Linx Ductwork System Chosen for Dark Horse Stages Expansion

Linx Industries, a manufacturer of innovative HVAC solutions, manufactured and delivered the ventilation system for the expansion of Wilmington, North Carolina’s Dark Horse Stages.

Dark Horse Stages is the first purpose-built studio in North Carolina in more than 40 years and has transformed the state’s film and entertainment industry since its founding in 2020. This expansion added two new soundstages that feature nearly 40,000 square feet of production space, essentially doubling the studio’s size.

Formerly known as Lindab USA, Linx specializes in developing, manufacturing, and distributing sheet metal products and system solutions for the HVAC industry. As a division of DMI Companies, Linx has become a preferred air solution provider for products ranging from single-wall ductwork to complex and custom heavy-gauge industrial solutions.

Linx representative Hahn Mason (Eastern North Carolina branch) was contacted by Odyssey Mechanical, a diverse multi-trade subcontractor located in southeastern North Carolina, after they were contracted to complete the studio expansion. Hahn Masons’ goal is to provide customers like Odyssey Mechanical with expert product knowledge by offering tailored solutions that are best suited for specific job requirements and ensuring seamless project coordination. Based on this project’s specifications, Linx was the perfect fit for this job.

For this project, approximately 700 linear feet of Linx Safe double-wall G90 galvanized steel spiral round duct with 2” thick insulation was used to create four identical runs of air supply ductwork with diameters ranging from 38 to 58”. Two exhaust stacks with Vanstone angle rings were also essential to complete this project.

Linx Safe for double-wall duct is an internally insulated and self-sealing duct system that delivers high-quality acoustic and thermal performance while exceeding industry standards for leakage performance. It features single-slip connections that are installed in less time than traditional connections and provides a clean, quiet look for exposed duct systems.

All 34,000 pounds of ductwork were suspended using the Cable Shark cable hanging system, a product from Linx’s sister company, Ductmate Industries.

Flawlessly executing the solution to this job’s unique challenges, this project was divided into five separate phases and was kept to a strict delivery schedule, with all material being delivered in rapid succession over two weeks. Odyssey Mechanical was there every step of the way, bringing its well-rounded, employee-focused commercial HVAC experience that they have been cultivating since 2018. To speed up and simplify installation and overcome time restraints, Linx provided the system with 40 factory-cut and prepared slots for easy air device attachment in the field. These factory-cut and prepared slots, alongside the Linx system’s self-sealing joints, provided exceptional value by reducing installation time and associated labor costs.

“We truly have assembled an amazing team of folks from our executive level through the operations team and field staff,” Odyssey Mechanical President and CEO Kevin Hommes said. “Odyssey Mechanical has been fortunate to be able to grow incredibly fast, and that’s due to our ability to work as a team to improve processes to fight against market conditions and create solutions in an otherwise adverse environment for the past four years. We are exceptionally committed to each and every customer, and that commitment reverberates throughout the organization.“

Hahn Mason aims to support its customers like Odyssey Mechanical by selecting the best products for their specific needs, assisting with logistics to meet project timelines, and ensuring the products that they provide are of the highest quality to meet the necessary performance standards of complex projects. It’s no wonder that Linx’s high-quality systems and exceptional team members were chosen for this unique studio project.

AIR SUPPLY: Odyssey Mechanical installed four identical air supply systems using roughly 700 linear feet of insulated, double-walled spiral ductwork made from G90 galvanized steel. (Courtesy of Odyssey Mechanical)

“Linx’s estimating and design teams were instrumental on the front end, ensuring the system met the project’s specifications,” Hahn Mason Sales Engineer Delina Howard said. “However, it was Karin Anderson, Linx’s Project Manager, who truly stood out. Her exceptional coordination of seven truckloads for a precise delivery made the entire process seamless, ensuring the project stayed on schedule without a hitch. It’s the combination of high-quality products and standout team members like Karin that make any project a success.”

Hahn Mason and Odyssey Mechanical are both committed to delivering high-quality products and solutions that meet their clients’ needs. Their collaboration on this project with Linx demonstrates the value of strong partnerships, effective communication, and products that focus on ease of installation and flexibility.

Linx, Hahn Mason, and Odyssey Mechanical appreciated the opportunity to work together on this successful project at Dark Horse Stages and look forward to future collaborations.

“We are very pleased with the results,” Odyssey Mechanical COO Andy Smith said.  “From a performance standpoint, the Linx duct system met the project’s functional requirements perfectly. The durability and ease of installation were key factors in delivering the project on time. The appearance of the final product also met expectations, as it blended in seamlessly with the overall design of the system while maintaining high-quality standards.”

This expansion will bring tremendous value to the state’s film industry by enhancing its capacity to meet the diverse needs of today’s productions. With North Carolina’s film industry alive and ripe with potential, Linx was honored to be a part of this expansion.