FedEx Freight STL Expansion

Location: St. Charles, MO    |    Owner: FedEx Freight    |    Architect: Castles Design Group, P.C.

Since 2001 FedEx Freight has operated a service center for the greater St. Louis area, processing approximately 3,800 freight shipments daily. With the current facility operating at near maximum freight capacities, an expansion was needed to ease equipment and freight constrictions, allowing for more efficient freight handling. This 74,680-SF expansion will accommodate the current and future business growth at the St. Charles facility, while also providing traffic flow improvements for the anticipated 300 additional truck trips and 500 employee trips daily.

Poettker Construction was contracted for the cross dock, yard, and shop expansion of the existing FedEx Freight facility located in St. Charles, MO. The building addition includes:

  • An expanded loading dock area consisting of 81 additional loading docks
  • Workroom
  • Driver check-in area
  • Dispatch
  • Breakrooms
  • Meeting room
  • Secure storage
  • Locker rooms
  • Restrooms

The vehicle service shop was expanded to provide a total of 5 tractor/trailer service bays, 1 forklift service bay, and tires, tools, and parts storage.

The sitework for this expansion also includes 20,567-CY of new 7” concrete pavement, 6,662-CY of new asphalt pavement, sidewalks, curbs/gutters, fencing, gates, and utilities.

The FedEx facility remained open and operational throughout the duration of construction, making safety a top priority for not only construction personnel, but for all individuals occupying the facility.


Increased Efficiency

Traffic Flow Improvements 

Concrete Pavement Expansion

square feet
dock door capacity
cy of new pavement


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