The LEGO Group recently marked installation of the final steel beam for the main production building at its new 1.7-million-sq-ft manufacturing campus in Chesterfield County, Va.
Constructed by a general contractor joint venture of Lexington, Ky.-based Gray and Richmond, Va.-based Hourigan, the Danish toymaker’s first U.S. manufacturing plant is located on a 340-acre site that will eventually total 13 buildings housing molding, processing and packing operations; offices; and a high-bay warehouse. LEGO says production is on track to begin in 2027, two years later than previously announced at the project’s 2023 groundbreaking. Published reports cite factors such as LEGO’s finalization of the construction contract, and refinements to the design developed by architect LS3P Associates Ltd.
In keeping with LEGO’s company-wide commitment to achieve net-zero greenhouse gas emissions by 2050, the new plant is designed to be carbon-neutral, with all day-to-day energy needs matched by on- and off-site renewable energy systems. According to LS3P, the project is designed to meet the highest possible LEED certification, with features such as roof-mounted solar panels, a rainwater recycling plant and select use of timber instead of steel and concrete structures.
The ceremonial final steel beam, hoisted into place on Oct. 1, included a 2.5-ft LEGO brick tree, a reminder of the company’s plans to plant 17 species of native trees at all Chesterfield County parks to minimize the environmental impacts of construction.
According to LEGO, the facility’s high-tech production equipment will ensure that each brick is made to the accuracy of 1/10th of a hair’s width. This precision enables new bricks to fit perfectly with those made over the past 60 years.
In nearby Prince George, Va., LEGO has authorized construction of a 2-million-sq-ft regional distribution center, scheduled to be ready concurrent with the start-up of toy production in Chesterfield County. The $366-million facility, which received a $2.3-million state grant, brings LEGO’s total investment in the Richmond area to more than $1.5 billion.
The Virginia plant will be LEGO’s second manufacturing facility in the Americas, joining an existing production complex in Monterrey, Mexico, and a distribution center in Fort Worth, Texas.
Structure Tone completed LEGO’s new U.S. headquarters in May. While LEGO officially opened its 157,000-sq-ft office space in Boston’s Back Bay on May 15, its relocation from Enfield, Conn., won’t be complete until the end of next year.