Fedex Facility

FedEx

Project Overview

FedEx’s facility in Hutchins, Texas, required a large-scale HVAC and control system upgrade to enhance operational efficiency and safety. The project included the installation of 43 new rooftop units (RTUs) totaling over 1,050 tons of cooling capacity, a full building automation system (BAS), and significant structural modifications. Upchurch also provided custom prefabricated solutions, including steel framing, custom walk pads, OSHA-compliant safety rails, and electrical infrastructure upgrades to support the expanded system load.

Our Approach

Upchurch’s ability to deliver complex infrastructure projects with a focus on safety, efficiency, and precision played a key role in the success of this initiative. Our team provided:

  • Comprehensive Project Management: Coordinated efforts across multiple trades, ensuring seamless execution while minimizing disruptions to FedEx operations.
  • Prefabrication & Custom Metals Expertise: Designed and installed 8,000 linear feet of custom walk pads and structural steel framing, ensuring safe and efficient maintenance access.
  • Advanced Control System Integration: Installed a new BAS to enhance monitoring and automation of the HVAC system for improved energy efficiency and performance.
  • Safety & Compliance Solutions: Installed 1,900 feet of OSHA-approved safety rails to enhance worker safety given the proximity of the new walk platforms to the roof’s edge.
  • Electrical System Upgrades: Installed a 4,000A main switchboard and multiple secondary panelboards to support the increased air conditioning load, ensuring long-term power reliability.

Outcome

Upchurch successfully delivered a modern, high-efficiency HVAC and control system for FedEx’s Hutchins facility. The project resulted in:

  • Enhanced climate control capabilities with 43 high-performance RTUs and a state-of-the-art BAS.
  • Improved operational safety through OSHA-compliant safety rail installations and expanded service access.
  • Increased electrical capacity to support long-term facility growth and performance.
  • Long-term maintenance efficiency with prefabricated access solutions designed for durability and ease of servicing.