Panel Built Provides Custom Modular Enclosure for Major Beverage Manufacturer
In October 2023, CE Thurston contacted Panel Built Inc., a modular building company, on behalf of a major beverage manufacturer. The manufacturer a place to house their large facility crane and a means of expanding office space within their existing plant. Panel Built Inc. was tasked with delivering a high-quality, functional structure that could meet those needs and do so quickly and efficiently.
The Challenge
The challenge was twofold. Firstly, Panel Built needed to create a spacious enclosure that could accommodate a large facility crane. This enclosure required a design that provided ample storage space and integrated seamlessly with the existing infrastructure. Secondly, the structure needed to incorporate office space that offered personnel an unimpeded, 360-degree view of the factory floor. Achieving these objectives within a stringent timeline was essential to ensure minimal disruption to the manufacturer's operations.
About Panel Built Inc.: Panel Built was founded in 1995 by brothers Pat and Mike Kiernan and began with the construction of pre-manufactured buildings. Today, Panel Built offers a complete line of custom modular offices, mezzanines, security booths, pre-assembled exterior buildings, and cleanrooms. All our product lines are manufactured on-site in one of our state-of-the-art modular production facilities. We offer "A Better Way to Create Space" for all your building projects.
The Solution
Panel Built Inc. responded to this challenge with a comprehensive modular building solution. The team designed, fabricated, and installed a 37' x 27' enclosure with a mezzanine, effectively augmenting the available space by 1,365 square feet. The enclosure featured 45 surrounding windows, which ensured panoramic visibility of the factory floor and enhanced operational oversight.
Project Timeline and Quality Assurance
Despite the project's complexity and the need for rapid completion, Panel Built Inc. completed the structure within approximately three months from the date of the order. Throughout the process, the company maintained a steadfast commitment to quality, ensuring that every aspect of the structure met high standards of craftsmanship and functionality.
The completed modualr enclosure featured 45 surrounding windows, which ensured panoramic visibility of the factory floor and enhanced operational oversight.
Key Features of the Solution
Class A Interior Walls: The walls were crafted with 3" thick composite sandwich panels featuring 1/8" Fiberglass Reinforced Plastic on the exterior and interior surfaces, finished in pristine white. An aluminum extruded binder post system, positioned every 4', housed all electrical components, maintaining functionality and aesthetic coherence.
Ceiling: A suspended ceiling system spanning 945 square feet was implemented to integrate seamlessly with the existing structure. The Class "A" suspension system and acoustic materials enhanced the interior ambiance and provided a platform for essential utilities, including lighting, heating, ventilation, and air conditioning systems.
Doors and Windows: The building was equipped with double doors to facilitate the easy transportation of equipment. Entry points were outfitted with 20-gauge insulated steel doors featuring half-glass panels to allow natural light to penetrate the interior. The interior picture windows were glazed with 1/4" clear tempered glass, ensuring complete visibility while maintaining safety standards.
Electrical Package: The entire enclosure was pre-wired with a modular electrical package. This package included wall switches, duplex receptacles, and 110-volt LED fixtures, allowing for future HVAC installation. The modular wiring allowed for easy set-up of the building's electrical grid, saving the project time and sparing facility installers the risk of electrical injury.
Mezzanine: The mezzanine was engineered to withstand 125 pounds per square foot, meeting the standards for a loading mezzanine system. This multifunctional space accommodated storage needs and housed a dedicated in-plant office. The elevated platform featured steel decking sub-flooring and resilient recessed decking for enhanced durability.
Stair Systems & Handrails: Safety was a top priority for Panel Built Inc. As such, the 42" tall railings and diamond plate stairs were designed to meet factory, storage use groups, and OSHA standards. The stair system and handrails received a powder coat finish, with the handrails colored a bright safety yellow for optimal visibility.
Conclusion
Panel Built Inc.'s innovative approach and modular building techniques effectively solved the major beverage manufacturer's dual challenge of storage and office space expansion. This case study exemplifies the capabilities of modular construction in addressing complex industrial needs and shows Panel Built Inc.'s expertise in delivering tailored solutions that enhance operational efficiency and safety.
More from Modular Advantage
How Rebel Concept Harnesses AI as a Design Tool to Improve the DFMA Process
“The complexity of projects and the size of project are so large, and the technology is so complicated that AI would do it so much faster than we are,” says Kris Droszcz, CEO at Rebel Concept. “Everybody’s struggling to control the manufacturing processes according to the design. And I think that’s what AI will do.”
One Answer from AI Can Provide Innumerable Opportunities, says Stack Modular’s Jim Dunn
The Stack AI Engine is not fully functional yet, but it offers an unlimited number of productivity benefits. Currently, the company is using AI for cost estimates, most recently for a project out in California.
GrayWolf: Building the Future of Modular Data Centers to Power the AI Revolution
The growth of artificial intelligence (AI) and cloud-based applications has created an urgent need for data centers capable of managing massive amounts of data. As businesses across industries increasingly rely on digital infrastructure to power their AI tools, the demand for data centers has skyrocketed.
Artificial Intelligence: Yes, it is a Construction Game-Changer
Much like other sectors of the economy, AI is reshaping construction, revolutionizing how projects are planned and executed across the country. While it is obvious that AI cannot do certain things by itself, like laying bricks, paving roads, or shingling roofs, its impact stands to be both massive and positive.
The Potential and Possibilities of AI for Offsite
AI is everywhere. Many industries have incorporated AI into business as usual with new organizational structures and new dependencies to be more efficient and to automate repetitive tasks. Offsite construction will not be immune to AI’s ubiquity. The technology offers unique benefits to the offsite building process.
Moving from AI Hype to an AI Advantage
Learning about AI will help you see past the overinflated hype and identify the opportunities specific to your own business. Learning about AI is like peeling an onion – each layer reveals something new, and occasionally it might make your eyes water. But in the end, you’ll have all the ingredients you need to cook up some real innovation in your organization.
The Blueprint for Smart and Ethical AI Integration in Your Business
The journey toward smart and ethical AI integration involves crafting a strategic vision that aligns AI’s transformative potential with your organizational goals. True success with AI is measured by its capacity to enhance human capabilities, foster sustainable growth, and generate value for all stakeholders while actively avoiding ethical pitfalls and harmful risks.
Five Factors for Success When Shifting Your Business to Modular
As labor, competitive and cost factors push more contractors and developers to embrace the opportunity to go modular as a first choice and not a last resort, it’s become clear that adopting this new model requires more than just a willingness to make it happen. Here are five factors to consider as your company moves to a modular construction model:
UniCool-Edge: Optimized Cooling Solutions for Modular and Edge Data Centers
In an industry where efficiency, scalability, and security are crucial, the UniCool-Edge™ system is a revolutionary solution for modular data center manufacturers. By offering external mounting for maximum space utilization, energy-efficient cooling, and pre-commissioned reliability, UniCool-Edge helps manufacturers stay ahead in the rapidly evolving AI-driven data center market. As edge data centers continue to expand, solutions like UniCool-Edge will play a vital role in supporting the next generation of modular data centers and their data center infrastructure.
Building Skills in a Virtual World: Immersive Training for the Modern Workforce
As both the hardware and software for developing and deploying XR applications continue to become more affordable, the investment in this technology as a training tool is increasingly appealing. XR also offers several other benefits, including performing potentially hazardous tasks in a safe environment and acquiring new skills without the immediate need for physical materials.