Oakville, Ontario -- CARSTAR Oakville West is moving forward with a roughly 325-square-metre (3,500-square-foot) expansion designed to support evolving repair procedures, accommodate new vehicle technologies and improve overall workflow at the facility.
Owner Lorenzo Pellicciotta said the decision to expand followed the sale of his CARSTAR Oakville East location nearly two years ago, allowing him to concentrate his efforts on a single operation.
"The decision was very intentional — driven by increasing repair complexity, the need for leadership focus, and long-term planning, including the fact that my kids chose to pursue paths outside the industry," said Pellicciotta. "That reality reinforced my decision to build a business centred on structure, culture, and sustainability rather than family succession"
Once complete, the expansion will bring the shop’s total footprint to approximately 1,464 square metres (15,750 square feet), following the acquisition of the final available unit within the building.
“The opportunity came available, so I had to jump on it,” he said.
Renovations include relocating the paint and prep departments to the newly acquired space, installing a new spray booth and prep stations, building a dedicated aluminum repair room and moving the frame machine to the rear of the facility. A non-structural wall separating the units will be removed, opening the shop floor and creating additional body repair space.
Pellicciotta is also expanding his AutoPro mechanical operation, located within the same building, by approximately 111 square metres (1,200 square feet). The additional space will be dedicated to EV and ADAS calibration. Mezzanines will also be constructed to house the parts department, clearing additional floor space within the facility.
“It’s more to keep up with the times and be able to follow procedures and OE recommendations,” Pellicciotta said. “I’m expanding so my technicians can follow procedures better — to get the work done quicker and properly.”
Pellicciotta said the expansion will also allow the shop to take on additional staff and better support employees with updated tools and equipment.
“I wanted to build a place where employees want to work,” he said. “Everything I do, I keep in mind, will the employee benefit from this? Will they want to work here compared to a shop that doesn’t have the proper tools and equipment, but expects them to do the proper job?”
From a customer and insurer standpoint, Pellicciotta expects the added capacity and improved layout to result in faster turnaround times.
“Our touch time will be better, our keys-to-keys will be better,” he said. “Customers will be happier, and insurance companies will be happier. It should be a win-win for everybody.”
Construction has been delayed by several months due to permitting challenges. Pellicciotta said confusion during the application process led municipal officials to believe the project was a new build rather than an expansion of an existing business.
Despite the delays, Pellicciotta said installation work is now underway and expects the expansion to be completed in spring.
Planning for the project began approximately 12 to 14 months ago, ahead of the unit becoming available last summer.
