Austin-San Antonio Mega-Metro

I-35 · Austin to San Antonio · Travis, Hays, Caldwell, Comal, Guadalupe, Bexar

Interstate 35 runs about 80 miles from downtown Austin to downtown San Antonio, joining two metros with about 5.5 million people across 13 counties. The stretch between Kyle and New Braunfels now holds two gigawatt-scale data center campuses, Tract Caldwell Valley and CloudBurst San Marcos, beside CFAN's jet engine fan blade plant.

  • Data centers
  • Aerospace and defense
  • Tesla, EV and robotics
  • Manufacturing and materials
Map of I-35 from Austin to San Antonio with SH 130 and I-10, showing CFAN San Marcos, Tract Caldwell Valley, CloudBurst San Marcos, Lefko USA, TSTC New Braunfels, Toyota Texas and Tesla Giga Texas Tesla Giga Texas Tract Caldwell Valley CFAN San Marcos CloudBurst San Marcos Lefko USA TSTC New Braunfels Toyota Texas I-35 SH 130 I-10 TESLA GIGA TEXAS TRACT CALDWELL VALLEY CFAN SAN MARCOS CLOUDBURST SAN MARCOS LEFKO USA TSTC NEW BRAUNFELS TOYOTA TEXAS AUSTIN KYLE SAN MARCOS LOCKHART NEW BRAUNFELS SEGUIN SAN ANTONIO LOCATIONS APPROXIMATE
Length
About 80 miles
Population
About 5.5 million
Counties
13
Largest campus
Up to 4 GW
Spine
I-35 and SH 130

Overview

I-35 Joins Two Metros of 13 Counties into One Labor and Freight Market

Greater Austin (five counties) and Greater San Antonio (eight counties) had a combined 2025 population estimate of about 5.5 million, and regional projections put the pair above 8.3 million by 2050. Texas State Demographer Lloyd Potter has said the US Census Bureau will likely treat the two as one combined metro area after the 2030 census.

San Marcos (Hays County) and New Braunfels (Comal County) sit at the middle of the road and have grown into job centers of their own: CFAN and Texas State University at San Marcos, Lefko USA and the Texas State Technical College (TSTC) campus at New Braunfels. East of I-35, the SH 130 toll road runs parallel through Lockhart (Caldwell County) and Seguin (Guadalupe County) and carries through-freight around both downtowns.

Profile
SpineInterstate 35
Parallel routeSH 130 toll road, Georgetown to I-10 at Seguin
Northern endAustin, Travis County
Southern endSan Antonio, Bexar County
Middle citiesKyle, San Marcos, New Braunfels
Counties13 (five Greater Austin, eight Greater San Antonio)
PopulationAbout 5.5 million (2025 estimate)
RailUnion Pacific line parallel to I-35

Anchors

Two Gigawatt-Scale Data Center Campuses and a Jet Engine Blade Plant Sit Between Kyle and New Braunfels

Tract Caldwell Valley Technology Park near Uhland began with 1,515 acres bought in May 2025; Tract added 1,458 contiguous acres in January 2026 and now rates the site at up to 4 GW. Tract, Bluebonnet Electric Cooperative and the Lower Colorado River Authority (LCRA) plan an on-site substation scalable to 1.6 GW, with the first 250 MW contracted for the first quarter of 2028. Tract has also begun planning on-site natural gas generation.

CloudBurst San Marcos in Hays County broke ground in November 2025 on a 1.2 GW AI campus powered by natural gas from Energy Transfer, with a first 50 MW phase targeted for the fourth quarter of 2026. Governor Abbott's Sept 21, 2026 order to the Texas Commission on Environmental Quality (TCEQ) halts data center air and water permits, including on-site power, until the Electric Reliability Council of Texas (ERCOT) finishes its large-load review, expected mid-December 2026; both campuses' on-site gas plans fall under that pause.

CFAN, the GE Aerospace and Safran joint venture founded in 1993, builds composite fan blades in San Marcos for the GE90 and GEnx engines that power the Boeing 777 and 787. Further south, Lefko USA, a Canadian maker of large blow-molded plastic parts, is investing more than $15 million in its first US plant at New Braunfels with 149 jobs and a $968,500 Texas Enterprise Fund grant announced Sept 30, 2025.

Named sites along the I-35 corridor south of Austin
SitePlaceCountySector
Tract Caldwell ValleyUhlandCaldwellData center park, up to 4 GW
CloudBurst San MarcosSan Marcos areaHaysAI data center, 1.2 GW
CFANSan MarcosHaysComposite jet engine fan blades
Lefko USANew BraunfelsComalBlow-molded plastic parts
TSTC New BraunfelsNew BraunfelsComalAdvanced manufacturing training
Toyota Motor Manufacturing TexasSan AntonioBexarTundra and Sequoia assembly

Freight, Power and Workforce

I-35, SH 130 and the Union Pacific Line Carry the Freight; Gas Pipelines Feed the Data Centers

I-35 carries most commuter and truck traffic between the two downtowns, and SH 130 serves as the truck bypass through Lockhart and Seguin. Union Pacific's line parallels I-35; the Lone Star Rail commuter plan to share it ended after Union Pacific withdrew and the regional planning boards dropped the project in 2016.

Power follows gas. CloudBurst's campus depends on Energy Transfer pipeline supply, and Tract plans on-site gas generation alongside its Bluebonnet and LCRA substation in Caldwell County. Large-load hookups on both campuses fall under Texas Senate Bill 6 (2025), which set ERCOT's interconnection rules for loads of 75 MW and up.

TSTC New Braunfels trains machinists and maintenance technicians through the Texas Federation for Advanced Manufacturing Education (TX FAME) program with area employers, and Texas State University in San Marcos supplies engineers to CFAN and the corridor's plants.

Record

Dataset Record

Sources
Data Center Dynamics, Tract, GlobeNewswire, CloudBurst, Energy Transfer, Argus Media, GE Aerospace, Office of the Texas Governor, TSTC, TX FAME, Bracewell, Troutman Pepper, Texas State Demographer, San Antonio Report
Last verified
October 2026