This project involved the construction of a six-level, cast-in-place, post-tension parking structure, supported by two helical ramps on each end for seamless movement between levels. The garage accommodates approximately 1,700 vehicles, with an additional 650 vehicles in surface parking. Key features include two vehicular bridges, curbside expansion access, and modifications to the adjacent I-90 on-ramp, ensuring enhanced traffic flow and accessibility.

Designed with functionality and durability in mind, the structure integrates modern safety measures, including advanced lighting and wayfinding systems. The project’s impact extends beyond functionality, improving regional connectivity and traveler convenience while supporting economic growth in the surrounding community. The construction team maintained an exemplary safety record, upholding high safety standards.

The creative design process for this project revolved around blending functionality, structural efficiency, and user-centric features while addressing complex challenges. The six-level, cast-in-place, post-tension parking structure was designed to maximize capacity, with helical ramps strategically positioned at both ends to ensure seamless vehicle movement between levels. The incorporation of two vehicular bridges added significant complexity, requiring precise alignment to maintain traffic flow and integration with the adjacent I-90 on-ramp.

One of the major challenges was integrating curbside expansion access and I-90 modifications without disrupting existing traffic patterns. Innovative phasing and design adjustments minimized impacts, maintaining community connectivity throughout construction.

The final design balances form and function, offering a visually appealing structure that supports increased traffic demands while seamlessly integrating into the surrounding infrastructure. Aesthetic enhancements included clean architectural lines, enhanced lighting for safety, and wayfinding elements that improve the user experience.

The construction of the six-level, cast-in-place, post-tension parking structure at one of the world’s busiest airports presented significant challenges, requiring innovative solutions and seamless coordination to maintain the highest quality standards.

Constructing this facility within an active airport environment added a layer of complexity unmatched by typical projects. The team worked adjacent to operational terminals, balancing tight construction schedules with the need to minimize disruptions to daily airport operations.

Additionally, the installation of two helical ramps and coordination of surface parking for 650 vehicles demanded careful logistical planning and staging. These challenges were compounded by the airport’s security protocols, restricted access zones, and the need for real-time adjustments to accommodate the dynamic environment of an active international airport.

Daily coordination meetings ensured all stakeholders—from subcontractors to airport authorities—were aligned on priorities, schedules, and safety protocols. Rigorous quality control processes, including ongoing inspections and adherence to stringent airport standards, guaranteed the integrity of every structural, mechanical, and electrical component.

Through meticulous planning, expert collaboration, and an unwavering commitment to safety and quality, the team delivered a world-class parking facility that enhances accessibility and operational efficiency at one of the world’s busiest airports.

The project’s exceptional safety record stands as a testament to the team’s unwavering commitment to worker well-being, proactive safety measures, and operational excellence. With over 500,000 work hours completed, the project achieved an impressive Lost Time Incident Rate (LTIR) of 0.37, significantly outperforming the construction industry’s national average of 1.1, as reported by the U.S. Bureau of Labor Statistics. Additionally, the project’s Total Recordable Incident Rate (TRIR) for 2024 was 2.4, which remains below the construction industry’s national average of 2.5.

These numbers demonstrate the team’s dedication to upholding the highest safety standards while delivering exceptional progress.

The project exemplifies a deep commitment to community engagement and workforce inclusion through impactful partnerships and programs, including the following:
• CPS Partnerships: Collaborated with over 200 Chicago Public Schools (CPS) to host annual events, including a skilled trades fair and three-day student experiences where 3,000+ CPS middle and high school students connect with local employers, trade unions, and workforce agencies.
• CPS Tours: Partnered with the Chicago Department of Aviation (CDA) to host tours for over 200 students at the CDA headquarters and the T5 Parking Garage project, providing exposure to aviation and construction career opportunities.
• Runway to Workforce Program: Bridging the gap between construction and future tradespeople, this program included visits to Hire360, HACIA U, Chicago Women in Trades, and Revolution Workshops. Students interacted directly with active T5 subcontractors, learning about hiring needs and industry insights.
• Holiday Coat Drive: Partnered with Revolution Workshop to sponsor a coat drive, raising $4,000 to provide 40+ heavy-duty coats for students, graduates, and local families. The event included a winter safety session for community members.
• Community Career Fairs: Engaged with citywide initiatives, including DPS and CDA events, to promote opportunities at the T5 Parking Garage. Hosted hands-on excavating demonstrations, business symposiums for minority- and women-owned businesses, and participated in a citywide college fair to introduce hundreds of CPS students to construction and aviation careers.
• Summer Internship Program: Provided hands-on experience for over 30 high school seniors and college undergraduates through partnerships with organizations like Youth Guidance, Urban Initiatives, Urban Alliance, Hope Chicago, and One Summer Chicago. Students rotated across departments and job sites, gaining skills in construction management, architecture, design, and professional development.

This project is a powerful example of how inclusive development can transform underserved communities. By prioritizing workforce development, community engagement, and economic inclusion, the project team delivered measurable and lasting benefits to the Chicagoland area.

• Empowering the Workforce of Tomorrow: Through initiatives like the Runway to Workforce Program and summer internships, we connected youth and emerging tradespeople to career opportunities in construction and aviation. Over 30 interns and hundreds of workforce program participants gained hands-on experience, mentorship, and direct access to hiring subcontractors.

• Supporting Local Students and Schools: Partnering with Chicago Public Schools (CPS), we engaged over 3,000 students annually in skilled trades fairs, three-day career events, and site tours, providing exposure to life-changing career opportunities. Students learned directly from local employers, trade unions, and workforce agencies, inspiring a new generation to pursue careers in construction.

• Investing in Local Businesses: Through business symposiums, we shared our expertise with local minority- and women-owned businesses, helping them grow capacity and expand opportunities.

• Prioritizing Community Well-being: Partnering with Revolution Workshop, we hosted a Holiday Coat Drive, raising $4,000 to provide essential winter gear to students, graduates, and community members. Safety education sessions during the event further demonstrated our commitment to community care.

• Hands-On Engagement: By organizing student tours and hands-on experiences like excavating demonstrations, we ensured the community gained direct access and exposure to construction careers, an area often unfamiliar to underserved groups.

This project goes beyond construction. It reflects a commitment to creating pathways for success, strengthening local businesses, and enriching the lives of underserved families and students. By fostering education, economic growth, and workforce readiness, we demonstrated the transformative power of community-focused development.

The project team has demonstrated an unwavering commitment to fostering diversity, equity, inclusion, and accessibility across multiple impactful initiatives:

• Promoting Workforce Diversity: Programs like the Runway to Workforce Program and partnerships with Hire360, HACIA U, Chicago Women in Trades, and Revolution Workshop provided underrepresented groups with direct pathways into the trades and construction industry.

• Engaging Underrepresented Communities: We reached 3,000 CPS students annually through skilled trades fairs, student tours, and interactive experiences, ensuring exposure to careers in construction and aviation—fields often unknown to underserved groups.

• Supporting Local Businesses: Business symposiums empowered minority- and women-owned businesses by providing tools, expertise, and opportunities to expand capacity and engage in transformative projects.

• Addressing Community Needs: Initiatives like the Holiday Coat Drive partnered with Revolution Workshop to directly support students, families, and recent graduates, emphasizing safety and inclusivity in community care.

• Creating Opportunities for the Future: Over 30 summer interns from underserved backgrounds participated in job shadowing, hands-on training, and soft skills development, fostering a diverse next generation of construction professionals.

By incorporating thoughtful outreach, strategic partnerships, and inclusive programming, this project exemplifies a model for breaking barriers and advancing equity within the workplace and community. Our work created tangible opportunities, addressed inequities, and inspired a more inclusive industry for the future.

Since 1948 when the original Damen Station closed, a significant 1.5-mile transportation gap has existed between the Ashland and California stations in Chicago’s Near West Side neighborhood. To address this need for greater connectivity, the Chicago Department of Transportation partnered with Perkins & Will, a global architecture and design firm, to complete the design and F.H. Paschen to manage the construction of a new, multi-modal Damen Station.

The modern, light-filled design references Chicago’s architectural history, particularly its iconic steel bridges, via the green, cantilevered pedestrian bridge. Working closely with the designer to ensure the design intent was achieved, F.H. Paschen constructed the new ADA-compliant structure, which includes a three-story, 8,700-SF station house, a new plaza with bus stop, a 1,260-SF mosaic mural created by local artist Fo Wilson, and a glass-enclosed, cantilevered pedestrian bridge that was delivered on-site in pieces via the Chicago River.

Perkins & Will, CDOT’s design partner, chose and arranged the station materials and design to create an intuitive user experience and to allow for a long-lasting transit facility with minimal maintenance requirements. A grand stair and escalator, visible through the transparent glass façade, guides passengers to the platform level. A glass bridge connects the inbound and outbound train platforms, offering spectacular views of the Chicago skyline and orienting visitors to neighborhood destinations and attractions. In a nod to Chicago’s architectural history, the green trusses along the station’s pedestrian bridge reflect the name of the CTA line and are a dynamic reference to Chicago’s iconic steel bridges.

The design elements primarily comprised a simple material palette: concrete, steel, timber, glass, and stainless-steel cladding. Since the finish materials are also the structural elements, the architecturally exposed concrete (ACON) and architecturally exposed steel (AESS) required exhaustive coordination to integrate and conceal systems within structural members and to achieve a high level of finish.

An additional design challenge was to detail the envelope to provide natural ventilation for passenger spaces to protect passengers from wind but avoid mechanical cooling. The detailing of these systems includes a shingled glass façade at the east elevation with open joints between panels, a gap between the top of all walls and the station house roof and detailing in the glass systems at the bridge which raises the sill above the floor line and holds the head below the roof line to allow air to move in and out of the bridge volume. All glass in the project is treated with custom frit patterns, designed to minimize bird strikes in transparent areas and enliven the experience while waiting for a train on the platform.
Finally, a mass timber roof deck is used in lieu of a traditional steel deck to provide a sustainable material and bring a biophilic aesthetic to the station palette. The challenge for the team was to design a system that could be fabricated locally. This led to the selection of nail-laminated timber (NLT), a mass timber product that was fabricated in panels and anchored to structural framing to create the roof deck ceiling.

Throughout the design process, CDOT encouraged the team to push the design envelope and deliver a station design that is both elegant and functional.

Based on Perkins & Will’s design, F.H. Paschen constructed the new ADA-compliant structure, which includes a three-story 8,700-square-foot (SF) station house with floor-to ceiling-windows and a unique NLT structural ceiling. The front granite slab plaza contains architectural lighting, two honey locust trees, and a new bus stop with underlit benches and a custom CTA sign. Passengers will utilize a glass enclosed, cantilevered pedestrian bridge painted a vibrant and iconic green to connect the inbound and outbound platforms. The station offers two elevators with the north elevator being completely enclosed in glass. The station house walls, stairs, and 70-foot elevator tower are all cast-in-place architectural concrete, with all architectural concrete work self-performed by F.H. Paschen’s in-house team. Upon entry into the station, there is a 1,260-SF mosaic mural created by local artist Folayemi (Fo) Wilson.

The platforms consist of precast concrete, an all-glass canopy, new LED advertising displays, and interactive system map touchscreens. A new alley and crosswalk on Seeley Avenue provide access to the existing residential area behind the station. At night, the station lights up with the illuminated windows, station house, and vertical “Damen” sign.

F.H. Paschen’s three-phase quality program, which is based on the U.S. Army Corps of Engineer’s quality process, was used successfully for the Damen Green Line project, which presented unique quality challenges due to the design and materials used.

For example, building information modeling (BIM) was used extensively throughout construction and not just for the expected MEP trades. Glazing, NLT, and metal panel systems all had unique components and custom details that required close coordination with multiple other trades to ensure all work met specifications. BIM allowed us to work with both the architect/engineer and the trades to identify and resolve issues prior to actual construction beginning and was key to accurate planning and scheduling of these customized components for F.H. Paschen’s project management team.

The NLT structure used for the station house ceiling required significant coordination and monitoring because the ceiling also acts as the structural roof deck. NLT is an engineered wood product that is made by placing dimensional 2x12s on edge and fastening them together with nails to create a solid timber panel. Its structural performance and aesthetic appeal made it suitable for both exposed and hidden portions of the station house ceiling while offering the strength and durability needed to support not only the structure but also the green roof installed above the NLT ceiling. The NLT panels were customized to fit the design vision while providing a sustainable, cost-effective solution. This required careful coordination with electrical and plumbing systems as all openings had to be cored in advance of installation.

We also had to closely monitor the AESS used throughout the construction. Different classes of AESS were specified for the steel structures ranging from AESS 2 (for feature elements not closely viewed) to AESS 4 for showcase elements that require a flawless look. The steel structures used included the north elevator tower and stair enclosure (AESS 2), the canopy steel over the platforms (AESS 3), and the pedestrian bridge (AESS 4).

The installation of the AESS required significant coordination with the designer and trades. For example, the AESS columns at the station house had to be coordinated amongst disciplines to maintain a slim profile while integrating conduit for attached light fixtures and downspouts from the roof above. The resolution conceals these systems from view and provides a refined aesthetic, seamlessly blending functionality with design excellence.

Further, the 1260-SF Fo Wilson glass tile mural, “Promise (for tomorrow from the past looking to the future),” at the station entrance is meant to be a visual representation of the various racial and ethnic groups that comprise the Near West Side neighborhood. Construction of the mural required close coordination due to the complexity of the design. The mural comprises nearly 800,000 individual ½-inch vitreous glass tiles in 31 different colors. We worked closely with the artist to ensure that the mural’s construction met the integrity of the design.

Further, F.H. Paschen had to overcome two key challenges during construction: minimizing impacts to normal CTA services and fabrication, delivery, and placement of the pedestrian bridge.

Part of the construction scope was to remove and replace the existing columns supporting the track structure so that the new station could be integrated into the existing network. However, because the tracks are part of the active Green Line operations, we could not close the tracks for extended periods. This meant taking an innovative approach to constructing the new columns and supports.

F.H. Paschen’s approach essentially reversed how support columns are usually constructed. After reinforcing the track structure with shoring towers and removing the existing columns, we hung the new columns from the existing track girders. Once those were in place, we poured the pile caps and piers up to the new column base plate instead of the more traditional approach of building the caps and piers and then placing the columns. After testing to ensure the new concrete met the design strength specifications, we transferred the load to the new columns and removed the shoring towers. Throughout this process, we monitored the track structure and shoring towers daily to verify that no settlement or movement had occurred. This allowed track operations to continue safely and without interruption as the new columns were built.

The second and perhaps biggest challenge was the fabrication and delivery of the pedestrian bridge. The design required AESS as a key feature. AESS has different standards for use, depending on how visible it will be in the final construction, and the bridge required AESS 4, the highest quality meant to create a flawless surface on showcase elements. This meant that to achieve the AESS 4 standard, we had to fabricate as much of the bridge as possible in the shop. However, this created a new problem: how would we deliver the nearly complete bridge to the project site?

Traditional trucking methods to transport the bridge weren’t possible because it was too large to safely navigate through overpasses and other tight spaces enroute to the jobsite. Instead, we opted to fabricate the bridge in two halves and load them onto a barge that traveled up the Chicago Sanitary & Ship Canal to the South Branch of the Chicago River. We then unloaded the bridge at the site of “The 78,” placed the bridge sections onto trucks, and transported them the remaining 4.5 miles to the jobsite.

Once the two halves of the bridge were on-site, we used a combination of welded connections and Cast Connex Diablo connectors to splice them together into a complete structure. Through careful coordination with the CTA, CDOT, and rail authorities, we orchestrated a 52-hour weekend track shutdown to erect the bridge using a tandem crane pick. We completed the bridge placement within the required timeframe, allowing the tracks to reopen as scheduled in time for the Monday morning rush.

As with any project of this complexity and scale, safety was a top concern throughout construction. We had to be particularly careful with the construction in and around the CTA train tracks due to the added hazards of the active train lines. Working closely with the CTA and CDOT, CTA flaggers were used whenever work was scheduled adjacent to or above the tracks to ensure all workers were protected from oncoming trains. Further, we protected workers from the energized third rail during activities near the track by using rail covers to prevent workers from accidentally touching the electrified rail.

Over the course of the 18-month project, a total of 189,290 manhours were worked. F.H. Paschen self-performed 41,518 manhours without a safety incident.

The City of Chicago’s goal for reopening the Damen Green Line station was to boost local development and neighborhood connectivity. The new station now provides easier access to public transportation for residents living in between the Ashland and California stops and offers sustainable transportation options such as bike-sharing and pedestrian-friendly spaces. In fact, the station is the proud home of Chicago’s 1,000th Divvy Bike Station. By restoring service to the neighborhood, the City also expects the station to spur economic growth by attracting businesses and creating new job opportunities in the area. For example, the new Damen Station was successfully opened in time for the Democratic National Convention that took place just blocks away at the United Center.

F.H. Paschen has played a key role in helping the City achieve these community-focused goals by achieving participation rates as follows:
MBE: 28.2%
WBE: 9.2%
VBE: 1.02%

This 425,000-square-foot ISO board manufacturing plant highlights innovation in construction and design, supporting the production of energy-efficient polyisocyanurate (ISO) insulation boards. The facility features state-of-the-art infrastructure, including precise sitework, robust utilities, and advanced manufacturing systems to ensure optimal production flow. The plant’s development boosts the local economy by creating jobs and enhancing sustainable construction practices. Designed with safety and efficiency in mind, the project achieved an outstanding safety record with zero incidents, adhering to rigorous protocols. This facility plays a key role in producing materials that advance energy-efficient building solutions across the construction industry.

The project was developed for an ISO board manufacturing plant, a facility requiring precise, climate-controlled operations to ensure product quality and safety. One of the project’s standout features was the interior rail unloading area. Given the need to efficiently transfer bulk chemicals—critical to the ISO board production process—the rail system was enclosed to maintain climate control, ensuring the chemicals remained stable during unloading. A steam-generating operation was incorporated to unload the chemicals safely from railcars into an adjacent bulk chemical storage area, meeting both operational and safety requirements.

The bulk chemical storage area was built with a depressed slab to serve as a chemical containment space, complete with containment drains to handle potential spills. This thoughtful design ensured the plant met stringent safety and environmental standards, while also enhancing functionality for continuous production.

The team overcame significant logistical challenges. Bulk tanks were essential to the plant’s operations but had to be installed vertically. Since they could not fit horizontally or through standard doorways, the design incorporated a left roof opening to place 13 tanks into the space. This solution allowed for efficient installation while maintaining the structural integrity of the facility.

See here for video of aerial footage

The project presented significant challenges requiring innovative solutions to ensure the highest quality of construction.

One notable challenge was the installation of bulk tanks which needed to be placed vertically. Standard horizontal installation or entry through doors was not possible, so the structural design incorporated sections of the roof be left out in order to place 13 tanks in the space, and complete the structure after tank placement.

The project’s constructability was further complicated by a concrete tilt-up construction method executed during November through March in central Illinois—a time when harsh weather conditions posed a significant obstacle. To address temperature variations, the team implemented custom concrete mix designs, allowing the concrete to cure properly and maintain quality despite the weather.

Additionally, roofing during the winter months required specialized materials. The team used a GAF RhinoBond roofing assembly, a product rated for extreme conditions, to ensure durability and performance under challenging winter weather.

Through proactive planning, creative problem-solving, and technical expertise, the team overcame these challenges, delivering a high-quality project that met the client’s expectations for both functionality and resilience.

The project demonstrated an outstanding commitment to safety, with 222,079 total work hours completed and only one recordable incident—achieving a recordable rate of 0.90, significantly lower than the national average of 1.7, according to the Bureau of Labor Statistics (BLS). The project reported zero lost-time incidents, underscoring the team’s proactive approach to workplace safety and dedication to ensuring every worker’s well-being.

At Clayco, safety is our first priority. Our mission is to ensure that every team member and partner goes home safely at the end of each day. This commitment was upheld on the project through robust safety protocols and continuous training programs, including:
• Daily Stretch and Flex sessions to promote physical readiness and reduce the risk of injuries on the job.
• Weekly Toolbox Talks to address job-specific hazards and reinforce safety best practices.
• Comprehensive Safety Audits conducted weekly by Clayco and trade partner team members to ensure adherence to all safety guidelines.

This project’s safety performance is a testament to the team’s dedication and the rigorous safety culture embedded in every phase of construction. The complex nature of the work—including the installation of bulk tanks, tilt-up concrete operations in challenging weather, and winter roofing assembly—demanded precise planning and execution. By adhering to Clayco’s proactive safety protocols and prioritizing worker well-being, the team successfully delivered a high-quality project with zero lost-time incidents, ensuring everyone went home safely at the end of each day.

This project has made a meaningful contribution to the local community by creating job opportunities and driving economic activity. At its peak, the project employed 140 skilled tradesmen onsite, providing steady work for construction professionals and supporting families in the area.

Beyond the construction phase, the facility continues to have a lasting impact through the creation of 130 permanent jobs, fostering ongoing employment and economic stability within the community.

Inclusion and collaboration were central to this effort, with the project team prioritizing partnerships with local contractors and tradespeople to maximize the economic benefits for the surrounding area. These efforts reflect Clayco’s commitment to not only building world-class facilities but also uplifting the communities where we work.