Coplas - Sterling Heights, MI
Customer Details
Customer: Coplas
Location: Sterling Heights, MI
Application: 2-Story Modular In-Plant Office
Product: Panel Built Modular Office
Company Overview:
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Coplas is an award-winning, Canadian-owned automotive manufacturer that has been serving the industry since 2005. With more than 600 employees, the company provides advanced design, engineering, injection molding, painting, and assembly solutions for some of the automotive industry’s leading vehicle manufacturers.
Challenge
Coplas needed additional enclosed office capacity within its Sterling Heights manufacturing facility, which supports GMC Sierra bumper assembly operations.
With approximately 600,000 square feet dedicated to a busy automotive manufacturing environment, available floor space is valuable. A traditional single-story office would have consumed additional production space, while a conventional building expansion would have required a significantly different scope of work.
The solution needed to provide functional office space close to plant operations while maximizing the existing footprint and integrating naturally into the active manufacturing environment.
As a long-standing partner, The Safety Source worked with Coplas to develop a solution that addressed both the immediate need for additional workspace and the facility's long-term use of available space.
The Safety Source Modular Office Solution
Building Up Instead of Building Out
The Safety Source provided a 20' × 34' two-story modular in-plant office, creating approximately 1,360 square feet of usable space from a 680-square-foot footprint.
By utilizing vertical space, Coplas was able to substantially increase its enclosed office capacity without dedicating twice the amount of manufacturing floor space to the project.
The four-wall modular office incorporates a free-span structural design, eliminating the need for support columns within the office and helping maintain an open, functional interior.
| Component | Details |
| Modular Office Size | 20' X 34' |
| Modular Office Height | 21'9" (Total Height) |
| HVAC | Mini Split System |
| Wall Panels | 3" Thick |
| Number of Doors | 7 |
| Number of Windows | 10 |
| LED Fixtures | 16 |
| Deck Capacity | 80 PSF |
The Result
More Office Space. Same Production Footprint.
The completed two-story modular office gave Coplas approximately 1,360 square feet of enclosed workspace while occupying only 680 square feet of plant floor.
The project demonstrates how modular construction can help manufacturers address space constraints without immediately turning to conventional building additions or sacrificing substantially more production area.
For Coplas, the solution created additional office capacity close to GMC Sierra bumper assembly operations while making better use of the vertical space already available inside the facility.
For The Safety Source, the project represents the type of turnkey facility solution we provide beyond traditional safety supplies—helping manufacturers solve space, workflow, and facility challenges with solutions designed around their operations.
"The two-story modular office gave us the additional workspace we needed without sacrificing valuable production floor space. The Safety Source worked with our team to develop a solution that fit within our existing facility and kept our employees close to the manufacturing operation. The finished office has been a great addition to our facility."
-Facilities Coordinator
Coplas
Our Process
- Step 1 -
Discovery
The Safety Source will work with you to figure out the best solution for your pain points.
- Step 2 -
Design
Based on your requirements, the Safety Source will design an inplant office that will fit your needs.
- Step 3 -
Installation
Our modular office experts will install the office structure according to the agreed upon design specifications.
Why Choose The Safety Source For Your Inplant Office?
- Turnkey Project Support – One partner to help coordinate your project from initial concept through installation.
- Custom-Built Solutions – Offices can be configured around your available space, workflow, personnel, and facility requirements.
- Single- and Two-Story Designs – Maximize your existing footprint by building vertically when floor space is limited.
- Industrial-Grade Construction – Durable wall systems, doors, windows, ceilings, electrical, lighting, and structural components designed for industrial environments.
- Flexible Options – Incorporate HVAC, electrical, insulation, sound-control materials, specialized wall systems, and other features based on your application.
- Manufacturing Experience – We understand the importance of minimizing disruption and preserving valuable production and warehouse floor space.
- One Point of Contact – The Safety Source helps coordinate the moving pieces, reducing the need to manage multiple suppliers throughout the project.
Success Stories
The team at The Safety Source sat down and looked at our current space and provided an out of the box solution - a two story mezzanine with a inplant office installed on the 2nd floor. This solution was not only cost effective it was designed and installed on time and on budget. Thanks for being a vendor we can rely on.
Facility Manager
Magna Seating Detroit
We have been contracting The Safety Source to manage our MRO supplies with their state of the art vending software we have seen on average $6,000 per month savings! They also perform pallet racking repairs and installation. Guard rails, dock safety and LED lighting retrofits. Their team has always accommodated our busy production schedule and provided the best value.
C&I Manager
Detroit Manufacturing Systems
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FAQs
What are the benefits of a modular in-plant office?
Modular offices allow you to add enclosed workspace while making better use of your existing facility. They can typically be installed with less disruption than conventional construction and can be customized around your available space, workflow, and operational requirements.
Can an in-plant office be customized?
Yes. In-plant offices can be customized by size, layout, wall system, doors, windows, ceilings, insulation, electrical, lighting, HVAC, flooring, and other features. The configuration is developed around your facility and intended application.
Can electrical, lighting, and HVAC be included?
Yes. Depending on the project scope, in-plant offices can incorporate electrical receptacles, switches, LED lighting, HVAC or mini-split systems, data requirements, and other utilities.
Are in-plant offices insulated?
Insulated wall and ceiling systems are available to help create a more comfortable working environment inside manufacturing and warehouse facilities. The appropriate insulation and wall construction will depend on your facility conditions and application.
How much weight can the second floor support?
Load capacity is determined by the specific design and intended use of the structure. For example, the two-story Coplas project featured an upper-level deck designed for an 80 PSF load capacity. Projects requiring heavier loads can be evaluated based on the equipment, storage, personnel, and other loads planned for the space.