Project Description

The Railhead Loading Facility project at Fort Drum is a $29 million contractor-led design-build project awarded to Structural Associates, Inc. (SAI) by the U.S. Army Corps of Engineers. Located at Fort Drum, New York, the project expands and modernizes the installation’s rail loading and unloading capabilities, enabling the safe and efficient movement of heavy equipment, materials and vehicles in all weather conditions in support of the 10th Mountain Division’s rapid deployment mission.

SAI served as the prime contractor and was responsible for both design and construction. The project team included multi-disciplinary design consultants, specialty subcontractors under direct contract with SAI, and SAI’s self-performed workforce, all coordinated to meet the stringent military and USACE requirements.

The scope of work included the design and construction of two facilities critical to the railhead operations: a 10,500 sf Scale House Building used to rapidly process and categorize vehicles for railcar loading, and a 10,000 sf Operations Building that serves as the administrative building and operational hub for military and Government personnel assigned to the railhead.

The project also required extensive site development across approximately 33 acres. Major site elements included 13 acres of new concrete and asphalt pavement, one mile of new railroad track, a covered rail loading ramp, stormwater drainage systems, electrical distribution and site lighting, fire and potable water systems, sanitary sewer, and telecommunication infrastructure. Additional improvements included perimeter security fencing, controlled-access vehicle gates, a guard house, and roadway improvements to support efficient vehicle circulation between the Scale House, loading ramp, container storage areas and the Operations Building.

To support the project schedule, SAI fast-tracked the design by advancing early structural design packages and specifications for long lead materials. This approach enabled early foundation construction, structural steel fabrication and material procurement, allowing building construction to begin during favorable weather conditions, mitigating potential schedule impacts.

This successful delivery of this project demonstrates SAI’s ability to manage and execute complex, mission-critical, large-scale design-build projects in support of the U.S. Army’s mission at Ft. Drum.