Construction of Robotic Coating System

Location: Red River Army Depot, Texarkana, TX
Client: NAVFAC Southeast

EMR was awarded a task order to design and build an automated vehicle coating application system for two vehicle types. The system had to be fully automated to convey the vehicle into the paint booth, apply a primer coat and then a finish coat of paint to a minimum of 80 percent of the vehicle surfaces, and then convey the painted vehicle to the drying oven.

EMR demolished the existing floors in the paint booth, drying oven, and approaches on both ends to accommodate the installation of the underfloor vehicle conveyance system. The required reinforcement steel and edge steel, as designated in the structural drawings, was installed prior to the installation of the tracks. Electrical systems included a master control panel, robot control cabinets, conveyor control systems, hazardous location wiring systems located inside the paint booth, interface with the building’s 480-volt power system, fire alarm system, building exhaust systems, and automatic door control systems. The communications and instrumentation systems included both pneumatic and electrical components. These control systems interconnected the conveyance, coating delivery, robotic systems, and the existing building exhaust, fire control, automatic door systems, and the electrical and pneumatic systems. The two-inch pneumatic piping system included automatic air drying and instrument air systems supporting the robots’ operations and the delivery of the coating materials to the robots.

Replacement of Runway 19 Approach Lighting

Location: Eglin AFB, FL
Client: Department of the Air Force

The replacement of runway approach lighting at Eglin AFB Runway 19 included new pilings, concrete caps, light towers, approach lights, electrical controls, a wood access walkway on timber piles, and wetland impact mitigation. The project also required the shutdown of Eglin’s main runway, Federal Aviation Administration permitting, design of pile-supported temporary access bridges, design and installation of temporary crane access, design of traffic diversion, and precision demolition of the existing system.

Since the existing approach lighting system was constructed in 1969, the creosote-coated timber pile-supported structures had outlived their lifespan. EMR was to replace the existing rotted system with a concrete-supported structural steel tower system that should last another 50 years.

EMR installed (55) 18-inch x 18-inch concrete piles, (16) 16-inch x 16-inch concrete piles, 32 timber piles, 570 linear feet of timber access walkway, and 480 linear feet of temporary access, including a steel bridge strong enough to hold an 85-ton crane. We poured 11 concrete caps to support the new approach towers. Each tower contained approximately 21 cubic yards of concrete, 22 feet of specifically designed hurricane-rated support towers, and a 20-foot frangible fiberglass mast that is designed to break in the event of an errant aircraft collision.

Repair and Modernization of Hangar 57

Location: NAS Corpus Christi, TX
Client: NAVFAC Southeast

EMR was responsible for the two-phase renovation of Hangar 57 to bring the hangar into compliance with applicable codes and regulations and restore its structural integrity. The renovation included 40,000 square feet of hangar space and 20,000 square feet of office space. Engineers and testing labs were employed to determine the extent of repair required to the existing structure.

The project involved lead abatement and epoxy painting of the structural steel in the hangar; demolition and replacement of the air conditioning system including a new chiller, boiler, air intake units, and fan coil units; installation of new compressed air lines, compressors, and tanks; interior office renovations including asbestos abatement, new ceilings, and floors; complete renovation of restrooms; and new site and runway paving. EMR also assessed the condition of the foam fire suppression and wet fire sprinkler systems and made all required repairs. Hangar 57 remained in operation during all phases of this project.

Design-Build of Addition to Fire/Crash Station No. 1

Location: Eglin AFB, FL
Client: Department of the Air Force

EMR completed an expansion/renovation of the Eglin Fire Station No. 1 apparatus bay encompassing 7,392 square feet, along with additional interior renovations to the laundry room, training rooms, restrooms, and structural bay. EMR designed and executed an addition that created a five-stall garage measuring 52 feet x 100 feet with five 15 feet wide x 17 feet high doors.

While ensuring that all construction debris was continually removed from the flight line, precise demolition of the original roof, two main supporting walls, a storage room, and a training room were successfully completed. A custom steel roof was installed, which included a highly sophisticated ambient exhaust extraction system with heavy-duty roof fans. An advanced sensor system was installed to control the integrated louvers and fans as low levels of toxic fumes enter the area.

An entry canopy was added to the front of the fire station, which was constructed with a split-face concrete masonry unit for continuity of design. A custom design steel truss system was manufactured for the canopy and painted to match the adjacent trim. A standing seam metal roof was attached to the custom canopy.

Replace Fuel Pump House

Location: Barksdale AFB, LA
Client: NAVFAC Southeast

EMR was responsible for the demolition of the existing pump shelter and support structures, construction of site improvements and infrastructure, and installation of a new Fuels Type III hydrant pump house (Pre-Engineered Metal Building) with a bridge crane and five 600 gallons per minute fuel pumps and filter separators. The project included a product recovery system, surge suppressors, HHT check-out station, 8-inch and 16-inch tie-ins to the existing hydrant system, control system, motor control, and programmable login controls center, manual transfer switchgear for the existing generator, and all utilities.