BY SHELBY TUTTLE
Greater Phoenix is experiencing a construction boom unlike anywhere else
in the U.S., with warehouses, distribution centers, and high-tech factories springing up across the region. Amidst this growth, Next Level Steel, based in Mesa, Arizona, has created a groundbreaking steel product that is reshaping the construction industry.
The company’s Castellated Steel Beams offer numerous advantages. They accelerate construction timelines, extend reach while using less material, and contribute to a greener building process. By supporting heavy rooftop solar panels without extra reinforcement and reducing the need for concrete in parking garages, these beams help mitigate the heat island effect and lower carbon emissions.
Next Level Steel’s rapid expansion is a testament to the product’s success. The company has opened a second facility in Goodyear, doubling its production capacity to 1 million square feet per month. Founded by second-generation steel fabricator Brandon Bell, the company serves a diverse clientele, including tech giants Intel and TSMC, as well as the upscale Hyatt Regency Scottsdale Resort & Spa.
The inspiration for Next Level Steel’s innovative beams came from World War II-era technology and the challenges posed by COVID-19 supply chain disruptions.
“During COVID there was a surge in warehouse building, but we previously didn’t focus on that business because, traditionally, most commercial warehouses/light industrial spaces in the Southwest are built with wooden roofs and use little structural steel except for the steel joists,” Bell says. “But because of COVID, the price for roof-building joists tripled as manufacturers struggled with supply chain issues and could not keep up with demand.”
To meet the growing demand, Next Level Steel established the only dedicated castellated steel beam fabrication line in the Southwest. Their process involves transforming American-forged steel I-beams into taller, stronger beams with hexagonal holes through precise laser cutting and welding. This design speeds up erection, reduces lead times, and offers greater functional flexibility compared to traditional roofing structures
