Warehouse Expansion

We develop detailed phasing plans that allow warehouse operations to continue during expansion. This includes constructing in sections, maintaining access routes, and scheduling work during off-hours when possible. Our crews work efficiently around existing inventory and equipment, using dust control measures and temporary barriers. We coordinate daily with warehouse management to ensure minimal impact on operations.

Warehouse expansions require concrete matching existing slab specifications, typically 4,000-6,000 PSI strength with flatness tolerances (FF/FL numbers) for operational equipment. Reinforcement includes wire mesh or rebar based on load requirements. Joint spacing follows existing patterns, and surface finishes must accommodate warehouse equipment. We verify specifications through testing and provide documentation for compliance.

Yes, we specialize in live expansions where operations continue. This requires careful phasing, temporary access routes, and coordination with warehouse staff. We can expand in sections, often working nights or weekends for minimal disruption. Dust control, safety protocols, and clear communication ensure operations remain uninterrupted. Some expansions may require temporary relocation of inventory for specific areas.

Warehouse expansions require building permits from the City of Mansfield, site plan approvals, and possibly special use permits for industrial facilities. Additional permits may be needed for stormwater management, utility connections, and traffic control. We handle all permitting and coordinate with local inspectors. Environmental permits may be required for expansions affecting protected areas.

Expansion duration varies by size and complexity, typically 4-12 weeks for concrete work. A 10,000 square foot addition might take 6-8 weeks including site preparation, concrete placement, and finishing. Phased construction allows partial use during construction. Weather conditions and permit processing can affect timelines. We provide detailed schedules with milestones.

Foundation requirements depend on existing building capacity and new loads. We may need to add piers, extend footings, or reinforce existing foundations. Soil conditions in Mansfield often require engineered solutions for stability. Geotechnical reports guide foundation design. We ensure new foundations match existing construction for structural integrity and prevent differential settlement.

Expansion costs range from $50-$150 per square foot depending on complexity, site conditions, and specifications. A basic 5,000 square foot addition might cost $75-$100 per square foot including concrete work. Factors include foundation requirements, phasing needs, and finish specifications. We provide detailed estimates after site assessment and can suggest cost optimization strategies.

Proper drainage prevents water accumulation that could affect operations. We design slopes away from buildings, incorporate stormwater management systems, and ensure compliance with Mansfield regulations. Large roof expansions increase runoff, requiring detention basins or permeable surfaces. We coordinate with civil engineers for comprehensive drainage solutions that handle increased water volume.

Yes, we specialize in connecting new concrete to existing slabs using proper joint design and reinforcement. This prevents cracking at the connection point and ensures structural integrity. We match existing concrete specifications, elevation, and finish. Expansion joints may be needed to accommodate movement. Testing ensures compatibility between old and new concrete for operational continuity.

Safety includes OSHA compliance, traffic control around operational areas, dust suppression, and emergency access maintenance. Our crews wear appropriate PPE and follow confined space protocols. We establish safety zones, provide training for warehouse staff, and maintain clear communication. Regular safety meetings and incident reporting ensure a safe work environment throughout the expansion.