6 Ways to Extend the Life of Logistics Warehouses

In the logistics property market, it’s often said that a warehouse becomes obsolete after 20 years. The lifespan of a warehouse depends on its initial design, materials, maintenance, and technological updates. How can we mitigate the ageing of buildings and facilities? What methods – technical, ecological, and technological – can help prevent obsolescence? This article explores 6 solutions.

The lifespan of logistics infrastructure is influenced by construction and maintenance practices worldwide, with considerable variation across regions. Let’s take a closer look at the international warehouse property market.

European Standards: Sustainability and Innovation

In Europe, the pursuit of excellence is reflected in warehouses designed to last decades, incorporating the latest technological and environmental innovations. According to Afilog, a logistics building in France has an expected lifespan of about 40 years. Germany, a leader in warehouse automation, demonstrates impressive durability, with logistics buildings often lasting up to 50 years due to high-quality materials and strict construction standards.

In The Netherlands: A Century-Long Warehouse

In the Netherlands, some warehouses are designed to last a century. Notably, the H.A.B.O.G. warehouse, managed by COVRA, stores vitrified, cemented, and nuclear waste. This extraordinary longevity is linked to the country’s historical commitment to sustainability and environmental responsibility in logistics.

American and Asian Giants: Emphasis on Size and Technology

In the United States, warehouses are notable for their vast size, with many logistics facilities spanning over 50,000 m² and incorporating advanced technologies like the Internet of Things (IoT) and sophisticated automation.

In Asia, logistics innovation leads the way, with autonomous warehouses and multi-storey fulfilment centres. Hong Kong, an early adopter, developed two-storey fulfilment centres, while urban automated micro-storage sites continue to expand to meet the demand for perishables.

Moving Towards the Modernisation of Warehouses Globally

While each region adapts to local conditions, one global trend is clear: the modernisation of warehousing is on the rise. Investments in advanced technologies, including autonomous logistics solutions and Autonomous Mobile Robots (AMR), are extending infrastructure lifespans and improving efficiency. Warehouse automation has become essential in responding to the rapidly evolving logistics landscape.

Against this backdrop, automation is no longer just an asset; it is becoming an essential part of the response to the challenges of a logistics industry in the throes of transformation.

The obsolescence of logistics warehouses is multifaceted, resulting from physical wear, technological obsolescence, and shifting e-commerce demands.

On the one hand, the physical ageing of logistics buildings, including roof, floor, and wall degradation, can undermine warehouse functionality. To remain operational and competitive, these ageing structures require regular renovation.

Technological obsolescence also accelerates decline, as outdated management and automation systems create bottlenecks, necessitating frequent upgrades to align with the latest innovations. Here, interoperability and adaptability in software are essential for maintaining competitiveness.

Finally, evolving logistics requirements, driven by e-commerce and urban logistics, reveal the limitations of outdated infrastructures. Those failing to adapt to these shifts fall behind, as warehouses that do not meet new standards quickly become unsuitable.

Sustainable design, regular maintenance, and automation are key solutions to help logistics facilities exceed the 20-year mark.

Careful Planning of Design and Construction

The selection of high-quality materials, like concrete and steel, is crucial to ensuring the durability of logistics infrastructures. Compliance with local and international standards is fundamental to laying robust foundations.

Today’s innovation lies in integrating sustainable, modern solutions in warehouse construction. Biobased materials and biomimicry-inspired technologies, like self-healing concrete and self-cleaning surfaces, offer new possibilities. Natural materials such as wood, bamboo, and mycelium are also gaining popularity for their ecological benefits.

For instance, British start-up Mykor is pioneering insulation made from biomass waste, mycelium, and green chemistry. According to Valentina Dipietro, Mykor’s CEO, using these materials can cut operational carbon emissions by 80% through efficient insulation.

Regular Maintenance and Upkeep of Logistics Warehouses

Regular maintenance is essential for preventing warehouse degradation. Periodic inspections, repairs, and replacement of ageing equipment like ventilation and lighting systems prevent infrastructure from deteriorating.

With the rise of automated warehouse solutions, maintenance is evolving to become more specialised. Standards such as AFNOR’s NF X60-000 in France and ISO 55000 internationally enforce rigorous asset management practices, including preventive and corrective maintenance, equipment assessment, and planning of interventions to ensure the reliability and efficiency of automated logistics systems.

Investing in Warehouse Automation

Warehouse automation, mechanisation, and robotisation are invaluable for extending the operational life of warehouses. Companies like Exotec offer automated storage and retrieval systems, such as the Skypod system, which uses AMR robots capable of navigating 3D warehouse shelves to access stored products quickly.

Equipped with advanced sensors and controls, the Skypod optimises order-picking while working harmoniously with human staff. This scalable, flexible system is designed to integrate with existing setups, enhancing the lifespan of equipment and infrastructure.

Incorporating Environmental Considerations

Warehouses exposed to harsh weather conditions require specialised materials and protective systems to ensure longevity. Location is also crucial; seismic or industrial zones pose a greater risk of damage, and coastal infrastructures face threats from rising sea levels and storms. Mega-cities like Tokyo, Delhi, and Shanghai, located in high-risk flood zones, present additional challenges.

Considering these environmental factors during warehouse construction enhances resilience against environmental risks.

Opting for Modular, Flexible Warehouses

Modular structures offer flexibility and adaptability without the need for complete rebuilding, accommodating diverse storage and handling needs. A modular system can also be reinforced for seasonal demand surges.

For instance, Exotec offers a robot hire service to help companies manage peak order volumes. Contractually guaranteed solutions ensure consistent maintenance and evolution in line with changing requirements.

Adapting to Local Regulations

Adapting logistics facilities to evolving safety, environmental, and labour regulations is vital for longevity. The international ISO 14001 standard, for example, sets out environmental management guidelines for warehouses, while France’s ICPE (Installations Classées pour la Protection de l’Environnement) defines requirements based on the types of materials stored and associated risks.

From design through to automation, good practices can significantly extend a warehouse’s lifespan. Intralogistics automation is a critical component of maximising existing warehouse efficiency. At Exotec, we provide automated and robotic systems that seamlessly integrate with current infrastructure, helping transform and optimise your facilities.