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Convert a Closed Drugstore into an Express Tunnel Car Wash

Vacant Freestanding Drugstore (Former Rite Aid, Walgreens, or CVS, roughly 11,000 to 15,000 sq ft) on a 1 to 2 Acre Corner Parcel with Drive-Thru → Membership-Based Express Exterior Tunnel Car Wash with Enclosed Tunnel, Water Reclaim, Pay Lanes, and Free Vacuum Stations

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America is working through the largest wave of drugstore closures in its retail history. Rite Aid shut its remaining roughly 1,300 stores and ceased operations in 2025, and Walgreens is in the middle of a plan to close about 1,200 locations over three years, with CVS trimming its fleet as well. That has dumped hundreds of nearly identical buildings onto the market at once: single-story boxes of roughly 11,000 to 15,000 square feet, sitting on one-to-two-acre "hard corner" parcels at signalized intersections with excellent visibility, curb cuts on two streets, and a drive-thru lane already wrapped around the building. Dollar stores, clinics, gyms, and thrift stores are backfilling many of them, usually at rents 20 to 40 percent below the old pharmacy leases, but one of the most distinctive second lives is the express tunnel car wash. Operators like Express Wash Concepts have converted several former Rite Aids and Walgreens in Pennsylvania and Michigan, reporting roughly $3 million to renovate, redevelop, and equip one, and in August 2026 Falls Township, Pennsylvania, recommended conditional use approval for another Rite Aid-to-tunnel conversion. The logic is simple: a drugstore's long rectangular footprint can swallow a 100-to-150-foot conveyor tunnel with the loud equipment indoors, which neighbors and planning boards like far better than an open-ended new build, and the corner parcel offers the traffic counts that a membership wash model lives on. The catches are real, though. Zoning boards will scrutinize stacking (queue) length, wash water must be kept out of storm drains, the slab has to be cut for trench drains and reclaim pits, dryer and vacuum noise must be controlled at the property line, and the existing building's column grid and roof height do not always cooperate. This guide walks through underwriting the site, testing the tunnel fit, winning zoning, engineering water and sewer, gutting and rebuilding the box, installing equipment, and opening with a membership base already signed up.

Cost Range

$1,800,000 – $4,500,000

Timeline

36–80 weeks

Materials Cost

$3,065,000

Permits Cost

$105,000

Estimates only. Costs shown are national averages and vary by location, year, project scope, and finish quality. Permit requirements differ by jurisdiction — always confirm with your local building department and get quotes from licensed contractors before starting.

Steps

1

Underwrite the Corner Before You Fall for the Building

An express wash lives or dies on car counts, membership density, and competition, so start with the market rather than the box. Pull state DOT average daily traffic counts for both frontages (most operators look for 20,000 to 25,000+ vehicles per day on the main road), map every existing and permitted tunnel wash within a three-to-five-mile radius, and look at household counts, income, and commuting patterns in the trade area. The 2025-2026 pharmacy closures mean you may be choosing among several vacant drugstores in the same metro, and landlords know a car wash pays more than most backfill tenants, so negotiate from data. Confirm whether the deal is a purchase or a long ground or building lease, because a $2 million to $4 million build-out needs a term of 20 years or more to amortize. Request the original site plan, survey, title report, and any recorded restrictions: some former pharmacy parcels carry deed restrictions or reciprocal easement agreements that prohibit car washes, automotive uses, or competing pharmacies, and those must be cleared or waived before you spend another dollar.

Estimated time: 30 days

2

Test the Tunnel Fit, Queue, and Traffic Flow on the Site Plan

Have a car wash design firm or equipment manufacturer lay a tunnel over the existing floor plan. Typical express tunnels run 100 to 150 feet of conveyor plus entry and exit aprons, so measure the building's long dimension and check whether the tunnel can run straight through, whether new overhead doors can be cut in both end walls, and whether interior columns land in the conveyor path. Then design the circulation outside the building: two or three pay lanes with automated pay stations and license-plate recognition for members, a stacking lane long enough to hold the queue without spilling onto the street, a clear exit path, and 15 to 25 free vacuum spaces. Stacking is where conversions get tested hardest. Many codes require room for roughly 9 to 12 cars per wash, and the Falls Township conversion needed variances to approve a 179-foot stacking lane for seven vehicles where the code called for 200 feet for ten. The old drive-thru lane often becomes part of the stack, which is one of the biggest advantages of a pharmacy site, so trace every turning movement with a traffic engineer before you commit.

Estimated time: 21 days

3

Run Due Diligence on the Shell, Slab, and Utilities

Commission a property condition assessment and a structural review focused on the things a car wash changes. The slab will be saw-cut for a trench drain running the length of the tunnel, a conveyor pit, and reclaim tanks, so core it to check thickness, reinforcement, and soil conditions below. Check roof framing and clear height for overhead equipment such as arches, mitter curtains, and dryer producers, and confirm the roof can carry rooftop units and exhaust fans. Evaluate the masonry or tilt-up end walls you will be opening for tunnel doors. A wash is wet and humid inside all year, so plan on replacing interior finishes with washable, moisture-resistant surfaces such as FRP panels or coated block, and check whether existing steel needs corrosion protection. On the utility side, ask the water provider about meter and tap sizes and capacity fees, ask the sewer authority about discharge limits and pretreatment requirements, and ask the electric utility whether the existing service (often 400 to 800 amps) can be upgraded to the 1,200 to 2,000 amps that a full equipment package with dryers and vacuum systems typically needs. A Phase I environmental assessment is standard; pharmacies are usually clean, but adjacent uses and old fill can surprise you.

Estimated time: 30 days

4

Win Zoning: Conditional Use, Stacking Variances, and Noise Conditions

Car washes are rarely a by-right use. In most commercial districts you will need a conditional or special use permit, site plan approval, and often variances for stacking length, lane counts, vacuum placement, or loading areas. Reusing the existing building is your strongest argument: the equipment is enclosed, dryer noise is contained inside the tunnel, and the site keeps its familiar footprint instead of becoming a demolition-and-new-build project. Bring a traffic study showing the queue never backs onto public streets, an acoustic study modeling dryers and vacuum producers at the nearest homes, a lighting plan with shielded fixtures, landscaping and screening, and a water management narrative explaining reclaim and sewer discharge. Expect conditions such as sound walls along residential edges (Falls Township required a sound barrier along one frontage), limited operating hours, vacuum stations oriented away from neighbors, and enclosed vacuum turbines. Meet with neighbors before the hearing; opposition to car washes almost always centers on noise, traffic, and the number of washes already in town.

Estimated time: 90 days

5

Engineer Water Reclaim, Drainage, and Sewer Pretreatment

Wash water must never reach the storm system. Inside the tunnel, a full-length trench drain carries water, soap, road grit, and oil to a series of settling and separation tanks, typically a sand and grit trap followed by an oil-water separator or interceptor sized to your sewer authority's requirements. A water reclamation system then filters and treats a large share of that water, commonly 50 to 80 percent, for reuse in early wash and undercarriage stages, with fresh or reverse-osmosis water reserved for the final rinse. Some states and municipalities, especially in drought-prone regions, mandate reclaim and set maximum fresh-water use per car, and many sewer authorities set limits on discharge volume and pollutants. Outside, regrade the vacuum and stacking areas so rinse water and drips flow to the interceptor rather than the parking lot inlets, and update the stormwater plan for any new impervious area. Size the tanks with a civil engineer and the equipment vendor together, because tank excavation inside an existing building is far easier to do once than to redo.

Estimated time: 30 days

6

Gut the Box and Build the Tunnel Shell

With permits in hand, strip the drugstore to its shell: shelving, pharmacy counter, ceilings, interior walls, and finishes all come out, and the old drive-thru window is removed or converted. Saw-cut and excavate the slab for the trench drain, conveyor pit, and reclaim tanks, then pour new reinforced concrete with sloped floors, embedded conduit, and heated slab loops if you are in a freeze climate. Cut new overhead door openings at the tunnel entry and exit with structural lintels, and install high-speed or insulated overhead doors that close at night and in winter. Build an equipment room for pumps, chemical storage, reclaim, compressors, and the motor control center, and plan a separate dry space for the office, break room, and membership sales. Line the tunnel with corrosion-resistant, washable surfaces, install high-volume ventilation and humidity control, add bright LED lighting that customers can see through glass, and upgrade the electrical service to the new load. The leftover square footage that does not fit the tunnel can become storage, a detail shop, or a small leasable unit.

Estimated time: 90 days

7

Install the Wash Equipment, Pay Stations, and Vacuum System

The equipment package is the heart of the business and typically runs $800,000 to $1.5 million or more for a well-equipped express tunnel. It includes the conveyor, correlator, prep and presoak arches, wraparound and top brushes or soft-cloth mitters, high-pressure rinse and undercarriage, tire shine, ceramic or wax applicators, spot-free rinse, and a bank of dryer producers that should sit inside the tunnel for noise control. Order early, as lead times for conveyors and controllers can run several months. Outside, install automated pay stations with credit card readers, membership RFID or license-plate recognition, gate arms, and clear lane signage. Build the free vacuum area with a central vacuum producer in an enclosed sound-attenuated room, canopies, drop stations, and trash receptacles. Integrate everything with a point-of-sale and membership software platform, add security cameras covering the tunnel and lot, and run water through the full system for leak, chemical, and reclaim testing before inspection.

Estimated time: 60 days

8

Pass Final Inspections and Open with Memberships Already Sold

Final inspections typically include building, electrical, plumbing, fire, the sewer authority's pretreatment inspection, and a zoning compliance check of landscaping, lighting, and sound walls before a certificate of occupancy is issued. Hire and train staff on prep, safety stops, and customer service, and run soft-opening days with free or discounted washes to tune chemistry, dryer settings, and traffic flow. The express model makes most of its money on unlimited monthly memberships, so start presale weeks before opening: banners on the old drugstore frontage, geofenced ads, founding member pricing, and a team signing up cars in the lot. Track wash counts, membership growth, churn, chemical cost per car, water use per car, and peak-hour queue length from day one. If the queue reaches the street, adjust staffing and lane management immediately; a backed-up stack is the fastest way to lose the goodwill you earned at the zoning hearing.

Estimated time: 30 days

Materials

MaterialEst. CostRequired
Site Acquisition or Long-Term Lease Deposit (Former Drugstore Parcel)$250,000Required
Car Wash Design, Civil, Traffic, and Acoustic Engineering$120,000Required
Interior Demolition and Removal of Pharmacy Fixtures$60,000Required
Slab Saw-Cutting, Excavation, and New Reinforced Tunnel Floor$180,000Required
Full-Length Trench Drain and Conveyor Pit$70,000Required
Sand and Grit Traps, Oil-Water Separator, and Reclaim Tanks$110,000Required
Water Reclamation and Spot-Free Reverse Osmosis System$120,000Required
Express Tunnel Equipment Package (Conveyor, Arches, Brushes, Applicators)$1,000,000Required
Tunnel Dryer Producers$120,000Required
Insulated or High-Speed Overhead Doors with New Structural Openings$90,000Required
Electrical Service Upgrade, Switchgear, and Motor Control Center$200,000Required
Tunnel Ventilation, Humidity Control, and Washable FRP Wall Liners$110,000Required
Automated Pay Stations, Gate Arms, and License-Plate Recognition$150,000Required
Central Vacuum Producer, Canopies, and 15-25 Vacuum Stations$180,000Required
Site Rework: Stacking Lanes, Striping, Curbs, and Regrading$150,000Required
Sound Barrier Wall and Landscape Screening$60,000Optional
Pylon and Building Signage Replacement$45,000Required
Heated Slab Loops for Freeze Climates$50,000Optional

Permits

Conditional or Special Use Permit, Site Plan Approval, and Zoning Variances

Car washes are a conditional or special use in most commercial districts, which means a public hearing before the planning commission or zoning board. Expect detailed review of stacking length and lane counts, traffic movements at both curb cuts, noise from dryers and vacuums at the nearest residences, lighting, landscaping, and water handling. Drugstore conversions often need variances, such as reduced stacking capacity, tunnel entrance location, vacuum placement, or loading area waivers, and approvals commonly come with conditions like sound walls and limited hours. Also confirm that no recorded deed restriction or reciprocal easement agreement on the parcel prohibits car washes or automotive uses, because zoning approval does not override a private covenant.

$40,000

Building, Electrical, and Plumbing Permits for the Change of Use

Turning retail space into a car wash is a change of use that requires a full permit set: structural drawings for slab cuts, pits, and new wall openings; electrical plans for the upgraded service and equipment; plumbing for the trench drain, separators, reclaim, and fresh water; mechanical plans for ventilation; and energy code compliance. Plan reviewers will also check accessibility for the office and customer areas and the fire code requirements for chemical storage. Inspections occur at each stage, and a certificate of occupancy is issued only after the final building, fire, and zoning inspections pass.

$35,000

Sewer Discharge, Pretreatment, and Water Connection Approvals

The local sewer authority will usually require a permit or approval for industrial or commercial discharge, specifying the interceptor and separator design, sampling access, pollutant limits, and sometimes maximum daily volume. Some jurisdictions, particularly in drought-prone states, require water reclamation or cap fresh-water use per vehicle. The water utility will charge tap and capacity fees for a larger meter, and the stormwater plan must show that wash water and vacuum-area rinse never reach storm inlets. These fees and approvals vary widely, so get them in writing during due diligence.

$30,000

Frequently Asked Questions

How much does it cost to convert a closed drugstore into an express tunnel car wash?

The estimated cost ranges from $1,800,000 to $4,500,000, depending on your location, project scale, finish quality, and whether you hire professionals or do it yourself.

How long does it take to convert a closed drugstore into an express tunnel car wash?

A typical conversion takes 36 to 80 weeks, covering 8 major steps including underwrite the corner before you fall for the building, test the tunnel fit, queue, and traffic flow on the site plan, run due diligence on the shell, slab, and utilities, and more.

What permits do I need to convert a closed drugstore into an express tunnel car wash?

You may need: Conditional or Special Use Permit, Site Plan Approval, and Zoning Variances (approximately $40,000); Building, Electrical, and Plumbing Permits for the Change of Use (approximately $35,000); Sewer Discharge, Pretreatment, and Water Connection Approvals (approximately $30,000). Requirements vary by jurisdiction.

What materials do I need to convert a closed drugstore into an express tunnel car wash?

Key materials include: Site Acquisition or Long-Term Lease Deposit (Former Drugstore Parcel) (~$250,000), Car Wash Design, Civil, Traffic, and Acoustic Engineering (~$120,000), Interior Demolition and Removal of Pharmacy Fixtures (~$60,000), Slab Saw-Cutting, Excavation, and New Reinforced Tunnel Floor (~$180,000), Full-Length Trench Drain and Conveyor Pit (~$70,000), Sand and Grit Traps, Oil-Water Separator, and Reclaim Tanks (~$110,000).

What is the difficulty level of this project?

This project is rated as expert. This is an expert-level project requiring licensed professionals and multiple permits.

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Tags

car washexpress tunnel washdrugstore conversionRite Aid closuresWalgreens closuresadaptive reuseretail real estatewater reclamation2026 trends