Luckett & Farley has worked closely with Ford Motor Company for nearly 30 years, providing architectural and engineering services for a variety of additions, renovations, and new construction projects. As one of Ford’s trusted design partners since 1998, we have supported efforts to improve and modernize the Louisville Assembly Plant through multiple phases of development.
A key milestone in this long-standing relationship was the $600 million near-total renovation of Ford’s Louisville Assembly Plant as part of the C-520 program, supporting production of the new Escape model. The program required extensive design and infrastructure transformation within a facility spanning several million square feet.
Luckett & Farley’s scope included the preparation of demolition bid packages for more than one million square feet of body shop interior tooling and infrastructure. Our team led the complex effort to cut, reinforce, and rebuild over 100 structural steel roof trusses, enabling the clearance needed for new overhead conveyance systems, including a raised roof section for vertical lift conveyors.
Additional design solutions included reworking the weld water systems, upgrading the process power substation and distribution networks, and planning over 50,000 square feet of building additions and canopies. These new elements supported updated process and material handling requirements and were paired with extensive site redevelopment relocating the plant’s perimeter roadway, utilities, and industrial rail sidetrack both inside and outside the facility.
To enhance day-to-day functionality for plant staff, Luckett & Farley designed new restrooms and break rooms throughout the body shop and final assembly areas, and restored over 75 office and restroom areas across the plant, paint shop, and administration building. The administrative headquarters also received a full exterior renovation including a new entry structure, window systems, and mechanical upgrades to eliminate the outdated steam system.
Outside the building, over 3.5 million square feet of employee and convoy parking areas were restored, incorporating asphalt replacement, pervious paving for stormwater diversion, fencing, lighting, and a new pedestrian overpass. Interior improvements included floor refinishing and painting throughout the main assembly and paint shops, covering nearly 3.5 million square feet.
As part of Ford’s ongoing push toward sustainability, Luckett & Farley conducted a feasibility study to eliminate steam throughout the facility in favor of more energy-efficient systems. This study informed future infrastructure investment and included full bid and construction documents, contractor support, and design coordination throughout demolition and construction phases.
Through each phase of the C-520 program, Luckett & Farley’s design expertise helped Ford reimagine the Louisville Assembly Plant as a modern, efficient production hub equipped for the future of automotive manufacturing.