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"Â thick composite sandwich panels featuring 1/8"Â 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
Housing Without Borders: Go Global with Haskell Modular Solutions
With the capacity to service over 15 diverse markets across multiple continents, Haskell is the reliable choice for our 80% repeat client base no matter how their needs evolve. So, when a longstanding client—typically known for their large-scale, institutional buildings—engaged Haskell with a very different need—multinational
housing projects—Haskell knew exactly what approach to take.
ProSet Co-founder Shares Expertise to Help Ensure Safe and Secure Modular Connections in Colorado
ProSet co-founder Matt Mitchell created and teaches an 8-hour course, based on Colorado’s modular installation regulations.
Women in Construction – Reflections on a Journey, Then and Now
From industry veteran Laurie Robert, a retrospective for women who are thinking about entering the modular construction industry or are looking to elevate their current position into leadership.
This Year’s Offsite Construction Summits Put Regional Priorities and Industry Realities in Focus
With Summits scheduled for Toronto, Los Angeles, Denver, Washington, DC, and Houston, this year’s series will connect manufacturers, designers, developers, contractors, public officials, and end-users around the practical use of offsite delivery in their own markets.
Affordable Housing, One Module at a Time
For builders and developers, modular factories offer significant scheduling and cost efficiencies compared with traditional site-built construction, regardless of whether the final product is workforce housing, single family homes, or apartment buildings.
Advancing Modular Housing Policy in California: An Interview With Tyler Pullen of Terner Labs/UC Berkeley’s Terner Center for Housing Innovation
Artificial intelligence is no longer a future concept in modular construction—it is already reshaping how complex buildings are evaluated, designed, and delivered.
Europe’s Modular Market Is Expanding, but Consistency Still Matters
Artificial intelligence is no longer a future concept in modular construction—it is already reshaping how complex buildings are evaluated, designed, and delivered.
How Stack Modular Is Using AI to De-Risk Mid- to High-Rise Modular Construction
Artificial intelligence is no longer a future concept in modular construction—it is already reshaping how complex buildings are evaluated, designed, and delivered.
Gearing Up for the 2026 World of Modular
The Modular Building Institute (MBI) is bringing its global World of Modular (WOM) conference and tradeshow back to Las Vegas in April, and with it comes some of the industry’s best opportunities for networking, business development, and education.
New High-Rise Modular Apartment in Abu Dhabi Points Toward the Future of Multifamily Construction
Eagle Hills International Properties chose the BROAD Holon Building for a 16-story market rate apartment building in Zayed City, a central business district of Abu Dhabi. The project highlights the potential of the Holon system of volumetric modular construction to accelerate housing delivery.