Warehouse Storage Expansion Checklist
Expanding your warehouse storage takes careful planning to keep disruption to a minimum. This checklist takes you through assessment, design, phasing, installation and handover.
Pre-Expansion Assessment
- Record how much stock you hold now and how much you expect to grow
- Record pallet dimensions, maximum gross weights, load overhang, stability and handling requirements
- Identify space constraints and vertical vs. horizontal expansion options
- Survey existing racking: manufacturer and system, component compatibility, history and condition. Reusing it also needs verified loading data for the proposed configuration
- Assess your forklifts: lifting height, residual capacity at the proposed height and load centre, attachments, turning space and operating clearances
- Check the floor: whether the slab or foundations can support the racking and handling equipment, plus its condition, levelness, joints and any limits on anchoring
- Identify planning, Building Regulations and any landlord consent requirements at the outset
- Work out how quickly the expansion will pay for itself
Design Phase
Layout & Configuration
- Create a detailed warehouse layout with new and existing sections
- Define aisle widths, beam heights and load specifications
- Plan how goods flow through the site and the quickest picking routes
- Plan for growth: a 3–5 year horizon is a sensible starting point, so you're not expanding only for current needs
- Confirm your forklifts are compatible with the new layout
- Review fire safety: escape routes, travel distances, access to fire equipment, emergency lighting and sprinkler suitability
- Agree with IT how your stock system will be expanded
Implementation Planning
Phasing & Site Safety
- Identify applicable CDM duties, appoint competent designers and contractors, and agree coordination arrangements before work starts
- Obtain the necessary permissions before work begins
- Split the installation into phases so you can keep working
- Agree exclusion zones and keep contractors separate from warehouse traffic, deliveries and unloading areas
- Check the stability of partly completed racking, and agree when each phase can be handed over and loaded
- Identify goods that must be relocated, and plan temporary storage if required
- Book the installation in for quieter periods
- Tell your warehouse and customer service teams the timeline
- Train staff on the new layout and equipment before they first use each new area
Handover & After the Expansion
Verification & Records
- Check the design basis, the manufacturer's loading information, installer competence and the installation handover documents
- Obtain completion documentation for Building Regulations, where applicable
- Display the correct load notices before the new or altered racking is used
- Confirm forklift compatibility through controlled operational checks after the installation checks and handover
- Check how quickly goods move in and out, and spot bottlenecks
- Keep approved layout and configuration records, handover documents, load notices and inspection and maintenance records
- Schedule ongoing inspections and maintenance
Expert Guidance for Your Warehouse Storage Expansion
Our team handles every stage of your warehouse storage expansion, from the site survey to installation and handover. We keep disruption to a minimum and make sure your new racking is safe, compliant and set up for the way you work.
Book Your Expansion Planning Session