REPORT OF THE PRESIDENT - SCOTT BROWN
Your Board of Directors, in concert with lead contractor Gnazzo corp., RIDOT and Structures Northeast, has been working diligently to satisfy remaining contract obligations on this incredible renovation. The United States Lighthouse Society has confirmed that to their knowledge, there has never been as significant a restoration of a lighthouse of this design.
Since last August, Gnazzo worked consistently through November completing another section of demolition, interior exfoliation, exterior hydro blasting and priming. As the surface coatings are extremely temperature sensitive, the thresholds for application became constricted as autumn temperatures dropped. Some of the epoxies we are applying require 24 hours at temperatures above 45 degrees. Eventually our surface prep subcontractor, Aulson Corp. pulled off site for the season. We did have one faux pas, the cherry red paint application on the light level. You could feel the embarassment of our proud old girl with such a gaudy hat on. It was quickly remedied.
As you have read in our status reports and seen in Mike Steers photos, the extensive jacking of wall plates due to the expansive nature of rust has rendered a huge number of bolt ears damaged to a point where they are no longer viable. Plates on lower levels with any south west exposure were particularly degraded. At each location where we had an unuseable ear, two new holes had to be drilled to either side of such ear and galvanized bolts were shimmed and installed at a cost of $201.25 per location. Some plates required up to a dozen such extra contract repairs. To date we have executed change bulletins for approximately 100 locations. Adds up quickly.
We also had some sections where what remained of the flange, post exfoliation, was so degraded it could not handle the tourquing pressure of re bolting. We also encountered locations where plates had cracked due lateral stresses from storm surge wave action. These locations were addressed by custom mending plates of radiused, hot dipped galvanized steel of approximately 33” X 12”. These are $1500 per on locations not specified in the original contract, of which there have been a number. Although these numbers seem large they pale in comparison to the original change bulletins which specified $914 / lineal foot. We have to date executed change bulletins for approximately 20 extra contract stitching plates.
Interior stairs have been taken off site to be repaired and galvanized and will be reinstalled within a few weeks. New center hubs, which encircle the central column and to which the pie shaped floor plates are bolted, were cast and on site but had to be modified at Metal Works to add vertical support for the floor plates which began cracking at install. These modifications are complete and the hubs installed.
New glass has been glazed in on the light floor and at sunset you would swear the original lamp had been relit as the sun refracts off the new panes. Bill Richmond is sourcing a new flagpole. The new windows and frames for the entire project are delivered but will be one of the final installs as the risk of breakage decreases. We have designed an inexpensive system for the portholes, which will similarly be installed towards, wrap up.
Interior masonry was completed two weeks ago and by any measure, that is a significant milestone. No one reading this will be around the next time anyone sees the efficacy of the steel work and protective coatings applied behind that brick so let’s hope we got it right. We can happily report that 75% of the bricks used were salvaged from the original lay up. They are actually preferable to new brick as they have long ago reached their moisture saturation level and are perfectly stable. New brick will absorb moisture over time and create a jacking force much like rust. We have left a small vertical seem in the masonry to allow for such expansion which we will infill in a decade or so. Remind me!
The only non-static piece of the project is the main bulkhead door, which needed replacement along with its failed frame. We have a beautiful new door, which will still be operational when the lighthouse final capitulates. It has received a galvanizing dip and was installed last Friday.
One of the remaining items of significance is the demolition and reinstallation of the caisson deck. Within the next few weeks the original deck will be demolished and a new steel re enforced concrete deck will be poured. This may be mobilized via helicopter and we will let you know should that come to pass. Other than that, the work season will end with a final rinse and paint applications. We have a number of extra contract punch list items to attend to prior to final demobilization but we are on schedule to wrap up this fall.
Next spring, when the three-story work platform will be gone, we will attack the only outstanding phase of the work – caisson repairs and painting. This is extra contract work and thus will be outside of DOT auspices. This will allow for a more competitive bid process without prevailing wage restrictions and the heavy administrative load integral to DOT contracts. The entire project should be complete by July 2012.
We were extremely fortunate to have completed the interior masonry prior to Tropical Storm Irene. Gnazzo requested and received from FOSL authorization for an emergency demobilization of the lighthouse. Unfortunately, due to specific clauses in the RIDOT contract, this request triggered several consequential protocols not the least of which is a mandated $45k payable to Gnazzo. The bulk of the expenses associated with a demobilization center on the sourcing and assembling of substantial internal bracing to address vertical shear forces from wave action during masonry demolition. It is noteworthy that a lighthouse of this design achieves the bulk of its stoutness from its masonry interior and it is the exterior steel protecting the masonry, not visa versa.
That said, we are now 100% complete with masonry and I am hopeful we have partially dodged a bullet. We required no internal bracing and I am currently working with Gnazzo and the DOT to amend the contract to allow for a limited demobilization payment to be priced and executed. I hope to keep these numbers under $8k but am mindful that Gnazzo does have a legitimate look at the full $45k if they want to play that card. I am confident that they will wish to continue our excellent working relationship and negotiate a fair compensation for this event. I will keep you all advised of progress on that front.
All in all, your Board is extremely pleased with the quality of work at every level of this project and in particular, Sharon Stone and the RIDOT, Gnazzo, Structures NE, Aulson and Metal Works.
Please enjoy Mike Steers terrific photo documentation and a pair of striking pictures Kristen Brown took during Irene. Please make sure to thank Bill Nightingale who stepped down after six of the most critical years in this lighthouse’s 125-year history. He has shepherded this project from conception through to its execution and carried the bulk of its burden with a smile and unbridled optimism. It has been an absolute pleasure to serve under him and the debt of gratitude we owe Bill is immeasurable. Thank you for your continued interest and support of this project and the future of Sakonnet Lighthouse.
Sincerely,
Scott P. Brown
President
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