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Gray Delivers Broad Range of Services on Complex Project.

Trex is a premier brand of sustainably made, wood-alternative decking and railing—all proudly manufactured in the U.S.—and a leader in high-performance, low-maintenance outdoor living products.


Offering products comprised of 95% recycled materials, Trex redirects more than 400 million pounds of plastic and scrap wood from landfills each year, making the company one of the largest plastic film recyclers in the U.S.


For its first project with Gray, the customer selected the company to design and build a phased manufacturing facility for synthetic resin and composite decking products. The customer chose the phased development approach to calibrate production capacity with demand trends.

In Numbers

  • Little Rock, AR
  • 788407 s.f.
    Square Footage
  • Mid-2025
Little Rock, AR
788407 s.f.

The project is located on a nearly 300-acre site. The first phase focused on the construction of a 788,000 s.f. facility for manufacturing resin and required 4,153 tons of steel to complete, as well as a superstructure installed above the steel decking to house process equipment.


Following construction of the resin manufacturing plant, Trex will begin work on phase II of the campus plan—a 1.5 million s.f. expansion to incorporate composite decking manufacturing. The finished project will substantially increase Trex’s manufacturing capacity and could transform the site into the company’s largest manufacturing operation.


When fully operational, the facility will provide jobs for more than 1,160 people in the region.


Explore Services

  • Engineering

    Process & Packaging Systems Engineering

    Civil/Building Engineering

    Mechanical/Electrical Engineering

  • Design



    Sustainable Design

  • Construction





  • Digital

    Automation & Controls

    Production-First IT



  • Equipment
    Custom equipment Ovens & cookers
    Process skids Batching equipment
    Clean-in-place systems Bioreactors
    Extruders Distributed products
    Mixers & blenders Control panel fabrication
  • Development

    Feasibility Studies


    Incentive Coordination

    Land Acquisition

    Construction Financing

    Build-to-Suit/Sale Leaseback

  • Planning

    Master Planning

    Front-end Services

    Strategy Consulting

About Gray

Gray is a fully integrated global service provider specializing in engineering, design, construction, digital, equipment manufacturing, and real estate services.