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Build Up, Not Out: Coplas In-plant Office Case Study

Sep 9th 2026

Posted by Nicole

Build Up, Not Out: Coplas In-Plant Office Case Study

When an industrial facility runs out of administrative space, traditional floor expansions often force a difficult compromise: sacrificing valuable manufacturing room or committing to costly building construction. A Panel Built modular inplant office solves this by utilizing overhead air space. The Safety Source delivers custom modular offices that fit every facility, allowing plant managers to build up instead of out, doubling usable square footage while keeping management on the active shop floor.  

 

Looking to double your office space without losing plant floor footprint?

 

Completed two-story modular in-plant office integrated within the production environment.

Request a free consultation to see how much space you can gain without expanding.

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Why Build Up Vertically?

- Zero Footprint Sacrifice: Expands workspace upward without consuming valuable assembly or storage floor space.  

- Substantial Cost Savings: Modular vertical builds cost 20% to 40% less than conventional ground-level drywall additions.  

- Quick-Install Execution: Pre-engineered components allow installation in days rather than weeks, preventing production downtime.  

- Proven Results: Coplas doubled administrative capacity in its 600,000 sq. ft. Sterling Heights, MI plant with zero floor space lost.  

Real-World Case Study: How Coplas Doubled Capacity at Sterling Heights

Inside Coplas’s 600,000-square-foot facility in Sterling Heights, Michigan, ground space was fully occupied by GMC Sierra bumper assembly lines.  

 

The Challenge: Coplas needed expanded administrative space for supervisors and operational teams. However, converting active floor space wasn't an option, and extending the physical building exterior was too slow and expensive.  

 

The Solution by The Safety Source: To solve the space crunch, The Safety Source provided a Panel Built two-story modular inplant office system. By capturing unused vertical clearance, the team installed two full levels of quiet, climate-controlled office space on the exact same ground footprint.  

"I was extremely impressed with how The Safety Source managed this two-story modular in-plant office solution. They communicated clearly and followed through with every aspect of this time-sensitive project."

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  • Facilities Manager, Coplas

Project Highlights & Operational Wins

  • - Vertical Clearance Captured: Created two entire levels of workspace directly within the active assembly area.  
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  • Quick-Install Performance: Delivered on time on a strict, time- sensitive schedule without disrupting GMC Sierra assembly lines.
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- Full Sightlines & Comfort: Outfitted with sound-dampening walls, climate control, drop ceilings, LED lighting, and wide windows overlooking operations.  

What is a Modular Inplant Office?

A modular inplant office is a pre-engineered, prefabricated enclosure constructed inside an active factory or warehouse. Instead of framing wood and hanging drywall, which creates dust, noise, and major operational delays—modular structures use demountable wall panels and steel framing that lock together cleanly.  

 

  • These enclosures create comfortable, sound-isolated, and climate-controlled environments for supervisor towers, shipping offices, quality control laboratories, and breakrooms.  
Key Factors to Consider When Building Up

If you are planning to utilize vertical space in your facility, consider these structural factors:

 

1.) Overhead Clearance: Ensure your building has adequate clear height for a two-story structure or a mezzanine-supported setup.

2.) Plant Sightlines: Position windows strategically on upper levels so management maintains full operational visibility.  

3.) HVAC & Sound Control: Choose insulated, sound-dampening panels and integrated climate units to keep offices quiet in noisy plants.

How to Get Started: Next Steps

1.) Measure Vertical Clearance: Identify overhead space above low-traffic floor areas.  

 

2.) Define Your Layout: Determine how many rooms, windows, and access points your team requires.  

 

3.) Work with The Safety Source: Our team provides end-to-end management, from engineering custom modular offices that fit every facility to quick-install execution.

 

Request a free consultation to see how much space you can gain without expanding.

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Frequently Asked Questions

Why should I build a two-story modular inplant office instead of a single-story office?

Building up doubles your usable office space on the exact same ground footprint, preserving high-value manufacturing or warehousing floor space for core operations.

 

How much does a Panel Built modular inplant office cost?

Pricing generally ranges from $35 to $100+ per square foot depending on structural levels, panel insulation, and climate control needs. Two-story systems carry higher structural costs but maximize overhead square footage. Reach out to The Safety Source to get your quote!

 

How fast can a two-story modular office be installed?

Pre-engineered quick-install components allow most two-story structures to be assembled in 5 to 10 days, minimizing disruption on active production floors.

 

Can The Safety Source provide custom modular offices that fit every facility?

Yes, The Safety Source works with Panel Built to deliver fully customized layouts, including specialized sound-dampening panels, fire-rated materials, custom window placements, and multi-tier structural designs.

 

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