Bespoke warehouse extensions designed to improve double deck access, increase speed of loading and boost storage at space-restricted sites



  • Goal/s: Boost/ enable DD deliveries at space-restricted sites
  • Product/s: Bespoke warehouse/dock extensions
  • Vehicle/s: Fixed DD/ single deck artics, rigids
  • Footprint/s: 7m x 8m
  • Special Features: rooflight panels – maximise natural daylight usage
  • Added Work/s: Site surveys, feasibility studies, bespoke designs
  • Install Time: 1.5 days per store, largest DC projects 5 days
  • Result/s: 25m road miles saved

The Client

Tesco is the largest retailer in the UK, with around 3500 stores and 27% of the grocery market share. As part of the retail giant’s drive to increase transport efficiency and cut carbon emissions, Tesco UK runs over 700 fixed double deck trailers in to its distribution fleet.

The Project

To enable double deck deliveries to Tesco’s largest UK stores and to expand double deck trunking between DC’s, Transdek was asked to design bespoke warehouse extensions – to accommodate space-restricted yards at DC’s and low canopies at stores.

The Results

Transdek designed and manufactured two warehouse extensions at Tesco’s Weybridge DC, each sealed to the main warehouse and dovetailed with 2x 20-tonne Double Deck Lifts. The lifts expanded loading capacity at the site and enabled the use of double deck trailer. A series of dock extensions were also designed for many stores to enable double deck lift installs and high-capacity deliveries

“Speed of converting the loading bays for double deck loading was critical to the success of the plan, with most back-of-stores having only one or two loading bays.”

Fresh Stream Transport Manager at Tesco