Warehouse Retrofit & Upgrades: Outdated Storage is Costing you Time, Space and Money.

Optimise your warehouse operations with upgraded storage systems that integrate seamlessly with manual and automated systems.

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WAREHOUSE RED FLAGS

When is a Warehouse Retrofit the Right Choice?

If your warehouse was designed for yesterday's operations, performance losses compound quickly. A retrofit is often the most cost effective response when...

Order volumes, SKU profiles, or picking methods have changed.

Storage capacity is constrained despite unused vertical space.

Existing racking no longer meets compliance standards, like EN15635.

Safety risks or rack damage are increasing maintenance costs.

Automation or WMS upgrades are planned, but the layout is incompatible.

Relocation or new build costs cannot be commercially justified.

What is a Warehouse Retrofit and Modernisation?

As your storage ages, you might consider upgrading or retiring what you no longer use. Retrofit is a strategic upgrade of your existing storage infrastructure, layout, and systems that modernises them to meet current requirements. It enhances safety and efficiency by creating systems designed for future automation, all without high costs, downtime, or the risks of building anew. Unlike simply replacing racking, a retrofit takes a holistic approach to your operations, considering flow, accessibility, compliance, and scalability. It delivers the performance of a new build while maintaining your existing footprint, workflows, and investments. What can be modernised:

Racking
Layout
Safety Systems
Automation Readiness

THE PROBLEM

Why Warehouses are Struggling Right Now...

Your warehouse is under constant pressure to deliver; not just packages, but results.

Logistics is a demanding industry

Higher SKU complexity
Lightning-fast picking speeds
Zero safety incidents or concerns
Easy integration with automated systems
Customer expectations for speed and accuracy

WHY RETROFIT?

How your Business Benefits from a Warehouse Retrofit and Upgrade

The fastest route to grow your ROI with a future-proof warehouse!

Increase in capacity without expanding

Optimised layouts and upgraded racking systems designed to unlock unused floor space. Up to 40% boost in storage capacity without expanding footprint.

Minimal disruption to live operations

Retrofit projects delivered using phased installation programmes, allowing warehouses to remain operational throughout.

Automation ready by design

Storage upgrades planned to support future automation, AMRs and evolving SKU profiles without structural change.

Upgrades aligned with compliance standards

All retrofit solutions are designed to meet load performance, rack inspection, and safety standards, ensuring full compliance with EN15635.

Faster return on investment

Many warehouse retrofit projects deliver ROI within 6-18 months, depending on the scope and the gains in throughput.

Over 80 years of engineering expertise

Supporting warehouse retrofit and upgrade projects across Europe and globally, engineered for safety, compliance and long-term performance.

COMPARISON

Retrofit vs New Build

For most operational warehouses, retrofit delivers faster ROI with less risk.

Warehouse Retrofit

Capital Cost - Significantly Lower
Project Timeline - Weeks to Months
Operational Disruption - Minimal (phased)
Sustainability Impact - Low
Planning Approval - Not Required

New Build

Capital Cost - Very High
Project Timeline - 12-36 Months
Operational Disruption - Major
Sustainability Impact - High
Planning Approval - Required

BEFORE & AFTER

See the Difference Retrofitting Makes

BEFORE

Yapp Brothers - Wine merchants

Facilities before upgrading and expanding.

AFTER

High-density layouts, strengthened structures,

safer aisles, efficient picking and packing

CUSTOMER STORY

Project Spotlight

See how our customers are upgrading

3StepIT & Constructor Sweden - Tornado VLM

RETROFIT PROJECT

3stepIT: Transforming Space and Efficiency with Automated Storage from Constructor Sweden

When fast‑growing circular‑IT provider 3stepIT outgrew its warehouse capacity, it turned to our Constructor Sweden team for a smarter, more space‑efficient solution. Installing two Tornado vertical lift machines enabled them to reduce their traditional shelving footprint from 250 m² to just 40 m² of high‑density vertical storage. The upgrade boosted efficiency by 200%, dramatically cutting error rates and creating a scalable foundation for continued growth so effective that a third machine is already on its way.

+ 200% Efficiency Boost

250m² to 40m² Reduction in footprint

84% Footprint reduction

Information Technology Retrofit Consolidation Sweden

Read Full Case Study

"The collaboration with Constructor has worked well. We have had to make some adjustments and changes to adapt the storage machines to our business, but Constructor has always been responsive and delivered."

Andreas Agnesson

Site Manager

3stepIT

DEXION RETROFITS

A Modernisation Journey Designed Around Your Operations

Our warehouse retrofit and upgrade process explained

We support every stage of transformation - From first inspection to final sign-off

Assessment

EN15635 audit, structural evaluation, capacity analysis, workflow mapping.

Planning

Phased installation timetable designed to maintain full operational continuity, creating minimal disruption.

Implementation

Our own installation teams deliver upgrades with precision, safety in mind and zero downtime for your operations.

Support

Predictive maintenance & inspections, tailored service packages, and easy access to spare parts.

FAQ'S

Your Frequently Asked Questions

How much does a warehouse retrofit cost?

Every warehouse retrofit project is unique; the costs depend on the size of the warehouse, existing infrastructure, storage system types and the scope of upgrades. Retrofit projects are typically significantly more cost-effective than new builds and deliver ROI faster. If you want to learn more about costs, we can review your project to assess the expenses.

How long does a retrofit project take?

Project timelines can vary, but most retrofits are completed faster than new builds due to reduced planning and construction requirements.

What is a warehouse retrofit?

A warehouse retrofit involves upgrading existing storage systems, layouts and safety components to improve capacity, efficiency and compliance. All without the need to build a new facility or relocate operations.

What does a warehouse retrofit typically include?

A retrofit can include upgrades to shelving and racking, reconfigurations of existing layouts, floor-loading assessments, safety enhancements, and future-proofing for automated systems.

What types of warehouses are suitable for a retrofit?

Most warehouses, including distribution centres, manufacturing sites, and e-commerce fulfilment facilities, are suitable for retrofitting. Providing the building structure and floor loading support the upgrade.

Is a warehouse retrofit cheaper than building new?

Yes. Retrofitting avoids buying land, planning permission and relocation costs - making it a more economical solution in most cases.

Will a warehouse retrofit disrupt operations?

Retrofit projects are typically delivered in phased installations, allowing your operations to continue with minimal downtime.

Can retrofits be carried out while the warehouse is operational?

Of course! With careful planning and a phased execution, upgrades can be completed while maintaining day-to-day activities at your site.

Does warehouse retrofit improve safety and compliance?

Yes. Retrofits often include rack inspections, load compliance checks, and safety accessories and layout improvements aligned with current regulations.

Can existing racking be reused or modified?

In many cases, your existing racking can be reconfigured or enhanced rather than replaced entirely, depending on its condition and compliance with regulations and safety standards.

Can a warehouse upgrade prepare my site for automation?

Retrofits and upgrades can optimise layouts, aisle widths, and load tolerances to support automation, conveyors and AMR's.

Why should I choose Dexion for warehouse retrofit and upgrades?

Dexion combines engineering expertise, compliance standards, and proven retrofit experience to deliver safe, scalable warehouse upgrades with minimal disruption.

Still got more questions? Our expert team is happy to help!

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