Nokian Tyres' First U.S. Plant

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

Nokian Tyres selected Barge Design Solutions (Barge) as its owner's representative for engineering and architectural services when it began constructing its first U.S. tire manufacturing plant in Dayton, Tennessee. The Finland-based manufacturer produces car and light truck all-season tires and all-weather tires for North American vehicles. In addition, Barge provided the complete design of the state of the art administration building as well as the equipment connection package, helping Nokian to finalize the installation of their process equipment.

The Solution

As the owner’s representative, Barge guided the design and construction of the plant’s 950,000-square-foot main building shell. Once complete, Barge took on the critical task of engineering design for the process equipment, utilities, support structures, and building systems’ modifications. The team conducted detailed engineering analysis, including stress calculations for the hot oil, high-pressure steam, and condensate systems, while also managing and updating the 3D General Arrangement model for the entire plant.

Barge developed piping and instrumentation diagrams for utility systems and created detailed piping design drawings using 3D modeling software to support process equipment installation. These drawings and specifications were essential forbid packages, ensuring clarity and precision for the equipment scope. The project team designed a 40,000-square-foot administration building which incorporated various sustainability initiatives. The office space is a show piece for both employees and guests and includes a European style garden leading to the entrance of the building.

The Result

The sustainable plant began production in 2020, with the capacity to manufacture around four million tires annually. By 2027, it is projected to contribute 25% of Nokian’s passenger car tire output. Today, the plant employs over 500 people, demonstrating Nokian Tyres’ commitment to innovation, sustainability, and growth in North America.

(Photo Credit: Aerial photo courtesy of Nokian Tyres)

Engineering

Architecture / Interior Design

Industrial

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