Planning a Warehouse Fit-Out? Key Steps for Facilities Managers

If you’re a facilities manager planning a warehouse fit-out, you’ll know it’s not just about getting a few contractors in and hoping for the best. A well-managed fit-out protects your budget, ensures compliance, and keeps your operations running smoothly - both now and in the future.

In this post, we’ll walk you through the essential steps for planning a warehouse fit-out, so you can avoid common pitfalls and make sure your project delivers on every front.

1. Start with clear objectives

Before talking to contractors or architects, be absolutely clear on what you want your new warehouse space to achieve.

• Are you expanding storage capacity with new pallet racking?

• Adding a mezzanine for offices or welfare facilities?

• Improving traffic flow and picking efficiency?

• Preparing for new equipment like VNA trucks or automated systems?

A detailed brief will save time, reduce design errors, and keep your project aligned with your operational goals.

2. Get your compliance sorted early

Warehouses are subject to stringent UK regulations, from CDM 2015 responsibilities to fire safety, electrical compliance and racking standards.

• If more than one contractor is involved (as is almost always the case), you’ll need to appoint a Principal Designer and Principal Contractor in writing.

• Make sure your contractors have the right SKER (skills, knowledge, experience and resources) for the type of work - and can back it up.

Overlooking these steps can result in costly delays, insurance problems, or even HSE enforcement action.

3. Consider future scalability

Too many fit-outs only solve today’s problems. Think ahead:

• Will you need more pallet positions next year?

• Could demand double in three years?

• Are you investing in automation or a new WMS that will change how space is used?

A good fit-out design should allow for future racking reconfiguration, additional mezzanines, or even changes in loading bay setups.

4. Involve your team

No one knows the day-to-day snags of your warehouse better than your floor supervisors and operatives.

• Run a workshop or quick feedback session to gather pain points.

• Involve health & safety reps early - they’ll spot operational risks others might miss.

This builds buy-in and helps create a layout that genuinely improves workflow and staff wellbeing.

5. Choose experienced warehouse fit-out specialists

There’s a big difference between general builders and specialists who truly understand warehouse operations.

Look for partners who:

• Have proven experience with racking, mezzanines, MHE layouts and HSE compliance.

• Can coordinate sprinkler design, lighting, emergency egress routes and even power/data for future automation.

• Offer turnkey solutions, managing the full process so you’re not juggling multiple contractors.

6. Plan your operational continuity

Think about how you’ll keep your warehouse running during the fit-out.

• Can sections be cordoned off in phases?

• Do you need temporary off-site storage or overflow warehousing?

• Will you need out-of-hours installation to minimise downtime?

Planning this early keeps customers happy and operations steady.

Final thoughts

A warehouse fit-out is a major investment. Done right, it will not only meet today’s needs but give you the flexibility and resilience to grow.

At KTCS, we specialise in complex warehouse environments, from CDM coordination to full turnkey fit-outs, ensuring your project runs safely, on time, and on budget.

✅ Ready to start your fit-out?

Contact us today to discuss your warehouse plans. Our experienced team can help you scope your project, navigate compliance, and build a space that works for your business - now and into the future.