The U.S. Army Corps of Engineers Louisville District is undertaking a vital construction project at Wright-Patterson Air Force Base, designed to enhance research capabilities critical to national defense. The $8.4 million project will add a ninth floor to an existing 13-story research tower, addressing a unique operational need while presenting challenges that demand innovation and close collaboration.
The project involves constructing a 750-square-foot ninth floor beneath the current 10th floor of the research tower. This new space will provide state-of-the-art laboratory facilities, including updated fire suppression systems, restrooms, power and lighting, mechanical, electrical, plumbing upgrades and modernized elevators.
The decision to place the new floor below the 10th floor reflects the specialized nature of the mission it will support. Current lab spaces in the tower are occupied by other programs, which cannot share space with the new lab space due to security and operational requirements.
Constructing a new floor in an existing high-rise research tower is no small feat. Elevated work introduces logistical challenges, including accessing confined spaces and managing differing site conditions. USACE teams are prepared to address these complexities by employing advanced construction methods and ensuring strict safety protocols.
“Working at these heights and in these conditions requires meticulous planning and execution,” said Chris Hesse, Wright-Patterson AFB resident office project engineer. “Our team is leveraging its expertise to deliver a facility that meets both the operational and security needs of Wright-Patterson AFB.”
The project’s location—adjacent to and above occupied spaces in the tower—requires seamless collaboration among USACE, contractors and the Air Force. Construction activities must be carefully coordinated to minimize disruptions to the critical research already underway in the building.
“Collaboration is key,” Hesse said. “We’re working closely with the base to ensure that construction doesn’t interfere with ongoing operations. This level of cooperation is essential to the project’s success.”
Environmental factors such as outside air temperature and wind velocity introduced the challenge of curing the epoxy used on the structure’s fasteners. The solution came in the form of teamwork between the contractor and the USACE resident office.
“The challenge was to create a solution to keep a minimum cure temperature of 40 degrees that could withstand the wind speeds encountered at more than 90 feet in the air,” said Jerald Zwiesler, USACE mechanical engineering technician. “The solution was to have the contractor mount a system of heating blankets to moderate the temperature and withstand the wind gusts.”
As the project progresses, USACE remains focused on overcoming challenges, maintaining strong collaboration and delivering a facility that meets the highest standards of quality and functionality. Construction for the facility is scheduled to be completed by July 2025.