Lexington, KY - Big Ass Fans, Inc., the Lexington-based manufacturer of industrial fans, is about to complete another chapter in its continuing story of growth and success. This week, the company is nearing completion of phase one of a new facility that will become home - headquarters, testing lab and manufacturing facility - for an organization that has gained national attention for innovation, creativity and continuous growth.
The first part of Big Ass Fans' innovative expansion plan includes two new buildings. The building in phase one includes a 46,000-square-foot testing laboratory. Phase two, scheduled for completion by 2010, will include office and manufacturing facilities. The buildings will be located on a 32-acre site on Innovation Drive, not far from the company's current facilities on Merchant Street.
True to the company's reputation for innovation, the first of the two new buildings is anything but typical.
"There is not another facility like this in the U.S.," said Stephanie Gilbert, senior design manager at Gray Construction, which worked on the design. "It is a landmark building."
The test center soars to a height of 60 feet, making it among the tallest industrial spaces in Lexington. Gilbert describes the interior as an "industrial esthetic," with the construction components exposed.
"But the first thing that you'll be struck by is the amount of light," she said. " No matter where you are, you can be there without the lights on at all."
A "performance testing lab" will utilize 42,000 square feet of the building space. The lab, which contains minimal floor obstructions, will contain large curtains, allowing the space to be divided for testing smaller fans. The curtains can also be pulled back into a single testing space for larger fans. The building's remaining 4,000 square feet is divided between a small workshop and office areas for test lab workers.
Part of the reason for the design of the first building is to have a dedicated building for fan testing, according to Christian Taber, applications engineer for Big Ass Fans. The company was in need of more testing space, in part because of the fast pace of new product development.
The company launched the 12-foot diameter Element in 2008 as the first industrial grade fan specifically for large air-conditioned commercial spaces such as shopping malls, office buildings, churches and recreational facilities. The Element received two Reader's Choice Awards from readers of Environmental Design and Construction and Sustainable Facility magazines.
The company plans more new products for 2009, and the new testing lab will play an essential role in their development, Taber said.
Function, however, was not the only major factor in the design of the building, but also reflects the philosophy and mission of the company itself, according to Nick Williams, Special Project Manager for Big Ass Fans. The company produces a product that is all about sustainability and its new facility reflects that, he said.
The new facility will use one-third less energy than other buildings of the same size, he said. The main portion of the building will not be air conditioned and instead will utilize the company's fans to create a three-mile-per-hour breeze to make it feel cooler than it really is, he said.
"One of the important goals for us is to become LEED certified," Williams said. "Our fans contribute to LEED certification; we would like to become gold certified."
Leadership in Energy and Environmental Design (LEED) certification is administered by the U.S. Green Building Council to promote standards for sustainable construction. LEED has four certification levels: Certified, Silver, Gold and Platinum. The goal is to promote practices that increase profitability while reducing environmental impact.
Architect Mike Adams of WS Construction in Versailles is a LEED-accredited professional who worked on the Big Ass Fans project. He said the company considered going for the platinum level, but found it was not cost-effective.
The new building does incorporate features such as low-flow fixtures to reduce water usage, mercury light fixtures, organic paints and recycled construction materials. In particular, he said, 98 percent of the steel used in the building's construction was of recycled content.
"I think the biggest thing they are trying to capture - and what they are most proud about - is the amount of energy they have reduced overall in this building," Adams said. "The fans they make are really an intelligent, economic choice."
"The building is very sleek looking but the materials are not very different," he concluded. "It is not overly done; it is complex and it is simple."
Marketing communications manager Emily McCarthy said that much of the vision for the building came from the president and owner of Big Ass Fans, Carey Smith. Smith purchased the 32-acre site for both buildings from Commerce Lexington with the help of Gina Greathouse and Kimberly Solsbury, members of Commerce Lexington's Economic Development team.
Smith wanted the new facility within the Lexington city limits. This would give employees access to public transportation, minimize travel time between buildings, and provide the option of biking to work. Since founding the company in 1999 as HV/LS Fan Company, Smith and his company have gained a reputation for their charitable and philanthropic work in the Lexington area. (Smith was unavailable for comment).
In August 2008, Big Ass Fans was named the fastest growing manufacturing company in Kentucky and the second fastest growing company in Lexington by Inc. Magazine. Despite the economic downturn, the company continues to experience double-digit growth, McCarthy said.
"All projects are unique," said designer Stephanie Gilbert. "This project is very different from a corporate project in that Big Ass Fans is building a legacy that reflects their business and their culture. They really worked on it and made us work hard."
"This building is very important for them and their desire to continue to grow," she said. "It is an amazing story."