efficient and organized production environment without expanding the facility. The completed system provides dedicated workspaces, improved separation between operations, and long-term flexibility for continued growth. This project highlights how mezzanine systems can support far more than storage by creating fully functional operational environments within existing buildings.

Special thanks to The Safety Source LLC and J. Eastom for their partnership on this project.