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Project Sysco Distribution Center, San Antonio

Project Size

635,000 sq ft

Project Dates

16 months

Project Location

1260 Schwab Road San Antonio, TX

Sysco believes that building customer relationships requires time, effort and sincerity. Big-D is proud to have built a relationship with Sysco based upon those very principles.

Project Description


For a giant supplier like Sysco Food Corporation, a warehouse is much more than four walls and a roof. When Sysco Central Texas needed to update its main warehouse facility, the company turned to Big-D Construction. Constructed on a 53.4-acre site and encompassing 635,000 square feet, the new warehouse in New Braunfels, TX (a suburb of San Antonio) became the largest Sysco facility in the United States. The massive facility has many features:

  • A245,000-square foot dry goods warehouse with a 37-door loading dock
  • A 299,000-square foot cold warehouse with a 45-door loading dock, several temperature zones for perishable goods, and a separate freezer area
  • A 70,000-square foot, two-story office area that supports all operations of the facility, including offices and cubicles for sales, shipping, and invoicing personnel, a mail room, employee break rooms, vending areas, restrooms, and locker rooms

The San Antonio Sysco Foods distribution center also includes a separate 15,000-square foot vehicle maintenance facility (VMF) that features a refueling station, four truck-mechanic bays, and a truck-wash bay. The refueling station has two 10,000-gallon above-ground fuel storage tanks and a complete fuel-dispensing system, a smooth soffit canopy structure, and water and compressed-air hose reels in each of the three fuel islands. Because this facility will experience regular high-weight traffic, it uses heavy-concrete roads, aprons, and access ways to facilitate heavy-truck operations.

The varied functions of this Sysco Foods facility required us to use a variety of construction techniques, including jobsite-cast, tilt-up concrete panels with a long-span steel structure at the docks, insulated metal freezer panels at the cooler and freezer warehouses, and steel frame and architectural tilt concrete at the office. The warehouse floors were built with shrinkage compensating trap-rock to increase longevity. We also installed integrated security features such as access control via card readers, CCTV, a security-monitoring room, standby diesel generators, and an Uninterruptible Power Supply (UPS) for sensitive and important building areas.