If you’ve driven past a massive, empty construction site in the suburbs lately, there is a decent chance you were looking at the future home of a 150,000-square-foot warehouse. For a long time, it felt like Sam’s Club was just chilling. While Costco was aggressively planting flags across the globe, the Walmart-owned warehouse giant seemed content to just sit on its existing footprint. That changed. Big time. After years of relative silence, the company dropped a bombshell announcement about its growth trajectory that basically signaled a new era for the brand.
It’s happening.
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We are talking about a massive multi-year investment. It isn't just about throwing up some metal siding and calling it a day. The Sam’s Club expansion plans currently underway represent the first major growth spurt for the company in terms of new store openings since roughly 2017. They aren't just building more of the same stuff, either. They're trying to out-tech the competition while fixing the supply chain headaches that have plagued retail since 2020.
What’s Actually Changing in the Neighborhood?
The core of the strategy is simple but aggressive: Sam’s Club aims to open over 30 new clubs across the United States over the next several years. If you’re a member, you probably know that feeling of driving forty minutes just to get the "good" toilet paper. These new locations are specifically designed to bridge those gaps. According to Chris Nicholas, the CEO of Sam’s Club, these stores are going to be significantly larger than the legacy buildings we’re used to seeing.
Most of the new clubs will clock in at around 160,000 square feet. That’s a lot of space. For comparison, the older models often hovered around 130,000. Why the extra room? It isn't just for more aisles of rotisserie chickens.
A massive chunk of that new real estate is dedicated to "omnichannel" fulfillment. Basically, they've realized that people don't always want to walk four miles inside a warehouse. They want to buy a pallet of Gatorade on their phone and have someone shove it in their trunk fifteen minutes later. Or they want it shipped to their house. The new floor plans include dedicated spaces for curbside pickup and home delivery teams to operate without tripping over the grandma looking at the $1.50 hot dog combo.
New Tech in the Aisles
Honestly, the most annoying part of any warehouse club is the exit line. You’ve already done the work. You scanned your stuff with Scan & Go—which, let’s be real, is Sam’s Club’s best feature—and then you still have to wait for someone to Sharpie your receipt.
The expansion isn't just about physical buildings; it's about the tech inside them. They are rolling out AI-powered "exit tech." It uses computer vision to scan your cart as you walk through a portal. No stopping. No waiting. It’s kinda spooky how well it works, but it’s a game-changer for getting people in and out. This tech is being baked into the new stores from day one, rather than being retrofitted into old plumbing and wiring.
Where are they building?
The company hasn't released a full "secret list" of every single city, but they've been pretty vocal about the first few. Florida is getting a lot of love. Georgia and Texas are also high on the list. Basically, they are following the sunbelt migration. They want to be where the rooftops are.
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Specific locations that have been publicly confirmed or are deep in development include:
- Florida: Locations in areas like North Port and Lake Nona.
- Georgia: New spots hitting the Atlanta metro sprawl.
- Texas: Massive pushes in the Dallas-Fort Worth area to compete directly with Costco’s stronghold there.
More Than Just Stores: The Supply Chain Secret
You can’t just open 30 stores and hope the trucks show up. Part of the Sam’s Club expansion plans involves a massive overhaul of their distribution center (DC) network. They are spending billions to build or renovate five new supply chain hubs.
This matters because of "The Last Mile." If you live in a city where they are opening a new club, you’ll also likely notice faster delivery times for online orders. These new DCs are highly automated. We are talking about robots doing the heavy lifting so that the inventory stays fresh and the shelves don't look like a post-apocalyptic movie on Sunday afternoons.
It’s an expensive gamble. Walmart Inc. is putting serious capital behind this because they see that the warehouse club model is actually more resilient to inflation than traditional grocery stores. When prices go up, people want to buy in bulk. It makes sense.
What Most People Get Wrong About This Expansion
A lot of folks think Sam's is just trying to copy Costco. That’s a bit of a lazy take. While they definitely compete for the same suburban families, Sam’s Club is leaning way harder into the tech side of things. They are positioning themselves as the "frictionless" alternative.
Costco makes you wait in lines. They don't have Scan & Go. They barely have a functioning website compared to modern standards. Sam’s Club is betting that the younger generation—Millennials and Gen Z who are now buying houses—will value their time more than a specific brand of Kirkland granola.
There's also the "Member’s Mark" factor. They’ve been aggressively rebranding their private label to be "chef-inspired" and higher quality. If you haven’t tried their newer private-label items, they’re actually trying to compete with high-end grocers now, not just the bargain bin.
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The Challenges Ahead
It’s not all sunshine and ribbon cuttings. Building massive warehouses in 2026 is a nightmare. Zoning laws are stricter than ever. Residents in many suburban towns don't necessarily want a 160,000-square-foot building that generates thousands of car trips a day.
Then there’s the labor issue. Who is going to man these clubs? Sam's has been hiking wages, but the retail labor market is still incredibly tight. Part of the reason for all the automation is simply because they can't find enough humans to do the mundane tasks like counting inventory or checking receipts at the door.
Why It Matters for Your Wallet
If a Sam’s Club is opening near you, it usually forces other grocery stores to lower their prices. Competition is good. It also increases the value of a membership. If you have two or three clubs within a twenty-minute drive, the $50 (or $110 for Plus) annual fee starts to look like a bargain, especially with the gas discounts.
The fuel stations at the new locations are also getting an upgrade. Expect more pumps and more space for those giant SUVs. In some locations, they are even looking at adding EV charging stations, though that’s rolling out a bit slower than the actual warehouses.
Actionable Steps for Members and Future Shoppers
If you want to make the most of this expansion, you need to be proactive. Don't just wait for the "Grand Opening" sign to appear.
- Check the Real Estate Filings: If you're curious about your specific town, look at your local county’s "Planning and Zoning" commission notes. They are public. Look for "Project Delaware" or similar code names, which Walmart often uses during the early phases of land acquisition.
- Upgrade to Plus if You’re a Pro-Shipper: With the new fulfillment centers opening, the free shipping benefit for Plus members becomes way more valuable. If you live within the "Next Day" radius of a new DC, you can basically treat Sam’s Club like Amazon for bulk items.
- Download the App Early: If a new club is opening in your area, start using the Scan & Go feature at an existing one to get the hang of it. By the time the new "No-Line" exit tech hits your local club, you’ll be ahead of the curve.
- Monitor the "Club Finder": The website is updated more frequently than news releases. Once a club hits the "Coming Soon" status on the Sam's Club website, it's usually less than six months from opening.
The landscape of American retail is shifting back toward the "big box," but this time, it's smarter, faster, and much more integrated with your phone. The Sam’s Club expansion plans are a clear signal that the company isn't satisfied with second place anymore. They are coming for the suburbs, and they’re bringing a lot of tech with them.
Keep an eye on the outskirts of your city. That forest or empty field might just be the place where you’ll be buying 48 rolls of paper towels by next year. It’s a massive undertaking that will likely change how millions of people shop for their basic necessities. Stay tuned, because the rollout is only just getting started.