Supporting Rapid eCommerce Growth with a Scalable Warehouse Storage Solution
As demand continues to grow across the eCommerce and retail distribution sector, warehouse operators need storage systems that can scale quickly without disrupting day-to-day operations.
Dexion Victoria recently delivered a major warehouse fit-out for Costway Wholesale in Truganina, Victoria, helping the business expand its storage capacity with a practical, high-volume pallet racking solution tailored to its growth plans. The project was completed across two stages, allowing the site to become operational while works were still underway.
The result was a high-capacity selective pallet racking installation delivering 30,838 pallet locations, designed to support current demand while providing a strong foundation for future growth.
Project Overview
Client: Costway
Location: Truganina, Victoria
Industry: eCommerce / retail distribution
Project duration: 31 October 2025 to 7 February 2026
Solution delivered: Selective pallet racking warehouse fit-out
Pallet locations delivered: 30,838
System height: 11,400mm
Number of aisles: 39
Installation approach: Two-stage installation, with live site conditions during Stage 2
The Client Challenge
Costway Wholesale required a new warehouse storage solution that could support its continued growth in Australia while remaining simple and efficient to operate.
The brief was not just about adding capacity. The client needed a solution that would maximise storage within the available footprint, support day-to-day warehouse activity, and be delivered within a tight timeframe. The layout also needed to remain practical for operations, with selective access across the facility and a straightforward operating model that could support ongoing growth.
A further layer of complexity came from the delivery program itself. Once Stage 1 of the installation was complete, the warehouse became operational while Stage 2 works continued. That meant the project had to be carefully managed around live warehouse conditions, with a strong focus on safe access, segregation and installation sequencing
The Objective
The client engaged Dexion Victoria to deliver a warehouse fit-out that would:
- maximise storage capacity with a simple solution
- support business growth in Australia
- provide a safe, practical and scalable racking layout
- allow the warehouse to become operational as early as possible in the project program
The Warehouse Storage Solution Delivered by Dexion Victoria
Dexion Victoria delivered a large-scale selective pallet racking system designed to provide high-capacity storage while maintaining ease of access and operational flexibility.
Selective pallet racking was the right solution for this facility because it allowed Costway Wholesale to store a high volume of palletised stock while still retaining direct access to individual pallets. For a fast-moving eCommerce distribution environment, that balance between storage density and accessibility is critical.
The completed system included:
- selective pallet racking
- custom-depth racks in selected areas
- 11.4 metre system height
- 39 aisles
- 30,838 pallet locations
- mesh decks
- rack protection
- safety barriers around office areas
- line marking to support safe movement through the facility
This solution gave the client a practical high-volume storage system that aligned with operational needs while also allowing for future growth.
Staged Warehouse Installation in a Live Operating Environment
One of the most important aspects of this project was the staged delivery model.
Dexion Victoria completed the installation in two stages. After Stage 1, the warehouse became live and operational while Stage 2 works continued. This allowed the client to begin using the facility earlier, reducing delays to occupancy and supporting a faster transition into the new space.
Delivering a project this way requires more than installation capability alone. It demands strong project coordination, clear communication on site, and careful planning around movement, access and safety. With installation crews ranging from 12 to 16 personnel, Dexion Victoria managed the works to maintain progress while supporting a safe live-site environment.
This staged approach was a major advantage for the client, helping reduce time to operation while keeping the project moving toward full completion.
Safety Features Integrated Into the Fit-Out
Safety was an important part of the delivered outcome.
In addition to the racking installation itself, the project included a number of measures designed to support safer warehouse operation, including:
- rack protection
- mesh decks
- warehouse safety barriers and protection systems
- warehouse line marking
These features support safer movement throughout the warehouse and help reduce the risk of damage to both infrastructure and equipment.
All systems were designed in line with AS 4084 racking standards, ensuring compliance with Australian requirements for racking design, operation and maintenance.
The project also aligns with broader WorkSafe Victoria warehouse safety guidelines, particularly around traffic management, separation of pedestrians and vehicles, and safe operating practices.
Results of the Truganina Warehouse Fit-Out
The completed project delivered a significant uplift in storage capacity and created a stronger operational platform for future growth.
30,838 pallet locations delivered
The new selective pallet racking system delivered a total of 30,838 pallet locations, providing Costway Wholesale with the storage capacity needed to support continued expansion.
Approximately 40% increase in pallet capacity
A standout project metric recorded internally was an increase in pallet capacity of 40%, demonstrating the scale of improvement achieved through the new fit-out.
Scalable solution for business growth
The project was driven by growth in Australia, and the final outcome provided a scalable warehouse solution capable of supporting that growth with a practical operating model.
Improved safety and site functionality
With rack protection, barriers and line marking incorporated into the fit-out, the warehouse also benefited from an improved safety environment and better-defined operational zones.
Why Costway Wholesale Chose Dexion Victoria
Costway Wholesale selected Dexion Victoria based on pricing and an existing relationship, reflecting the strength of the ongoing partnership.
From a delivery perspective, this project also highlights the areas where Dexion Victoria adds value beyond product supply alone, including:
- strong project coordination
- ability to deliver complex installations
- engineering expertise
- efficient installation teams
- minimal disruption to operations
- on-time delivery
Dexion Victoria continues to support clients with warehouse design and layout solutions that focus on efficiency, safety and long-term performance.
Need a Warehouse Racking Fit-Out in Melbourne or Victoria?
If your business is planning a new warehouse, expanding capacity, or upgrading an existing facility, Dexion Victoria can help with tailored storage solutions designed around your operational requirements.
Whether you need selective pallet racking, a new warehouse fit-out, or a broader warehouse storage solution in Melbourne or Victoria, our team can work with you to design and deliver a practical outcome that supports safety, efficiency and growth.
Speak to Dexion Victoria and National Make Good Solutions about your next warehouse project.
