I-24 CM/GC Bridge Replacement Over S. Germantown Road

Location: Ohio
Market: Federal Government
Services: Architecture / Interior Design / Engineering

The Challenge

In 1934, Building 23 at Wright-Patterson Air Force Base was constructed as an aircraft hangar and test facility. More than 70 years later, the U.S. Air Force wanted to renovate the building to provide a modern lab facility for state-of-the-art energy research. It requested a design that retains the historic feel and aesthetic of the original building, while also creating a modern interior that meets security and force protection requirements.

The Solution

A three-story facility was created within the existing brick shell, adding new spaces for material processing, data acquisition, operations, and fabrication. The design also had special acoustical needs due to the use of vibration-sensitive equipment such as lasers and optical equipment. The superstructure is composed of a structural steel frame and designed to resist collapse in accordance with Antiterrorism/Force Protection (AT/FP) requirements.

Barge Design Solutions provided HVAC, plumbing, steam, lighting and power distribution, communications and security, utilities, storm drainage, lighting protection, and fire protection. Site work included sidewalks, curbs and gutters, access drive control systems, and site upgrades to meet AT/FP requirements. Architectural and interior design were also included as part of the project.

The Impact

The renovation of Building 23 was a testament to Barge's engineering expertise and commitment to excellence. Barge successfully transformed a historic asset into a modern, sustainable, and secure facility, meeting the evolving needs of the U.S. Air Force. The team's ability to balance preservation with innovation while also prioritizing sustainability and security positioned Barge as a valuable partner in this critical project. The project exceeded the original goal of designing to a LEED Silver level, making it the first LEED Gold building on the base.

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The Challenge

With as many as 100,000 vehicles driving along I-24 each day, heavy traffic was no surprise to travelers in the Chattanooga, Tennessee, area. Traffic had doubled over the past 40 years, contributing to the need for two bridge replacements – the I-24 bridge over Germantown Road and the Belvoir Avenue bridge over I-24.

The Solution

Working closely with the Tennessee Department of Transportation (TDOT), Barge Design Solutions created a plan to encourage a more seamless approach to design and construction, shortening project timelines. The team applied two key approaches to meet the need: the alternative delivery method of the Construction Manager/General Contractor (CM/GC, CMGC) and Accelerated Bridge Construction (ABC) techniques.

The CM/GC process allowed the construction manager to participate in both bridge design processes before completion, paving the way for more accurate cost estimates, constructability assessments, and scheduling. ABC methods were also applied to the S. Germantown bridge design to improve safety and limit traffic disruptions through accelerated scheduling and multitasking.

To support the S. Germantown bridge design, 172 micropiles were drilled more than 160 feet deep into the foundation to resist compressive, uplift/tension, and lateral loads. This method was chosen due to the site's complex karst geology of clay-like soils, small boulders, and complete voids in soil, which were found during geotechnical exploration.

The Result

ABC techniques were the perfect match for the I-24 bridge replacement over Germantown Road. Traditional daily lane closures were reduced from 510 days to only nine, replacing the bridge superstructure in 58 hours for less risk and cost. The CM/GC method – only the third time it has been applied in the State of Tennessee – enhanced collaboration for both bridges, making the process more efficient. Barge earned high accolades for the CM/GC bridge replacement project, receiving a Structural System Honor Award and a People's Choice Award at the 2021 American Council of Engineering Companies of Tennessee Engineering Excellence Awards.

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I-24 CM/GC Bridge Replacement Over S. Germantown Road

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