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Lifetime Products Mascot Facility

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.

The Challenge

Lifetime Products was looking to repurpose an existing vacant 360,000-square-foot warehouse to expand to 700,000 square feet and accommodate 500 employees. The client needed flexibility for an efficient flow of truck traffic in shipping/receiving, and to accommodate specialized blow mold machines custom-built in Germany, including a 50-foot high bay manufacturing area.

The Solution

After evaluating several options, Barge Design Solutions was asked to provide architecture and engineering services for site development, rail spur, and expansion of the existing building. Barge extended the form of the warehouse and added complementary high bay area to accommodate the tall blow mold machines.

The successful installation of a new industrial rail spur crossing at Mascot Road was a major milestone for the project. Complex negotiations and coordination with Norfolk Southern Railway, Knox County Engineering, the Tennessee Department of Transportation, and numerous utilities were conducted to obtain necessary approvals for this crossing with automated signalization.

The Result

Barge's successful expansion of the Lifetime Products facility demonstrates the team's ability to address complex project challenges, deliver innovative solutions, and meet the specific needs of their clients. Barge's expertise in facility design, infrastructure development, and permitting processes was instrumental in achieving a positive outcome.

Architecture / Interior Design
Engineering
Industrial
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Lifetime Products Mascot Facility
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