Panel Built installs ResinDek flooring on mezzanine over ICON Mechanical cleanroom

ICON Mechanical added a modular ISO 8 cleanroom and elevated work platform to its Charlotte, North Carolina facility, using about 2,500 square feet of ResinDek LD flooring on the mezzanine. The project was designed to preserve cleanroom conditions, improve workflow and create extra storage and maintenance space without internal columns.

Why it matters: - ICON Mechanical needed more than a cleanroom. The company also wanted usable space above it for tools, parts storage and maintenance access. - The project shows how modular construction can create vertical space in a tight footprint while protecting cleanroom performance. - The mezzanine flooring had to support foot traffic and dollies while staying smooth, durable and easy to clean.

What happened: - ICON Mechanical, a fast-growing mechanical contractor in Charlotte, North Carolina, asked Panel Built and distributor Stein Supply to design and fabricate a modular ISO 8 cleanroom under a structural mezzanine. - The installation used about 2,500 square feet of ResinDek LD engineered floor panels on the elevated platform. - On-site construction moved quickly after approvals were finalized, with the project completed in about six weeks. - The cleanroom and mezzanine were built as one integrated system rather than separate structures.

The details: - The cleanroom was built for high-purity stainless steel and pharmaceutical welding and pipe fabrication. - The lower-level space had strict environmental requirements and engineered airflow systems. - The cleanroom includes 3-inch, 3-ply wall panels with vinyl-covered gypsum and a polystyrene foam core. - The room has a 10-foot ceiling height and HEPA filters. - A 12-foot by 10-foot framed opening for a high-speed roll-up door supports access. - Windows and personnel doors were added to support daily use. - Workers reach the upper level by bar grate stair treads with closed risers. - An integrated vertical conveyor moves materials between levels without interrupting personnel traffic. - ICON Mechanical wanted a wide-open cleanroom with no internal columns. - Panel Built shifted structural support points to the perimeter while maintaining load capacity and stability. - The mezzanine deck uses ResinDek engineered floor panels over a steel B-deck sub-surface. - Panel Built chose ResinDek instead of oriented strand board or standard flooring. - The ResinDek tongue-and-groove design reduced the number of screws and fasteners needed while keeping the deck stable for foot traffic and dollies. - Panel Built has used ResinDek on multiple projects for more than a decade.

Between the lines: - The project reflects a design priority that is common in advanced manufacturing: maximize usable square footage without sacrificing environmental control. - Moving structural supports to the perimeter is a practical tradeoff that keeps the center open but requires tighter engineering around joists and load paths. - The ResinDek selection points to a preference for a flooring system that installs efficiently and holds up in a high-use, cleanroom-adjacent setting. - The facility was also designed with flexibility for future expansion and additional interior buildouts.

What's next: - ICON Mechanical can use the mezzanine for tools, parts storage and maintenance while keeping the lower-level cleanroom active for fabrication work. - The modular layout leaves room for future expansion inside the facility. - Panel Built said its modular approach can be adapted for offices, cleanrooms and mezzanines depending on customer needs.

The bottom line: - The project combines cleanroom control, vertical storage and durable mezzanine flooring in one compact build. For ICON Mechanical, that creates more working space without giving up cleanliness or access.