Renovation & Modernization of a Warehouse and Assembly Hall
Project Overview: The Starting Point – From Initial Assessment to Goal Definition
“Renovating an industrial hall from a site manager’s perspective: assessment, goal setting, and planning – this is how every successful renovation project begins.”
Article Series Overview
- Project Overview: The Starting Point – From Initial Assessment to Goal Definition
- Deconstruction – Reconstruction – Interior Fit-Out: From Shell to Functional Hall
- Fire Protection – Rethinking Safety: From Risk to Code-Compliant Solutions
- Sustainability – Energy Efficiency as a Competitive Advantage
- Project Management – Communication and Site Logistics
- Cost Control – Smart Use of Funding Programs
- Commissioning – Handover and Client Acceptance
- The 10 Most Common Site Manager Mistakes
- Conclusion of a Successful Renovation
When a site manager takes on the renovation of an old industrial hall, one thing is clear: nothing is left to chance. Before a single hammer is swung, the “big picture” must be on the table – from the current building condition and technical requirements to the owner’s goals.
A renovation project is like a chess game – without the first strategic move, you lose the match.
For our project with RausBau GmbH, we were dealing with a warehouse and assembly hall built in 1987 that required a full technical and energy upgrade. Goal: Future-proof the existing structure – with modern technology, high energy efficiency, and a robust safety concept.
In this chapter, you will learn how we assessed the initial situation, defined the project objectives with the client, and laid the foundation for seamless construction execution.
Why Initial Assessment is the Most Important Step
As I always say as a site manager: “If you don’t know what you’re dealing with, you’re building blind.” A detailed initial assessment is the absolute foundation of any successful renovation. It answers key questions such as:
- How structurally sound is the existing building?
- Are there any hazardous materials present (e.g., asbestos, contaminants)?
- Where are the energy performance weaknesses (roof, façade, windows)?
- What does the current Building Energy Act (GEG) require – and how does this affect the client?
Site Manager’s Checklist for Initial Assessment:
- Structural integrity check, including static recalculations
- Review of building services (electrical, heating, ventilation systems)
- Thermographic imaging to detect heat loss
- Blower door test for airtightness
- Crack analysis of the floor slab and sealing inspection
- Hazardous material analysis (asbestos, PCB, PAH)
Pro Tip: In this early stage, involve a certified energy consultant. Their findings can directly impact available funding opportunities.
The Building – Key Facts at a Glance
- Location: Industrial area with ideal HGV (truck) access.
- Year Built: 1987 – a time when energy efficiency was barely considered.
- Size: Approx. 3,200 m² of usable floor space.
- Existing Issues:
- Poor energy performance (insufficient insulation, no heat recovery).
- Outdated fire protection (no smoke and heat exhaust ventilation (RWA), non-compliant escape routes).
- Structural deficiencies in the roof and damage to the floor slab.
Site Manager’s View: This hall was a classic “renovation case” – technically outdated, a real “energy sink,” but structurally sound enough to justify refurbishment.
The Client and Their Objectives
The client briefing is always the first kickoff meeting where we clarify: “What is the goal, and what is the budget?”
Client’s priorities:
- Reduce operating costs through energy-efficient refurbishment.
- Upgrade to modern electrical and HVAC systems.
- Reconfigure for new logistics processes (larger racking systems, optimized floor layout).
- Ensure compliance with current fire safety regulations and improve workplace safety.
Our Approach: General Contractor & Quality Guardian
At RausBau GmbH, we act not only as site managers but also as general contractors. This means we oversee everything from the initial assessment to final handover. Coordination, scheduling, and quality control – all from one source.
Our team structure:
- Project management (strategy, budget control)
- Site management (on-site coordination, safety management)
- Architects (planning, building permits, visualizations)
- Specialist planners (electrical, HVAC, fire protection)
- Craft teams (roofers, window installers, drywall specialists, etc.)
Regulatory Framework and Requirements
A renovation project without permits is like a house without a foundation.
We secured the following permits and documentation:
- Building permit, including change of use
- Fire protection concept in line with industrial building regulations
- Energy consultancy in accordance with the GEG
- Workplace guidelines (air quality, lighting, ceiling heights)
- Construction insurance and liability coverage
Experience Tip: Fire protection in existing buildings can become a cost trap if planned too late. We always coordinate with the fire safety engineer early on to avoid expensive retrofitting.
Conclusion of the Initial Phase
The project overview and initial assessment are not “bureaucratic red tape” but the DNA of the project. They determine how smoothly the construction process will run and whether the budget will hold.
For this hall, it was clear:
- A new build would have been more expensive and less sustainable.
- Renovation delivers both economic and ecological benefits.
Are You Planning a Hall Renovation?
Benefit from our experience as site managers and general contractors. We assess your existing building, identify weaknesses, and develop a clear modernization concept – cost-effective, sustainable, and with guaranteed deadlines.
📞 Request your site manager consultation now: +49 811 5554790
🌐 www.rausbau.com
📧 info@rausbau.com