Project Overview
When global toy giant LEGO broke ground on its first U.S.-based manufacturing facility in Chesterfield County, Virginia, the development team turned to CP&P for a vital component of the site’s utility backbone: precast electric and communication vault systems.
Working with Spectator Enterprises, CP&P’s Dry Utility Division supplied a total of 115 precast vaults across multiple sizes, tailored specifically to support the facility’s electric and telecom duct bank network:
- 47 Electric Utility Vaults (8×12)
- 29 Communication Utility Vaults (6×8)
- 39 Handholes (3×3)
Backed by in-house engineering and the ability to deliver from multiple regional plants, CP&P played a key role in helping LEGO meet its aggressive construction timeline and deliver a scalable, long-lasting utility infrastructure.
Project Challenges
The LEGO Virginia project presented two primary challenges: a tight construction schedule and a clear mandate to avoid cast-in-place (CIP) construction for utility systems.
To keep pace with site sequencing and weather unpredictability, the project required precast vault solutions that were ready to be installed upon arrival. That meant:
- Tailored Knockouts: Each vault needed custom knockout configurations to align with duct bank routing and minimize field modifications.
- CIP Avoidance: Onsite pouring, forming, and curing would have introduced delays, increased labor costs, and created scheduling conflicts during critical utility phases.
The client needed a solution that offered speed, precision, and flexibility—without compromising on structural integrity or design specifications.
The CP&P Solution
CP&P’s extensive network of manufacturing facilities across the Mid-Atlantic and Southeast made them a standout partner for this high-volume, high-demand project. The team’s ability to:
- Deliver custom-fabricated vaults with tailored knockouts
- Support staggered production from two separate plants
- Provide engineering and design consultation
This collection of solutions gave the contractor the resources and confidence needed to move fast and stay aligned with LEGO’s development milestones.
Vault Customization
Every vault was designed with project-specific knockout dimensions, eliminating the need for field coring or retrofitting. This reduced risk, accelerated install times, and maintained a high level of consistency across all installed systems.
Precast vs. CIP Advantages
The decision to use precast systems over cast-in-place provided measurable benefits throughout the project:
- Accelerated Installation: Vaults arrived ready to set, shaving days or weeks off install timelines.
- Weather Resilience: Precast products eliminated the impact of rain, temperature swings, or curing delays.
- Factory-Controlled Quality: Uniform strength, dimensions, and finish ensured high-performance vaults across the entire site.
- Reduced Onsite Labor: No forming, curing, or complex inspection sequences—just precision delivery and placement.
Implementation
With multiple vault sizes and a large total volume, the project required precise coordination between CP&P production plants. Every component was produced in just 66 days, a testament to CP&P’s coordination and manufacturing capabilities. Delivery schedules aligned to match construction phases, and communication between CP&P’s logistics team and the site contractor ensured efficient delivery windows and clear crane access for vault placement. All 115 vaults were delivered and installed quickly—keeping the larger utility installation on pace with the overall construction schedule.
Results & Impact
The LEGO Virginia project remains one of the most high-profile industrial expansions in the Mid-Atlantic region, with the facility expected to employ 1,760 people once fully operational.
For the contractor and development team, CP&P delivered:
- Reliable product availability
- Custom-engineered vaults
- Reduced field labor
- On-time installation of all units
The partnership between CP&P and Spectator Enterprises showcased how precast innovation and manufacturing flexibility can help meet the complex needs of fast-moving, large-scale development.
Download the Case Study Brochure here.
To learn more about CP&P’s full range of Dry Utility solutions and how our experienced team can support your project from planning through installation, contact us at info@concretepandp.com to discuss your specific needs and available options.
