Modular Assembly Support Towers (MASTs)

1500-ton project in North Kingstown, Rhode Island, required innovative staging solutions. Gehman Iron, based in Knoxville, PA, was selected as a key team member to achieve this mission. They developed and fabricated modular, reconfigurable staging that significantly optimized space, reduced manual labor, and improved overall operational efficiency of the staging.

A 1,500-ton Department of Defense contractor project in North Kingstown, Rhode Island demanded an inventive answer to a familiar constraint: too much work, not enough space. Gehman Iron was selected to help deliver that answer – designing and fabricating modular, reconfigurable staging that transformed tight quarters into an efficient, safer workflow, cutting manual handling and accelerating throughput.

The project launched in May 2024 with staggered installation; two platform designs were delivered in February 2025, and the remaining four were completed and installed in December 2025. The criteria were demanding: a single footprint capable of supporting the construction of five different components, each with different heights and widths, incorporating retractable decks to navigate known obstructions. This herculean feat was accomplished with innovative engineering and executed with close collaboration.

The winning design-build team delivered the design, detailing, fabrication, and installation of large-scale, adjustable structural-steel work platforms to fit around different DOD Contractor components at various fabrication stages. Platforms measure 65 ft wide by 65–90 ft deep, with two or three decks at heights ranging from 10–35 ft.

Key challenges included creating a platform system that could be assembled and disassembled using the client’s mobile or overhead crane; engineering an adjustable floor to fit multiple components; detailing long members for galvanizing; and meeting a compressed installation schedule – all without sacrificing safety or durability.

Because the platform system will be stored outdoors for extended periods in a coastal environment, corrosion protection was non-negotiable. An anti-slip duplex coating was selected to deliver durable corrosion resistance, reliable traction underfoot, and a finish that holds its color and performance over time.