Project Summary

Cheatham Lock and Dam is a vital multipurpose facility operated by the U.S. Army Corps of Engineers (USACE) Nashville District on the Cumberland River at River Mile 148.7 in Cheatham County, Tennessee.

The Cheatham Lock & Dam Tainter Gate Rehabilitation project involved the complete repair and painting of seven double-skinned plated Tainter Gates (interior and exterior surfaces) along with one bulkhead lifting beam. Additional scope included the fabrication, painting, and installation of two sets of downstream bulkhead seal angles (four seal angles total).

Key Challenges

Rehabilitating and repainting seven large double-skinned Tainter Gates at Cheatham Lock & Dam presented several significant technical, logistical, and environmental challenges:

• Lead-Based Paint Removal: Complete removal of the existing lead-based paint system, thorough surface preparation, and application of a USACE-specified vinyl coating system while maintaining strict environmental and safety compliance.
• Complex Structural Repairs (AWS D1.1): Replacement of vertical ribs, strengthening of the strut arms,  installation of several new drain holes, repair of deteriorated welded connections, replacement of stiffener plates, skin plate repairs (both interior and exterior), and miscellaneous weld repairs.
• Seal System Replacement: Removal and replacement of side seal assemblies and J-bulb seals.
• Confined Space Work: Abrasive blasting, painting, and welding repairs inside the gates were particularly difficult due to limited access, confined spaces, and poor natural lighting — requiring the introduction of specialized artificial lighting and ventilation systems.
• Marine-Based Operations: All work was performed from a floating plant using work barges. Paragon self-performed the installation and removal of stop logs utilizing company-owned cranes.
• Heavy Lifting Requirements: Stop log operations required a 320-ton crane, demanding highly skilled riggers and crane operators for safe and precise handling.
• Rapid Flood Response: Contract requirements mandated the ability to fully demobilize the containment system and marine plant within 24 hours’ notice in the event of flooding.

How We Delivered 

We successfully completed the project by implementing targeted solutions, specialized equipment, and proactive planning:

• Environmental & Coating Compliance: Developed and executed a comprehensive lead abatement and containment plan that met all USACE, EPA, and OSHA requirements. We utilized high-efficiency containment systems on the barges and implemented rigorous monitoring to ensure zero environmental release during paint removal and surface preparation. The USACE-specified vinyl coating system was applied under controlled conditions, achieving full compliance with coating thickness and adhesion standards.
• Structural Repair Expertise: Our experienced welding and fabrication teams performed precise repairs, including complete replacement of deteriorated bracing members, stiffener plates, and skin plates. All weld repairs were completed to USACE welding procedures and underwent rigorous non-destructive testing to restore full structural integrity.
• Confined Space Execution: We designed and deployed custom lighting and ventilation systems tailored to the interior of the double-skinned gates. This allowed our crews to safely perform abrasive blasting, welding, and painting in confined spaces while maintaining high productivity and strict safety standards.
• Marine Operations & Logistics: Operating entirely from our floating work barges, we maintained continuous progress while coordinating closely with lock operations. Our in-house crane and rigging teams safely handled all stop log installations and removals using our 320-ton crane, minimizing downtime and ensuring precise placement.
• Flood Preparedness & Rapid Demobilization: We developed and drilled a detailed flood demobilization plan that enabled our team to remove all containment systems and marine equipment from the dam within 24 hours of notice. This proactive approach prevented any project delays or damage during high-water events.

Through meticulous planning, specialized marine expertise, and a strong safety culture, the project was completed safely, 9 months ahead of schedule, and to the full satisfaction of the U.S. Army Corps of Engineers.