Chesterfield celebrates Lego’s progress on $1B manufacturing complex
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Lego’s $1 billion manufacturing complex in Chesterfield County, Virginia, has reached 35 percent completion, marking a major milestone for one of the state’s most significant industrial projects in recent years. The Danish toymaker celebrated with a topping-out ceremony at its 340-acre site in Meadowville Technology Park, where a steel beam signed by Governor Glenn Youngkin and business leaders was lifted into place on the factory’s packing building.
“This is a milestone in commitment, collaboration and impact,” Youngkin said, commending the project’s role in shaping Virginia’s economic landscape. While the day lacked Lego’s signature colorful bricks, the towering steel structure on-site symbolized a tangible step toward production that will soon make the world’s most recognizable toy in Virginia soil.
Originally announced in July 2022, the Chesterfield facility will be Lego’s first US manufacturing site and its second in North America, following its Monterrey, Mexico operation. The company expects full completion in January 2027.
Lego’s billion-dollar blueprint for US production
The project represents Lego’s largest single investment in the United States to date. Once finished, the factory will consist of 13 buildings totaling more than 1.7 million square feet. It will include molding, processing, packing and warehouse operations alongside offices designed to support modern production lines.
General contracting is being handled by Gray | Hourigan, a joint venture between Lexington, Kentucky-based Gray and Richmond’s Hourigan, with a workforce of roughly 1,000 construction employees currently on-site.
Sustainability is central to the factory’s design. The site will incorporate renewable power generation through rooftop and ground-mounted solar installations, with Lego targeting carbon-neutral operations. The initiative aligns with the company’s global sustainability goals and broader industry trends toward energy-efficient manufacturing.
Building the workforce behind the bricks
Even before the main facility is complete, Lego has already established a workforce pipeline in the region. More than 500 employees are currently packaging toys at a temporary site in Chesterfield’s Walthall Interchange Industrial Park. According to Lego Manufacturing Virginia General Manager Jesus Ibañez, those workers will transition into permanent roles once operations begin in 2027.
“We will transition the colleagues,” Ibañez said. “We will run both facilities at the same time for a while as we ramp up operations.”
The company plans to create about 1,760 jobs over 10 years, reflecting Virginia’s strategy to attract high-skill manufacturing employment. Local workforce programs, in partnership with economic development agencies, are already training residents for technical and logistics positions in support of the new plant.
Expanding Lego’s North American supply chain
The Chesterfield factory is part of a broader logistics strategy that strengthens Lego’s ability to meet growing US demand. The company is also investing $366 million in a new 2 million-square-foot distribution center in Prince George County, scheduled to open in 2027. The facility will serve as the second major hub in Lego’s Americas network, joining the existing center in Fort Worth, Texas.
“With the opening of the factory, we will be able to shorten our supply and respond more quickly to US consumer demand while reducing the environmental impact from long-distance shipping,” Ibañez said.
This integrated regional approach is designed to increase flexibility, improve speed-to-market, and strengthen supply-chain resilience, priorities that have defined US manufacturing investment strategies since the pandemic.
Virginia continues to position itself as a hub for advanced manufacturing. Over the past decade, the state has seen steady industrial job growth, supported by infrastructure investment and competitive business incentives. The Virginia Economic Development Partnership and the Virginia Manufacturers Association are actively promoting reshoring and sustainable production initiatives, reflecting a broader national push for domestic capability.
In support of the Lego project, Governor Youngkin has proposed a $25 million allocation to widen the Meadowville Road bridge over Interstate 295 to improve access to the site. The infrastructure update underlines the state’s commitment to facilitating long-term industrial development in the region.
When completed in 2027, the Chesterfield site will not only supply North American markets but also serve as a symbol of the state’s manufacturing evolution. Lego’s investment blends global innovation with local opportunity, linking Virginia’s industrial future to one of the world’s most iconic brands.
Sources:
Virginia Business