LEGO: Construction Projects at Heart of Americas Expansion

LEGO is set to begin construction on a two-million-square-foot regional distribution centre (RDC) in Prince George County, Virginia, as part of a long-term strategy to grow its operations across the Americas.

The new hub sits around 20 miles from LEGO’s factory project in Chesterfield County, giving the Danish toy giant a streamlined supply network that connects production and distribution more closely than before.

The US$360m investment establishes LEGO’s second RDC in the Americas, alongside its existing Fort Worth, Texas site. Once operational in 2027, the Prince George centre becomes the company’s sixth distribution facility worldwide.

Carsten Rasmussen, COO at LEGO, describes the start of construction as "an exciting milestone as we expand from one distribution centre in each region to two".

He adds: "Together with our LEGO Manufacturing Virginia factory, this site reflects our long-term commitment to strengthening our operations and supporting growth across the Americas."

Strengthening delivery links

LEGO has set out a clear aim for the new RDC: to bring its products to “millions of children and adults alike” across the region with more speed and reliability. The site’s proximity to Richmond provides shorter lead times and quicker reaction to demand shifts.

Locating the RDC near the Chesterfield manufacturing site supports this regionalised model. It also cuts transport distances, helping LEGO to reduce the environmental impact of moving goods and supporting the company’s strategy of placing production and distribution close to end markets.

Cindy Sikora, Vice President of Supply Chain Operations for the Americas, explains: "Our regional distribution centre will strengthen our supply chain network across the Americas, helping us bring LEGO play to more fans and retail partners efficiently and reliably.

"We are grateful for the ongoing collaboration we have had with partners across the Commonwealth of Virginia who support our ambition to build this distribution centre."

With capacity for more than 200,000 pallets, the RDC will be operated by a third-party logistics provider (3PL) and is expected to create more than 300 jobs in the area. LEGO has signed a built-to-suit lease agreement with Crosspointe Commerce Center, a project led by Hillwood Investment Properties and The Silverman Group.

As LEGO shifts towards more flexible supply networks, the site features advanced automation systems. Its integration with the nearby factory also allows for the use of electric vehicles to move goods between locations, helping to limit CO2 emissions and link production directly with distribution.

Building with energy targets in mind

LEGO has set high environmental targets for the Prince George project. The company plans to run the RDC entirely on renewable energy and has designed it with a range of energy-efficient features.

It is also aiming to secure LEED Gold certification – a recognised green building standard that measures things like energy use, waste, water efficiency and materials.

In addition to energy targets, the company is seeking WELL certification for the new site. WELL is a standard that assesses a building’s impact on the health and wellbeing of its occupants, with categories in the certification including air, light, sound, materials, comfort and access to movement and nourishment.

LEGO will use electric vehicles between the RDC and the Chesterfield plant, aligning with its global commitment to lower-carbon operations. This supports both its logistics optimisation and its emissions reduction plan.

The new facility plays a key role in LEGO’s strategy to meet consumer demand efficiently while managing its impact on the environment.

Scaling regional presence and social impact

The Prince George site forms part of a wider expansion programme across LEGO’s global network. Across the Americas, the organisation is investing in infrastructure, retail and community projects to build its footprint in line with regional needs.

In 2025, LEGO handed grant funding to six non-profit organisations in Virginia. These projects aim to reach nearly 400,000 children in the state. LEGO also opened a new retail store in Short Pump Town Center in Henrico County.

At a global level, LEGO’s logistics and manufacturing network continues to grow. The company opened its sixth factory in Vietnam, added 30% capacity at its Hungary site and launched new distribution hubs in Belgium and Vietnam in 2024 and 2025 respectively.

Together, the Prince George RDC and Chesterfield manufacturing facility give LEGO a more agile logistics base in the Americas. With both scheduled to be operational in 2027, the projects position LEGO to scale its supply chain while pushing ahead with its environmental and social goals.