Case Study: Ducting Infrastructure for Ford Blue Oval SK
Battery and Vehicle Manufacturing Campus
Project Overview
Client: Ford Blue Oval SK Project, Stanton, TN
Application: Battery and Vehicle Manufacturing Campus
Scope: Campus-wide exhaust and dust collection systems across multiple specialized facilities
Client Profile
Our client operates across construction and engineering, operations and maintenance, staffing, and security and defense sectors, delivering solutions for leading corporations and governments worldwide. This project involved establishing a state-of-the-art battery and vehicle manufacturing facility requiring environmental control systems that could adapt to evolving production demands.
The Challenge: Infrastructure for a $5.6 Billion Investment
When Ford's Blue Oval SK project began in Stanton, Tennessee, the engineering team faced a complex issue. This $5.6 billion investment in the future of electric vehicles isn't just another facility—it represents one of the largest automotive investments in recent history, spanning a massive 4,100-acre campus designed as the future of vertically integrated electric vehicle production.
The campus houses diverse operations across multiple buildings: stamping facilities, assembly operations, Body and MP&L centers, and cutting-edge battery assembly and build areas. Each presents unique environmental control requirements that demand specialized solutions within this landmark facility that's reshaping the automotive industry.
Battery mixing and fabrication areas generate exhaust containing volatile organic compounds requiring careful containment and removal. High-temperature processes need robust systems capable of managing extreme heat while maintaining operational efficiency. Traditional manufacturing areas require reliable dust collection and weld fume extraction, while testing facilities demand precise environmental control for accurate results.
The real challenge wasn't just meeting current requirements—it was designing ducting infrastructure that could evolve with the rapidly changing landscape of electric vehicle manufacturing. Any solution had to be comprehensive enough for today's demands yet flexible enough to accommodate tomorrow's innovations across this massive vertically integrated production complex.
Ducting Solution: Engineered for Performance and Adaptability
System Specifications
Primary System: Nordfab QF Clamp-Together Ducting with Compression Clamp Seals
Campus Coverage: 4,100-acre facility with multiple specialized manufacturing buildings
Applications: General manufacturing exhaust, VOC extraction, high-temperature processes, dust collection, and weld fume management
At Industrial Ducting Systems, we understand that successful large-scale projects require more than quality products—they demand comprehensive partnership from design through delivery. After extensive consultation and site analysis for this $5.6 billion investment, we recommended Nordfab®'s Quick-Fit® clamp-together ducting with compression clamp seals.
This solution addresses the real-world challenges of complex manufacturing environments at unprecedented scale. Traditional welded systems would create maintenance nightmares and costly modifications across such a vast facility defining the future of EV production. Instead, the QF® system's modular design enables rapid assembly, easy disassembly, and seamless reconfiguration without disrupting adjacent operations across this massive vertically integrated campus.
Our installation teams worked efficiently across the campus, confident that each component would integrate perfectly within this landmark facility. The compression clamp seals deliver airtight connections essential for VOC containment, while the robust construction handles demanding high-temperature applications. The result is more than ducting—it's adaptable infrastructure engineered for long-term performance at one of the most significant automotive facilities ever built.
System Features:
Modular QF Design: Quick-fit clamp-together system for rapid installation and future modifications
Versatile Applications: Handles standard exhaust, VOC extraction, and high-temperature processes
Campus-Wide Integration: Comprehensive coverage across all specialized buildings within the 4,100-acre complex
Maintenance-Ready: Easy access for cleaning, inspection, and component replacement
Results: Delivering Performance That Exceeds Expectations
The transformation was immediate and measurable. Air quality management across this massive, diverse manufacturing environment now operates with confidence and reliability. Specialized VOC extraction systems perform flawlessly in battery mixing areas, while high-temperature exhaust management keeps critical processes running safely and efficiently across the vertically integrated production campus.
The real validation comes as production ramps up and processes evolve within this $5.6 billion facility. What would have been costly, disruptive modifications with traditional systems became simple reconfigurations with our QF® solution. Maintenance teams find they can access, clean, and replace components with minimal downtime, keeping production lines running smoothly and budgets on track across this landmark automotive complex.
When the facility needs to expand operations, new process areas are integrated seamlessly into the existing infrastructure. The modular design that made installation efficient across this massive campus now makes growth sustainable and cost-effective.
Long-Term Value Delivered:
Streamlined Maintenance: Easy system access reduces downtime and labor costs
Operational Flexibility: Simple reconfiguration as processes evolve
Cost-Effective Lifecycle: Reduced maintenance expenses and simplified parts management
Scalable Growth: Straightforward expansion capabilities across the 4,100-acre complex
Client Testimonial
"I am pleased to provide a reference for Industrial Ducting Systems as a trusted supplier of dust collection, central vacuum, and other process exhaust duct work system materials.
For more than a year, we have worked closely with Industrial Ducting Systems on our scope at the Ford Blue Oval SK Project in Stanton, TN, that involved the plant's duct work systems, and they have consistently impressed us with their quality and reliability.
Nathan Turner and the entire team at Industrial Ducting Systems have been highly responsive and professional, always prioritizing our needs. Their commitment to customer service is evident in their proactive approach to problem-solving, ensuring a seamless partnership. Whenever we've faced challenges, they have always stepped up to resolve issues quickly, reinforcing their dedication to excellence.
Additionally, their transparent production schedule and clear communication have been instrumental in facilitating efficient planning and timely project completion.
I have no hesitation in recommending Industrial Ducting Systems to any company seeking high quality products and dependable services. We have been extremely satisfied with their professionalism and the way they conduct business."
— Project Manager, Ford Blue Oval SK Project
Why Partner With Industrial Ducting Systems?
The Ford Blue Oval SK project demonstrates what happens when expert product knowledge meets comprehensive project support on one of the largest automotive investments in recent history. From initial consultation through final commissioning, we work as an extension of your engineering team, understanding not just what needs to be built, but how it supports your operational goals across massive, complex facilities.
Nathan Turner and our project team bring decades of industry experience to every challenge. We deliver transparent communication, proactive problem-solving, and solutions engineered for real-world performance at any scale. Our comprehensive approach includes detailed system design, accurate material estimates, and seamless logistics coordination—so you can focus on getting the job done right.
Whether you're designing a new facility or upgrading existing systems, we simplify the process and deliver clean air solutions that work. We partner with contractors, engineers, and facility managers to streamline product selection, design, and procurement, helping you achieve project milestones and exceed client expectations.
Contact us today for expert consultation and comprehensive solutions engineered for performance, durability, and easy installation.
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