Distribution Center Additions and Expansions
Seamless distribution center additions and facility expansions in the DFW metro area.
Distribution center expansions present unique challenges that differ significantly from new construction. Operating facilities throughout the DFW Metroplex require expansions that add capacity without disrupting ongoing operations. We specialize in additions and expansions that integrate seamlessly with existing buildings while maintaining the safety and productivity of active distribution operations.
Expansion planning begins with understanding current operations and future requirements. How will goods flow during construction? Where can staging areas be located without impacting operations? What phasing allows continued operation while construction proceeds? We work with facility operators to develop plans that balance construction efficiency with operational needs.
Site logistics for active facility expansions require careful planning. Construction traffic must be separated from operational traffic. Material staging must avoid interference with dock operations. Utility interruptions must be minimized and scheduled around operational needs. We develop detailed logistics plans that address these requirements.
Structural integration with existing buildings demands attention to connections, differential settlement, and matching of building systems. New foundations must account for existing conditions. Building connections must handle loads while preventing water intrusion. We coordinate with structural engineers to develop solutions that work for each specific situation.
MEP integration-particularly fire protection-requires careful coordination. Existing systems must remain operational during construction. New systems must integrate at points that minimize disruption. We schedule tie-in work during periods of lowest operational impact.
What's Included
When This Service Applies
Distribution company adding dock capacity for increased volume
E-commerce operator expanding fulfillment center square footage
Manufacturer adding warehouse for finished goods storage
3PL provider increasing facility size for new customer
Example Project Capability
Project Scope
75,000 SF addition to operating distribution center with 20 new dock positions
Client Situation
Distribution company needs additional capacity while maintaining 24/7 operations during construction
Our Approach
Phased construction plan separating construction from operations with minimal tie-in disruptions
Expected Outcome
Completed expansion integrated with existing facility for seamless operational transition
Contact us to discuss expansion of your distribution facility.
Frequently Asked Questions
Can you expand a building while operations continue?
Yes, we regularly perform expansions at operating facilities. This requires careful planning, phased construction, and close coordination with facility operations. Safety protocols and traffic management plans keep construction and operations separated.
How do you minimize disruption to operations during expansion?
We develop detailed logistics plans that separate construction from operations. Work is phased to limit disruption. Critical operations like utility tie-ins are scheduled during low-activity periods. Regular coordination with facility management addresses issues before they impact operations.
What if our existing building has different construction than the expansion?
Expansions don't need to match original construction exactly. Steel additions to tilt-wall buildings are common. We design connections and transitions that work structurally while maintaining weather integrity. Exterior appearance can be matched as needed.
How do you handle fire sprinkler systems during expansion?
Fire protection coordination is critical. We maintain existing system functionality during construction. New systems are installed and tied in with minimal disruption. Fire watch coverage is provided when required during transition periods.
Can expansions include dock additions?
Yes, dock additions are common expansion components. New docks can be added at building extensions or by converting non-dock walls. We coordinate dock equipment with building construction for efficient installation.
Get a Quote for Distribution Center Additions and Expansions
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Contact us to discuss your project requirements. We work directly with developers, property owners, and facility operators.