Industrial & Automotive
Disciplines & Markets Luckett & Farley’s architects and engineers are leaders in a broad range of services. Our talents encompass every major building system. Our professionals use sophisticated design tools to integrate design and building physics – collaborating with our clients – to create highperformance and budget-sensitive environments. We are registered in nearly every state and provide design services nationwide and thrive off of projects in our local communities.
Comprehensive Services • Architecture • Mechanical Engineering • Electrical Engineering • Plumbing Engineering • Structural Engineering • Civil Engineering • Interior Design & Procurement • Planning
2 | Industrial & Automotive
Markets Served • Industrial • Corporate/Commercial • Higher Education • Health & Wellness • Casual Dining • Government
160+ years
of service to clients nationwide
ABB Inc. Active Transportation Aisin Automotive Castings Alcan Packaging Alcoa Aluminum American Air Filter Co., Inc. American Fuji Seal Atlas Machine & Supply BAE Systems Beam Suntory (Jim Beam) Brown-Forman CertainTeed Chita-Kogya Clariant Chemicals EEMSCO Eurofins Ford Motor Company Gallatin Steel General Dynamics General Electric Co.
General Motors Corp. Genlyte Thomas Harcourt & Co. Hitachi Honda Huish Detergent Idemitsu Jack Daniel’s Jeffboat, Inc. Johnson Controls JOM Pharmaceutical Kasle Steel Plant KDMK Manufacturing KIA Kentucky Manufacturing Kentucky Utilities Louisville Bedding Louisville Gas & Electric Louisville Water Co. Marathon
Martinrea Mitsubishi North American Stainless Nucor Gallatin Steel Owensboro Riverport Raytheon Missile Systems Rohm & Haas Company Rotary Lift Samuel Adams Brewery Saturn Corporation St. Joe Paper Co. Standard Foods The Trane Co. Ticona Plastics Toyoda Boshoku Manufacturing Transit Authority of River City United Defense United Parcel Service, Inc. Woodford Reserve Zeochem
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Ford Motor Company Assembly Plant, Louisville, Kentucky
4 | Industrial & Automotive
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. Most recently, 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 were provided for their C-520 program to support the production of the new model Escape.
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Ford Motor Company Kentucky Truck Plant, Louisville, Kentucky
Luckett & Farley has provided Architectural and engineering services for a wide range of both simple and complex additions, renovations and new construction at the Ford Motor Company Kentucky Truck Plant totaling hundreds of millions of dollars. These projects have included a 5,000,000sf expansion to the Commercial Light Truck Project The following types of spaces have been designed and built for Ford Motor Company: • Quality Control Documents • Facility Engineering • Maintenance and Production • Battery Charging Room & Canteens • Industrial, Process & Plant Engineering • Body, Trim, Paint & Chassis Offices • Construction Management • Real Estate/Lease Negotiations • Conference Areas, Lobbies, and Corporate Office Space • Training and Fitness Center • Equipment and Monitor Rooms A 130,000sf body shop building addition to accommodate tooling, conveyors and miscellaneous support facilities for the production of automotive bodies for the Ford Super Duty pick-up trucks. Project features include: • Relocating Existing Plant Perimeter Road • Design of Two New Rail Spurs to Serve the New Body Shop • Relocation of Outbuilding Including a Hazardous Waste Material Storage Facility
6 | Industrial & Automotive
Luckett & Farley also provided a detailed facility study for a 1,200,000sf expansion project to Ford’s Truck Plant. The study included site, structural, architectural, mechanical, plumbing, and electrical programming, preliminary and schematic design to define the scope of the expansion. The expansion was in the areas of stamping, body construction, paint, material handling and logistics, and final assembly. Study elements include: • Site planning, roadways, truck marshalling and logistics, employee parking; • Structural analysis, studies and design; • Building programming, planning concepts and schematic design; • Agency approval and permitting process identification; • Survey and Geotechnical consultant coordination; • Mechanical studies and design for storm water, domestic water, process cooling water, gas, compressed air, sanitary waste and industrial waste; • Electrical load studies and distribution design including primary feeds, substations and bus ducts, preliminary systems distribution design, including communications, fire alarm, grounding and BMS strategy.
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Jack Daniel’s Distillery Campus, Lynchburg, Tennessee
Luckett & Farley designed the first phase of a new green field multi-level distillery for production of whiskey for Jack Daniel Distillery Campus. This project is the first phase of a $100 million expansion by Brown-Forman. The process includes grain handling and mixing operations, yeasting, mash cooking, fermenting, charcoal mellowing, scale house, distillery and barrel fill operations. This phase of the distillery features fourteen 40,000 gallon Fermenter Tanks and fourteen 3,500 gallon Charcoal Mallowing Vets with expansion of four times this amount planned to complete the campus.
8 | Industrial & Automotive
Building Square Footage Distillery Building: 38,701sf Distillation Tower: 7,130sf Weigh Hopper Building: 14,090sf Fire Pump Building: 1,450sf DDG Building: 8,232sf DDG Loading Building: 2,100sf Dryhouse Building: 6,185sf
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Woodford Reserve, Various Projects
Restoration and New Visitor Center
Barrel Warehouse
Luckett & Farley designed A complete renovation and rejuvenation 140 year old distillery in the heart of Bluegrass Country. The historic buildings were restored to preserve their exterior appearance.; however, the interiors were completely revamped for a modern distillery including copper kettles from Scotland. Luckett & Farley provided complete architectural and engineering services for this monumental project. The new systems included:
Luckett & Farley also developed a campus of palletized whiskey aging barrel warehouses for Brown-Forman’s premium bourbon whiskey brand Woodford Reserve near the distillery in pristine surroundings of rolling meadows and horse farms in Central Kentucky. The project involves design of 4 warehouses and a Barrel Transfer building. Each warehouse is 91,000 SF with clear height to store seven high pallets.
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Water treatment Chilled water system Steam & boiler system Sanitary & process waste sewer system Fire pump & fire protection system Electrical services & power distribution system, motor control systems, switch gear, etc.
The barrel storage warehouses were renovated. A new bottling process was installed. The lake was dredged and a pumping and piping system was installed to send water upstream to keep the stream flowing in dry weather.
10 | Industrial & Automotive
The construction of each warehouse consists of insulated precast concrete panels with stone face appearance to immolate the existing distillery and the barrel warehouse structures, with steel structural framing, metallic roof and large open space smooth concrete floors. The design includes a sophisticated heating and ventilating system to provide controlled multiple temperature variations to aid the aging of the bourbon whiskey. The site work design involved site layout and grading for over a 60 acres site, bringing all utilities to the site and to each building, industrial and sanitary waste disposal, pavements and an underground insulated alcohol line from the warehouse site to the distillery site with a pipe trestle across the creek.
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Brown-Forman Corporation Magnolia Sawmill, Stevenson, Alabama
Luckett and Farley recently finished work on a new sawmill for BrownForman Corporation. The facility manufactures staves from American white oak that are used to assemble whiskey barrels. The design included interior and exterior debarking and milling operations, operation offices and maintenance facilities. Site features include log unloading and storage weight scales, truck circulation roadways and a pond for log sprinkling operations.
12 | Industrial & Automotive
Corporate Administration Building
This 3 story, 39,000 SF Administration Building will serve as the hub of the power plant. It includes employee facilities on the first floor, such as, locker rooms and showers for over 120 employees, exercise room, a large cafeteria with vending and dining facilities, large meeting/training room, and a records room. The second floor will have individual offices around the perimeter and several open work stations in the interior open space, as well as, a large records room, several meeting rooms and auxiliary spaces. The third floor will have executive offices, conference rooms and auxiliary administrative spaces. The exterior of the building will feature glass and metal panels that will provide a modern appearance. The interior finishes include
very durable surfaces such as resinous flooring, tiles and other high grade finishes that could withstand the industrial foot traffic and still maintain the high level finish. Luckett & Farley designed the HVAC system using a unique “Chilled Beam� System. This provided a very tightly controlled temperature and humidity environment using a very sophisticated air distribution system using chilled beams. The system provides a high level of energy efficiency using water (hot and cold) for distributing energy with minimal energy losses. The system also reduces the air distribution noise to negligible level and creates a very quiet environment.
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Jack Daniel’s Cooperage, Trinity, Alabama
14 | Industrial & Automotive
Luckett & Farley provided full A/E services for the new plant building. The building has 156,000sf manufacturing space and 11,400sf of modern office space. The plant facility included environmentally controlled toasting room, boiler room, docks, shipping office and more. The plant receives white oak staves, which are then raised into a barrel, and then the barrel is toasted and charred in a special process to enhance the flavor and color of the whiskey. The steel hoops are placed and the lids, manufactured on a separate line, are placed on the barrels. Luckett Farley designed the structure and utilities infrastructure to support all the process requirements. The project also included an extensive sawdust collection and disposal system and several wood drying kilns. The office area included executive offices, conference rooms, training room, employee cafeteria, security office, restrooms, touring room, locker rooms, etc. Luckett & Farley also provided interior design and furniture selections. The 60-acre green field site was developed for the plant which included bringing utilities from the entrance road to the plant, site layout, traffic circulation to keep the trucks and passenger vehicles away from each other, paving, drainage, stave storage areas, kilns etc. The site work involved extensive coordination with the local utilities companies and local authorities having jurisdiction.
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Transmission Manufacturing Associates Center, Ohio
Luckett & Farley designed the Associates Center Facility for a Japanese Automotive Transmission Manufacturing Plant in Ohio. The 31,500sf, two-story facility is the gateway entry to the plant for both the visitors and the employees. The building includes locker rooms, a gymnasium facility that includes a full-size basketball court/volley ball court and exercise room with a running track, security office, first aid and nurses station, credit union with ATM facilities, central data/ communication room and a truck dock area. Luckett & Farley also designed a 250,000sf plant expansion that included a clean room transmission assembly facility, enclosed tank farm, waste recycling facility, new chiller plant and other amenities.
16 | Industrial & Automotive
Ticona Plastics Headquarters, Florence, Kentucky
Luckett & Farley provided master planning and space planning studies for the relocation of Ticona’s headquarters and R&D facilities from New Jersey to Kentucky. Following the master planning, costing and approval phase, Luckett & Farley provided A/E design and construction administration services for the 125,000sf building that was added to an existing manufacturing site. The building houses over 200 employees and includes: Research laboratory spaces Chemical storage area R&D high bay process Warehouse space The building was designed to present a corporate image of Ticona as a leader in their industry and blend with the industrial park setting.
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Marathon Refinery, Detroit, Michigan
Luckett & Farley provided architectural, structural engineering including blast resistant design, HVAC, plumbing and electrical engineering for the Marathon Refinery. The project consists of 3 preengineered metal buildings. The 6,420sf Team Building is designed for blast resistance and includes facilities for administrative offices, locker rooms, showers and rest rooms, break rooms, conference rooms etc. This building will serve as the employee personnel facility. The 3,500sf Equipment Shelter building is designed to store equipment. A small area is used for chemical storage. The 371sf Chemical Injection Building is designed for chemical storage and mixing.
18 | Industrial & Automotive
KIA Training Center, West Point, Georgia
Luckett & Farley provided design services for a new 70,000sf training center that includes classrooms and lab space for instruction programs in industrial systems technology, Programming Logic Computer systems technology (PLC), robotics technology, and machine tool technology.
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Architecture | Engineering | Interior Design 737 S. Third St. Louisville, KY 40202 (502) 585-4181 | luckett-farley.com Atul Mashruwala, PE, LEED AP Director - Industrial amashruwala@luckett-farley.com