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About this project

Luckett & Farley has teamed with Ford Motor Company to provide Architectural and engineering services for a wide range of both simple and complex additions, renovations and new construction totaling hundreds of millions of dollars for nearly 30 years. We have been one of a few alliance A/E firms supporting Ford since 1998.

Luckett & Farley has provided design services to support the $600 million near total renovation of Ford’s Louisville Assembly Plant on Fern Valley Road in Louisville, Kentucky. The scope of design services we provided for their C-520 program to support the production of the new model Escape include:

  • Preparation of the demolition bid package for the demolition bid package of interior body shop tooling and infrastructure for over $1 Million square feet of plant area.
  • Cutting, rebuilding and reinforcement of over 100 steel roof trusses to allow for additional clearance of new overhead conveyance systems including raising a section of roof for vertical lift conveyors.
  • Rework to the existing and a new weld water system to support the new body shop tooling and rework and additions to the process power substation and distribution.
  • Several building additions and canopies of over 50,000 square feet to support the new process and material handling needs. These include extensive site work to relocate the plant’s main perimeter roadway, utilities and industrial rail sidetrack inside and outside the building.
  • Installation of new plant restrooms and break rooms throughout the body shop and final assembly areas.
  • Restoration of over 75 existing office and restroom areas in the assembly plant, paint shop and administration building.
  • Restoration of the Administration building façade including a new entry structure and building window replacement, New sprinkler systems, Fire Alarm systems and a new mechanical system designed to eliminate the aging steam heat system serving the office areas.
  • Restoration of over 3.5 million square feet of employee and convoy parking areas including asphalt removal, replacement and overlay, pervious paving systems to divert storm water from the cities storm infrastructure, a pedestrian overpass, fencing, turnstiles and lighting replacement.
  • Painting and floor restoration of the Assembly building and paint shop of nearly 3.5 million square feet.
  • A design study to provide direction on the feasibility to eliminate the use of steam throughout the facility and replace it with more energy efficient systems. The design scope included design studies, bid and construction document preparation, bidding support and construction design support throughout the demolition and construction process.

    Project Details

    Owner
    Ford Motor Company

    Construction Value
    $600,000,000

    Size
    1,500,000sf

    Services Provided
    Architecture
    Engineering

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