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Metal and the floating museum: The Intrepid Sea, Air & Space Museum is restoredAuthor: Erik Latranyi Date: Jan 1 2009 12:00AM URL: www.hendrickmfg.com  Working to refurbish a historic landmark is a daunting task for any architect. Redesigning a historic landmark that weighs over 27,000 tons (24,300 metric tons) and floats could be considered a nightmare! Fortunately, the right architect,coupled with a skilled fabricator and supplier, equate to innovative solutions and aesthetically successful results.Only four of the original 24 Essex-Class aircraft carriers exist today. One calls New York City its home, the USS Intrepid. Known as the Intrepid Sea, Air & Space Museum since its founding in 1982, the attraction is a staple for tourists visiting the Big Apple. USS Intrepid The USS Intrepid was launched in 1943 and served the United States until its final decommission in 1974. The USS Intrepid has a storied history for aficionados of such naval vessels. Aside from serving as a platform in wartime, the USS Intrepid also recovered several astronauts and acted as the host for various ceremonial duties. When the ship was decommissioned in 1974, the USS Intrepid hosted exhibits in Philadelphia as part of our nation’s bicentennial celebrations. The original plan called for the USS Intrepid to be scrapped, however, real estate developer Zachary Fisher and the Intrepid Museum Foundation campaigned hard to save the historic carrier. In 1982, the ship was towed to New York City’s Pier 86 as the Intrepid Sea,Air & Space Museum. In 1986, it was officially designated as a National Historic Landmark. For a brief time, the USS Intrepid was called back into service (unofficially) as the emergency operations center for the FBI after the Sept. 11 terrorist attacks. A fund was established early to restore the USS Intrepid and improve the quality of the museum bearing its name. In 2006, Stephen Dargo, of Dattner Architects in New York City, was charged with the project.  The RestorationAside from respecting the history and majesty of such a vessel, Dargo was intent on designing the variables seamlessly into the overall project. The design called for four towers that act as gangways, providing access to/from the ship. The design of the towers was meant to reflect the feel of the ship. It had to have a certain appropriate strength of character while at the same time having an architectural elegance. It also could not distract from the primary purpose of the museum, which is to display the aircrafts and spaceships used by this nation. The steel on the towers is hot-dipped galvanized by V&S Galvanizing in Perth Amboy, N.J. This resulted in a more industrial finish than stainless steel, blending well with the ship’s exterior. The stairs themselves (on Tower 1) are cantilevered off the main elevator hoist-way in such a way as to appear as though they are floating. The connections to the columns are as discrete as possible. Also, careful attention was paid to conceal as much of the electrical wiring for the lighting and electrical outlets, which are used for maintenance purposes. The USS Intrepid is moored to the pier with mooring lines that have a great deal of flexibility, and it is this flexibility that needed to be incorporated into the design of the gangways and towers. Dargo decided that the gangways will be hinged on the ship. They actually “roll” on the towers, meaning they provide for both regular movements of the ship (the daily tides), as well as for extreme high and low tides. He also had to make provisions for a 50-year flood condition, as well as certain abnormal wind conditions. The final design element was the elevator incorporation. The elevator has no machine room, which is the newest technology in elevators. Traditional elevators have a machine room at the top of the hoist-way, which was not acceptable for this design. The machine that drives the elevator is a small piece of equipment that is nearly invisible. JC MacElroy Co., Piscataway, N.J., was enlisted to construct these towers and keep the project on schedule. After studying the logistics, Pete Mastrola of JC MacElroy presented to the owner, Hudson River Park Trust, and contractor, Skanska USA Building Inc., New York City, the idea to build the towers off-site and bring them to the project virtually complete. After ironing out a few of the engineer’s concerns, fabrication on the towers began in November 2007. The erection of Tower 1 began at a waterfront yard in Perth Amboy in February 2008 and was completed in April 2008. Because ofthe size and weight constraints, Tower 1 was built in two sections, each weighing approximately 60 tons (54 metric tons). The two pieces were then picked up with a Weeks 553 Water Crane, which is a 500-ton (450-metric -ton) crane situated on a barge, and shipped to Pier 86 for assembly.  Towers 2, 3 and 4 were slightly smaller, 55 tons (50 metric tons) each, and were completely assembled at the same time in May and June 2008, and all were placed on the pier by June 26, 2008.The five gangways were also assembled 100 percent in the Perth Amboy yard and brought to the project on a deck barge. They were installed on the recently returned ship in October 2008. Mastrola knew the project was immense; using 400 tons (360 metric tons) of Grade 50 steel is no small task. Mastrola also knew that JC MacElroy could handle most of the fabrication work itself, but needed expertise with regard to the perforated metal panels used on the towers and elevator shaft. In keeping with Dargo’s “floating” design, Ken Ward of Hendrick Manufacturing Co., Carbondale, Pa., worked closely with Mastrola to ensure each panel would appear invisible from a distance, yet attractive from close-up. The hole-pattern chosen was 1-inch (25-mm) round on 2-inch (51-mm) centers in a straight pattern. This resulted in a 20 percent open area. The panels were used as railing-infills and to shroud the elevator shaft. All were made from 3/16-inch (5-mm) aluminum and powder coated to compliment the design. Dedication In October 2008, the USS Intrepid made its ceremonial voyage up the Hudson and back to the newly refurbished Pier 86. As it was moored, the gangways were installed connecting the towers to the classic carrier. On Nov. 8, 2008, the museum was rededicated. Dignitaries and tourists attended the ceremony, starting a new chapter for the USS Intrepid. Everyone boarded the vessel, giving little notice to the towers, gangways and perforated metal panels. Instead, most people paid attention to the historic vessel and the incredible displays of aircraft and spaceships on board. That is everyone except for a very satisfied architect and the fabricators and suppliers who ensured history would be the focus of the museum for many years to come. Erik Latranyi is the national sales manager at Hendrick Manufacturing Co., Carbondale, Pa. Details are available at www.hendrickmfg.com. | ||||||||||
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