How PWI Helped a Food Manufacturer Expand with a Custom Superstructure & Mezzanine

Introduction

When a leading food product manufacturer needed to expand their facility for a new product line, they encountered a major structural challenge. Their expansion required a climate-controlled chiller room, but their existing building wasn’t designed to support the insulated walls, ceiling, and glycol piping necessary for temperature regulation. To overcome this obstacle, they turned to PWI.

The Problem

The facility had loading constraints that prevented attaching insulated side walls directly to the building’s structure. Without a way to properly support these walls, the new chiller room wouldn’t be feasible. Additional challenges included:

• Strict timeline: The project needed to be completed quickly to keep production on schedule.
• On-site obstructions: Unexpected hazardous piping and other structural interferences complicated the installation process.
• Structural limitations: The existing facility could not support additional weight, requiring a fully independent solution.

The Solution

To meet the facility’s needs, PWI designed and built a custom superstructure, a steel framework with its own foundation, capable of supporting the insulated walls, ceiling, and glycol piping—essentially functioning like a mezzanine without a floor or guardrails.

Key Features of the PWI Solution:

• Superstructure: Built as a fully independent support system for the chiller room’s insulated walls.
• Mezzanine: Constructed inside the superstructure but outside the cold storage area, providing essential storage space.
• Refrigeration Support: Installed steel tubes through the superstructure’s roof to allow a separate company to mount refrigeration units on top of the building.

Overcoming Challenges:

• Working Around Obstructions: The PWI team adapted on-site to navigate hazardous piping and unexpected obstructions.
• Tight Deadlines: Crews worked nights and weekends to ensure the project stayed on schedule.
• Custom Engineering: PWI’s expertise in steel structures for industrial applications ensured a solution that met both structural and operational requirements.

The Result

• Project Completed On Time: Despite the challenges, PWI successfully delivered the project within the required deadline.
• Structural Success: The new Superstructure and mezzanine provided the necessary support for the chiller room, ensuring seamless production expansion.
• Client Satisfaction: The manufacturer was thrilled with the results, and PWI is now bidding on additional projects with them.

Need a Custom Structural Solution for Your Facility?

At PWI, we specialize in custom steel solutions. If your facility needs a tailored approach to overcome structural challenges, reach out to get a free quote today!