Expertise
Smurfit-Westrock Manufacturing Facility
Type
Industrial
Size
593,565 SF
Architect
Partners In Design Architects
Location
Pleasant Prairie, WI
RECOGNITION & AWARDS
2025 AGC BUILD Wisconsin Award
Industrial New Construction and Renovation
Project Leader
Erik Dillon
Riley Construction partnered with Dermody Properties to transform the former WE Energies site in Pleasant Prairie, Wisconsin, into a modern rail-served industrial campus. This redevelopment marks the first major step in repositioning the dormant property for new manufacturing and logistics investment. As part of this effort, Riley served as general contractor for a 593,565-square-foot build-to-suit corrugated packaging plant for Smurfit-Westrock, a global leader in paper-based packaging.
The facility includes about 27,000 square feet of office space. It also features a quality testing laboratory, a maintenance and parts shop, and several supporting utility areas for the plant’s large-scale manufacturing operations. One of the project’s defining features is its direct rail integration. Riley coordinated construction of five rail spur lines that connect to the Union Pacific mainline. As a result, raw materials move directly into production through an on-site rail yard.
To support the facility’s high-output equipment, Riley installed major infrastructure upgrades. The team coordinated three 4,000-amp electrical services. In addition, crews installed extensive HVAC systems designed to meet demanding air exchange and environmental control needs. These systems were carefully integrated with the plant’s manufacturing layout to ensure reliable performance and long-term efficiency.
Beyond the building itself, Riley also completed major site redevelopment work. The team performed mass grading for the Smurfit-Westrock facility. At the same time, crews prepared two additional rail-served building pads for future industrial tenants. Because of this work, the site is now positioned for continued development and future manufacturing investment.
For Smurfit-Westrock, the project represents a major milestone. The company transitioned operations from its former North Chicago facility into a modern plant designed for greater capacity and improved logistics. Meanwhile, the development created nearly 200 jobs across three shifts and reactivated a long-vacant industrial property. As a result, the Pleasant Prairie campus now serves as a catalyst for long-term economic growth in the region.


