Carpenter Technology Specialty Steel Mill

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

Carpenter Technology undertook a huge initiative to build a new 200-acre facility in Athens, Alabama, to increase production capacity and subsequently provide faster customer response time. To achieve their goals, they collaborated with Turner Construction and Barge Design Solutions (Barge) on a fast-track design-build initiative for the Athens Operations Program, a $500+ million investment focused on specialty alloy steel products for high-performance products such as jet engines, turbines, and medical devices. 

The project’s initial phase centered on developing essential site infrastructure and the installation of the world’s largest radial forge. A total of 10 buildings needed design ranging in size from 20,000 to 500,000 square feet, optimized to operate in a streamlined, assembly-line style that supports Carpenter’s goal of reducing lead times for their clients. 

The Solution

In a fast-track design/build initiative with Turner Construction, Barge provided architectural, electrical, mechanical, structural, controls-automation, machine, and civil design. Phase I included the installation of the world’s largest radial forge and the site development and infrastructure. Our team designed a total of 10 buildings ranging in size from 20,000 to 500,000 square feet. Carpenter and the design/build team chose the optimum equipment and layout to make the facility work as if it were an assembly line, rather than a traditional batch-by-batch operation.

The operations goal was to reduce lead times so their customers could better manage their own lead times. The scope of work featured full design for multiple buildings, equipment foundations, a data center, and ancillary process control systems. Barge also led coordination with local authorities on permits and tie-ins. Buildings in the complex housed ingot conditioning, remelt, forge/finish area, switchgear, data center, material and chemical laboratory, shipping, locker rooms, maintenance, and guard station.

The Result

Today, the Athens, Alabama facility significantly impacts the local economy by providing high-paying jobs in advanced manufacturing, acting as a major hub for producing specialized alloys. This project has been recognized by the American Council of Engineering Companies (ACEC) with a National Recognition Award and a Grand Award by ACEC of Tennessee.

Engineering

Architecture / Interior Design

CAD/BIM

Industrial

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Carpenter Technology Specialty Steel Mill

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