MSHA Mine Academy Design-Build Fire Tower, Elevator, Burn Tunnel
AGENCY: U.S. Department of Labor – Mine Safety and Health Administration (MSHA)
LOCATION: Beaver, West Virginia
SIZE: $2,850,00
AWARD DATE: September 2021
COMPLETED: May 2023
AACON served as the prime Design-Build contractor for the U.S. Department of Labor’s Mine Safety and Health Administration (MSHA) Academy, delivering a technically complex, multi-facility construction program that included a new fire training tower, burn tunnel addition, and passenger elevator retrofit. This project required the integration of vertical construction, underground utility relocation, and interior renovation within an active federal training campus, demanding careful phasing and coordination to ensure uninterrupted operations.
The centerpiece of the project was a new three-story structural steel fire training tower measuring approximately 22' x 16' and 34 feet in height, featuring a 14' x 16' smoke and storage annex. The tower included complete underground electrical service, a dedicated breaker panel, smoke generation and exhaust systems, interior and exterior lighting, and a riser fire protection system with a Fire Department Connection (FDC). The roof deck, constructed of galvanized steel, incorporated multiple 10,000-lb anchor points and a parapet guard system with chained openings to support rappelling, rescue, and fall protection training exercises.
Adjacent to the tower, AACON constructed a 75-foot-long by 45-foot-wide burn tunnel addition that tied into existing training infrastructure. This work involved site excavation, new concrete slabs, drainage improvements, and plumbing tie-ins to existing systems. To support the enhanced training functions, AACON extended an existing water line by approximately 150 linear feet, installed a new fire hydrant, and performed utility relocations and tie-ins to the campus’ active underground service network.
The final phase of work involved the design and installation of a state-licensed passenger elevator within the Academy’s gym facility. AACON performed selective demolition, structural reinforcement, mechanical and electrical coordination, and finish carpentry to support the retrofit. The firm also reconfigured second-floor space to create a new hallway and renovated the recreation specialist’s office with new partition walls, ceiling grid, and finishes. All elevator work was phased to minimize disturbance to facility occupants and training activities.
A major challenge involved relocating and reconnecting underground utilities across multiple buildings while maintaining water, power, and communication service for MSHA’s operations. AACON mitigated these risks through detailed pre-installation planning, after-hours utility tie-ins, and synchronized construction sequencing—ensuring concurrent progress on all scopes while staying ahead of schedule.
AACON self-performed approximately 25% of the project, including project management, supervision, QA/QC oversight, safety management, light demolition, electrical support, permitting coordination, and utility tie-in oversight. The company also managed all contract documentation, submittals, and closeout deliverables through its Project Management Office (PMO).
Despite complex logistics, phased construction, and strict regulatory oversight, AACON completed all major scopes ahead of schedule and without disruption to MSHA operations. The successful delivery of the fire training tower, burn tunnel, and elevator retrofit reinforced AACON’s capability to execute highly technical, multi-discipline construction within secure, occupied federal environments. MSHA leadership commended AACON’s proactive scheduling, precise trade coordination, and commitment to safety and quality throughout project delivery.
