FedEx Ground Distribution Facilities

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Project Overview


Castles Design Group


San Angelo, TX; Lowell, AR; Little Rock, AR, Pittsburg, KS; Dodge City, KS; S. Houston, TX

Contract Value




Delivery System

Bid/Negotiated Design-Build


45,000 to 250,000 sq. ft.

Project Completion


Buffalo Builders has worked on four cradle-to-the-grave builds with FedEx Ground: we worked with the developer from inception through architectural, civil, electrical, mechanical and structural design.  Our work with FedEx is among our most demanding and rewarding.  It is a testament to the far-reaching expertise of our construction managers and crew.

After ensuring permits are in order, construction of a FedEx distribution warehouse begins with mass grading of sites from 5 to 80 acres. Next, we oversee installation and coordination of all utility services to the site and facility.  Then, to ensure long-lasting construction, we tackle the installation of storm drains.

Once the site is fully prepared and up to codes with city and utility standards, we begin design and installation of all paved surfaces according to area usage.  This includes basic paving such as:

  • Concrete footings
  • Dock walls
  • Fiber and steel reinforced slabs
  • Truck aprons
  • Entrance and heavy load aprons
  • Dolly parking aprons

Once all basic paved surfaces are finished, we focus on specialty paving for sloped floor slabs and trench drains for vehicle drainage.  Next is the coordination, purchase, design, and installation of the structural shell of the facility—whether it be pre-engineered metal building or conventional steel with a hard-wall exterior.  Then comes the heaviest installation of all: dock doors, overhead coiling vehicle doors, loading dock equipment, and shelters.

With a structure in place and doors installed, we turn our attention to the design coordination and installation of all specialty mechanical systems, such as:

  • Office area HVAC
  • Warehouse ventilation and heating
  • Fume detection systems
  • Destratification fans
  • Radiant tube heaters
  • Trench drains
  • Oil water separators
  • Natural gas piping
  • Exhaust louvers

For a final touch on the primary structure, we focus on the design, coordination, and installation of all electrical systems, including fire alarms, security systems, building energy management systems, LED lighting, and data and computer room setup.

With the primary building complete and functional, we put our finishing touches on-site security and design, including:

  • Perimeter fencing
  • Vehicle control gates
  • Guard houses
  • Pedestrian control devices
  • Metal detectors
  • Card readers
  • Emergency vehicle access

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