ABOUT THIS PROJECT

As one of the largest manufacturing facilities in the region, the Ford Kentucky Truck Plant has continued to evolve to meet the growing demands of commercial vehicle production. Ford engaged Luckett & Farley as a trusted partner in the ongoing transformation of the campus, providing comprehensive architectural and engineering services for a wide range of additions, renovations, and new construction efforts—totaling hundreds of millions of dollars in value.

Luckett & Farley’s design solutions have supported a five-million-square-foot expansion tied to the Commercial Light Truck Project, helping to optimize operations across key production and support areas. Scope areas have included quality control, facility engineering, maintenance, battery charging, process and plant engineering, and spaces for body, trim, paint, and chassis functions. Additionally, Luckett & Farley delivered workplace design solutions for corporate offices, training and fitness centers, conference spaces, and lobby areas, reinforcing Ford’s commitment to both production excellence and employee well-being.

As part of the ongoing expansion, Luckett & Farley also designed a new 130,000-square-foot body shop building, tailored to accommodate tooling, conveyors, and key support systems required for Ford Super Duty truck production. The project also included significant logistical coordination, such as the relocation of existing plant functions, construction of two new rail spurs to serve the body shop, and the relocation of an outbuilding housing hazardous waste storage.

To support a future 1.2 million-square-foot expansion, Luckett & Farley conducted a detailed facility study addressing site planning, structural analysis, architectural programming, and full MEP schematic design. The study focused on expanding the stamping, body construction, paint, material handling, logistics, and final assembly functions. Key elements included planning for roadways, truck marshaling, employee parking, agency permitting, and coordination with survey and geotechnical consultants.

Mechanical studies covered stormwater management, process cooling, compressed air, gas, and waste systems, while electrical planning included load studies, primary feeds, substations, distribution systems, and communication and fire safety strategies. This in-depth planning ensured Ford could move forward with confidence in the long-term growth and modernization of one of its most critical production sites.