Brentwood Shop Expansion

The design-build team used its experience and expertise to successfully coordinate with the Shop Personnel and Construction Division, to minimize disruptions to the operation of the Brentwood Shop, while performing an extensive overhaul of the facility.
Patrick Yerdon, Project Manager, WMATA
Location: 
Washington, D.C.
Client: 
Washington Metropolitan Area Transit Authority
Contract Value: 
$46,500,000
Year Completed: 
2008

The Brentwood Shop Expansion project is a design-build renovation to Metro's existing train maintenance facility. The expansion included the addition of three new service and inspection train tracks through the center of the building. Clark completed the complicated construction and expansion without interrupting the client's day-to-day operations.

The Clark team modified existing building structures in order to accommodate the new track construction. They demolished 30,000 square feet of concrete slabs and placed 3,500 cubic yards of concrete, erected 500 pieces of structural precast, and drilled 42 minipiles in the basement of the building. The newly constructed loading dock features a freight elevator, as well as numerous employee amenities, such as a locker room with showers, a lunchroom, and a vending area. The team also installed four 75-foot skylights in the existing roof over the occupied shop areas.

The team installed new and upgraded machinery. They salvaged an existing wheel truing machine and coordinated the construction of a new pit and foundation for the installation of a new wheel truing machine. They also installed 24 car hoists, used to lift the trains, and embedded track and turn tables. In addition to work in maintenance areas, Clark also renovated the Brentwood facility's admistrative and support spaces.

The Brentwood Shop remained operational 24 hours a day, seven days a week, throughout construction. The project team operated around the presence of high-voltage DC power systems that could not be interrupted for any reason. Their extensive coordination and cooperation allowed the project team to minimize their impact on the Brentwood Shop and complete the project in 30 months depite changes to access during construction. 

Awards: 
ABC of Metro Washington - Excellence in Construction, Heavy Industrial/Transp. Category
AGC of Washington DC - Washington Contractors Award, Heavy/Industrial
DBIA - National Capital Chapter, Transportation Under $50 Million
Mid-Atlantic Construction Magazine - Best Transit Project, Award of Merit