Costco is making another major investment in its nationwide expansion strategy with plans for a new 166,000-square-foot warehouse in Clayton, North Carolina. The project, valued at $100 million, will introduce the retailer’s first location in Johnston County, complete with a 24-pump gas station that is expected to become a major draw for residents. As the region experiences rapid population growth and increasing retail development, Costco’s arrival marks a significant milestone that could reshape the local shopping landscape and intensify competition among national retailers.
Costco Bets On Explosive Growth In Clayton
According to reporting by The U.S. Sun, Costco has purchased land at 12649 Clayton Boulevard to anchor a large mixed-use commercial development in Clayton. The warehouse will sit directly across from a Walmart Supercenter, placing two of America’s biggest retailers in direct competition within one of North Carolina’s fastest-expanding communities.
The planned warehouse will span approximately 166,000 square feet, making it one of the largest retail developments in the area. The project also includes a 24-pump gas station, offering Costco members another incentive to visit the location. Fuel stations have become one of the warehouse chain’s strongest competitive advantages, with members often citing discounted gasoline as a primary reason for maintaining their memberships. The addition of a large fueling facility is expected to generate substantial traffic while reinforcing Costco’s value-focused business model. As residential neighborhoods continue expanding throughout Johnston County, the retailer appears to be positioning itself to serve a growing customer base for years to come.
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A Retail Boom Is Transforming Johnston County
Clayton has experienced remarkable growth over the past decade and a half. The town’s population has increased from roughly 16,100 residents in 2010 to an estimated 32,600 people in 2025, creating demand for additional shopping, dining, and everyday services.
Costco is entering a market that is rapidly attracting national brands looking to capitalize on this demographic expansion. The broader $100 million mixed-use development is expected to feature several well-known businesses, including Target, Chick-fil-A, Dutch Bros Coffee, and Cava. Plans also include approximately 400 low-rise multifamily residential units, creating a mixed commercial and residential destination designed to support long-term economic growth. Construction has already begun on a new ALDI nearby, further highlighting how major retailers view Clayton as an increasingly attractive location. The concentration of large national chains reflects growing confidence in the area’s future consumer demand and continued population gains.
Costco Continues An Aggressive Nationwide Expansion Strategy
The Clayton project represents just one piece of Costco’s broader growth strategy across the United States. The company has continued opening new warehouses while expanding into underserved markets where population growth supports additional membership-based retail operations.
Costco reportedly has 180 new locations planned for 2026, illustrating the scale of its ongoing expansion efforts. Rather than concentrating solely on major metropolitan areas, the retailer has increasingly targeted fast-growing suburban communities that can sustain high-volume warehouse stores. Clayton fits that profile as housing development accelerates and more families relocate to the region. By establishing its first presence in Johnston County, Costco gains access to a customer base that previously lacked a local warehouse club, potentially reducing travel times for existing members while attracting thousands of new ones.
New Store Opens Amid Ongoing Legal Challenge
While Costco continues investing heavily in new locations, the company is also facing legal scrutiny unrelated to its expansion plans. A recently filed lawsuit alleges that Orgain Organic Plant-Based Protein Powder, sold by Costco, contains elevated levels of heavy metals, including lead, cadmium, and arsenic, based on independent testing cited by the plaintiffs.
The lawsuit claims that affected flavors, including Vanilla Bean and Creamy Chocolate Fudge, were marketed as providing “good, clean nutrition” despite allegedly containing unsafe levels of certain contaminants. These allegations remain claims made within the legal filing and have not been proven in court. The litigation is separate from Costco’s expansion activities in North Carolina but comes as the retailer continues opening new stores and investing in large-scale developments across the country. Despite the legal challenge, Costco’s growth strategy remains active, with the Clayton warehouse standing out as another major step in its nationwide expansion.
