Harpers Ferry Design & Learning Center

Brayman Foundations Division was subcontracted to provide a Design-Build micropile foundation solution for the new U.S. Customs and Border Protection (USCBP) Integrated Design and Construction/Design Learning Center (IDC/DLC) Facility in Harpers Ferry, WV. Our role was crucial in addressing the foundational requirements to ensure the stability and durability of the facility’s foundation being built in a region characterized by its challenging karst typography.

Scope of Project

Initial geological assessments confirmed the presence of karst terrain, necessitating a tailored approach to the micropile design and installation.

Our team delivered a solution that included the installation of 199 each 5.5-inch diameter micropiles and 97 each 7-inch diameter micropiles drilled from a cleared area inside the CPB secured facility. The total drilling for the 5.5-inch and 7-inch micropiles amounted to 4,240 feet and 1,700 feet, respectively, meticulously calculated to accommodate the site’s specific geological challenges.

In response to the expedited project timeline, the micropiles were designed with a threefold safety factor. This strategic decision effectively eliminated the need for test piles, helped accelerate the project’s progress. The use of two drill rigs further streamlined the installation process, enabling our team to complete the project two weeks ahead of the anticipated completion date.

Logistics and coordination with on-site security were paramount, as all deliveries and operations had to be prearranged to avoid any disruptions. Our team’s proactive planning and coordination efforts ensured uninterrupted access to the site, facilitating a smooth and efficient project execution.

Challenges and Adaptive Strategies

The principal challenge was navigating the project’s accelerated schedule in conjunction with the unpredictable karst typography conditions. Our adaptive design and strategic use of dual drill rigs demonstrated our capacity to innovate under pressure and deliver a foundation solution that met the rigorous safety and stability standards required by the USCBP.

The completion of the micropile foundation for the Harpers Ferry Design and Learning Center reflects Brayman Foundations’ expertise in delivering high-quality, specialized foundation solutions under challenging conditions. As a subcontractor, we provided a critical component of the construction project, demonstrating our commitment to excellence, adaptability, and collaboration. This project demonstrates our ability to navigate complex geological challenges and stringent project timelines, reaffirming our position as a leader in the foundation construction industry.