Warehouse
Reconfiguration &
Relocation Services

Warehouse reconfiguration is the physical rearrangement or modification of storage systems — pallet rack, shelving, conveyors, pick modules — within the same building. The facility does not change; the equipment configuration does. Reconfiguration is triggered by capacity problems, layout inefficiency, new automation, SKU mix changes, or a need for higher density without moving buildings. Warehouse relocation is the physical move of storage systems and material handling equipment from one facility to a new one — including teardown, palletizing, transport coordination, and reinstallation at the destination. The two services share technical execution methods — both require trained installation crews, RMI/ANSI MH16.1-compliant teardown and reinstallation, and post-project recommissioning — but they serve different triggering events and buyer contexts. MWS handles both as a single-source integrator, which is particularly valuable when a relocation requires a full reconfiguration of the new space, or when a reconfiguration surfaces a need for new equipment or facility upgrades. Call 515-635-1555 to discuss which service fits your current situation.

Yes, in most cases. MWS designs reconfiguration and partial relocation projects in phases so your operation continues in unaffected aisles and zones while work proceeds in designated work areas. For a full-facility reconfiguration, a zone-by-zone approach with temporary rack staging maintains at least 60–70% of pick capacity throughout the project — your operations team agrees to the sequencing plan before work begins. For facility-to-facility relocations, a phased approach moves equipment zone by zone over multiple weekends while the balance of the facility operates normally from the origin site. The critical requirement for a live-operation reconfiguration is that the rack being worked must be completely cleared of inventory before MWS touches it — we coordinate with your operations team on the buffer stock and alternate storage plan that makes the sequencing possible.

Yes. MWS routinely schedules pallet rack teardown, relocation, and reinstallation during off-peak windows — including overnight shifts, Saturday execution, and full Friday-to-Sunday weekend cutovers — particularly for active warehouses with five- or six-day operational schedules. A weekend cutover plan consolidates the most disruptive work into a single window so Monday morning operations are unaffected. This is available for both in-place reconfiguration projects and for full-facility relocation projects where distance between buildings makes a phased approach practical. Weekend and after-hours execution may carry a labor premium; MWS provides a clear cost comparison between standard and off-hours scheduling so you can make the right call for your operation. Call 515-635-1555 to ask about current weekend scheduling availability.

Costs vary widely by scope. A small in-place reconfiguration — repositioning 10–25 rack sections, adjusting beam heights in one zone — may cost $5,000–$20,000 in MWS labor and services. A medium-scope multi-zone reconfiguration with conveyor modifications can run $20,000–$75,000. A full-facility reconfiguration involving 200+ rack bays, conveyor rerouting, and mezzanine modifications can reach $100,000–$250,000 or more. Key cost drivers are: total rack sections in scope, whether conveyors or mezzanines are involved, the degree of component replacement required (damaged uprights, worn hardware), and whether weekend/after-hours labor is needed. MWS provides a line-item project estimate before mobilization — no surprises mid-project. For a preliminary discussion of your scope, call 515-635-1555 or email sales@warehousesolutionsinc.com.

For a standard selective pallet rack facility under 50,000 square feet, MWS labor and services typically range from $40,000–$120,000, excluding freight and replacement components. A larger facility of 50,000–150,000 square feet with mixed rack types, a conveyor system, and a mezzanine typically runs $100,000–$350,000 in MWS execution costs. Major distribution centers over 150,000 square feet with structural rack, conveyors, and cranes can reach $300,000–$600,000 or more. The key framing point: relocating existing equipment typically costs 30–50% of buying and installing new at the destination. If your existing rack is in serviceable condition, you almost always save money by relocating it. Additionally, equipment you choose not to relocate — surplus rack, conveyors, shelving — can be sold through MWS's used equipment program, with proceeds offsetting your total project cost. Call 515-635-1555 for a scope-based estimate.

Physical execution by MWS — teardown through reinstallation — typically runs 2–4 weeks for a smaller selective rack facility and 4–8 weeks for a facility with mixed rack types, a conveyor system, and a mezzanine. Large distribution centers with structural rack and complex equipment can take 8–16 weeks. However, the planning that must precede physical execution — Phase 1 site assessment, engineered CAD layout for the destination, permit applications, and business continuity planning — takes an additional 4–12 weeks depending on facility complexity and jurisdiction. Facilities under a hard lease deadline should plan to begin the MWS engagement at least 3–6 months before the required move completion date. If your timeline is already compressed, call 515-635-1555 immediately — MWS has experience executing fast-track relocations, but early engagement is essential.

Yes. After any relocation or reconfiguration, pallet rack must be re-inspected and re-anchored per RMI/ANSI MH16.1-2023. Load plaques must be reviewed and updated to reflect any configuration changes. In most jurisdictions within MWS's 12-state service area, pallet rack installations — including reinstallations — require building permits and a final inspection by the local Authority Having Jurisdiction (AHJ), particularly for high-piled storage applications. For mezzanines and VRCs, permit re-inspection is mandatory after any relocation. MWS manages the permit application process, coordinates the AHJ inspection, and provides the recommissioning documentation package as a standard project deliverable. This is not optional compliance — it is the difference between a professionally executed relocation and a liability waiting to surface.

Yes — this is one of the most commonly overlooked compliance requirements in warehouse relocation. FM Global Property Loss Prevention Data Sheets and NFPA 13 govern the open vertical flue spaces required between rack rows to allow adequate sprinkler water penetration to lower rack levels. When rack rows are repositioned — even within the same facility — the flue geometry changes. If the new row configuration reduces flue spacing below code requirements, your sprinkler system will not function as designed during a fire event. MWS performs a fire suppression geometry review as part of every Phase 1 site assessment and flags any proposed rack positioning that could create a flue spacing problem. We coordinate with your fire protection engineer or the local AHJ before repositioning any rack row that affects sprinkler coverage. Ignoring this step is one of the eight common mistakes we see on self-managed relocations — and the correction after the fact is always more expensive than addressing it upfront.

Warehouse decommissioning is the full teardown, inventory, and removal of all storage systems and material handling equipment from a facility being vacated — typically at lease expiration, post-acquisition facility closure, or post-disaster facility exit. It differs from relocation in that there is no destination facility for reinstallation; the scope is teardown, component disposition (resale, reuse, scrap), removal, and landlord handoff documentation. MWS offers decommissioning as a standalone service across Iowa, Illinois, Indiana, Michigan, Minnesota, Missouri, Ohio, Wisconsin, Kansas, Nebraska, North Dakota, and South Dakota. Our decommissioning scope includes top-down rack teardown, component condition grading, resale coordination through MWS's used equipment program, responsible scrap processing for damaged components, and a final decommissioning report with facility photos for landlord handoff. Decommissioning projects often surface significant asset recovery value — quality pallet rack can return 15–30% of original purchase price — which partially or significantly offsets teardown costs. Call 515-635-1555 or email sales@warehousesolutionsinc.com to discuss.

A phased warehouse relocation moves zones or departments of a facility sequentially — typically over multiple weekends or in planned operational windows — while the balance of the operation continues running at the origin site. Rather than a single move event that shuts everything down, a phased relocation transfers the facility incrementally, maintaining operations at both the origin and destination simultaneously during the transition period. This approach is ideal when: the new facility is within reasonable distance of the old one (typically under 200 miles), the operation cannot tolerate a full-stop move, inventory buffering can cover the transition windows for each zone moved, and the overall project timeline allows for an extended move period (typically 8–16 weeks of active relocation weekends). The trade-off is a longer overall timeline and a period of split-site operations that requires careful planning. MWS has executed phased relocations across all 12 Midwest states and can design the specific sequencing plan that fits your operational constraints. Call 515-635-1555 to discuss your scenario.

Equipment you choose not to relocate has multiple disposition paths, and MWS can manage each of them. During the Phase 1 site assessment, we grade your surplus rack components by condition: reusable-as-is, reusable-with-repair, or scrap. Reusable pallet rack — particularly from manufacturers like Unarco (Steel King), Ridg-U-Rak, and Interlake Mecalux — can be sold through MWS's used equipment program. We inventory the components, photograph them, and list them through our channels; proceeds are applied against your project costs. Cantilever arms, wire decking, conveyors, and shelving in good condition also have active resale markets. For components that cannot be sold, MWS coordinates responsible scrap pickup and processing. The combination of asset recovery and scrap coordination often offsets 15–30% of total decommissioning costs — turning what feels like a pure expense into a partial capital recovery event. Contact us a 515-635-1555 or sales@warehousesolutionsinc.com to start the assessment.

General moving companies handle furniture and commercial freight — they do not design, engineer, or execute rack reinstallation. A freight broker coordinates transport but has no installation crew. MWS is a warehouse systems integrator: we assess, design, disassemble, transport-coordinate, reinstall, and recommission — everything under one contract, one project manager, and 50+ years of Midwest execution history. Practically, this means: we can confirm the destination layout fits before teardown begins; we inspect every component during disassembly and flag what must be replaced before reinstallation; we handle the permitting and compliance obligations so you don't receive a violation notice 60 days after move-in; and we produce the documentation — anchor torque records, load plaque updates, recommissioning report — that protects you in any OSHA inspection or insurance audit. The cost of hiring MWS versus patching together a mover + a rack installer + an inspector is almost always lower when you account for coordination failures, compliance gaps, and the cost of correcting a non-compliant reinstallation after the fact. Call 515-635-1555 to discuss your project.