UNITED STATES COAST GUARD 
CIVIL ENGINEERING UNIT CLEVELAND 
1240 EAST NINTH STREET 
CLEVELAND, OHIO 44199-2060 


USCG Contract No. HSCG83-07-D-3WF172 

USCG Task Order No. HSCG83-10-J-PCU005 

STRUCTURAL INSPECTION AND ASSESSMENT 
OF THE U.S. COAST GUARD FRYING PAN SHOALS LIGHT 
STATION 


Location: 
CAPE FEAR, NORTH CAROLINA 


P/N 2705210 


JANUARY 2010 




STRUCTURAL INSPECTION AND ASSESSMENT 

OF THE 

U.S. COAST GUARD FRYING PAN SHOALS LIGHT STATION 
IN 

THE ATLANTIC OCEAN 

32.5 MILES SOUTHEAST OF 
CAPE FEAR, NORTH CAROLINA 

JANUARY 2010 

Prepared For: 
UNITED STATES COAST GUARD 
CIVIL ENGINEERING UNIT CLEVELAND 



COLLINS JOB 6277-40 



EXECUTIVE SUMMARY 


Collins Engineers, Inc., as a subconsultant to Michael Baker Jr., Inc., 
under contract with CEU Cleveland, was issued a task order to perform a 
structural inspection of the Frying Pan Shoals Light Station. A field 
inspection was performed on January 5, 2010, during which a three person 
team consisting of professional engineers conducted a visual and tactile 
examination of the accessible structural steel members. 

Overall, the primary structural elements were in satisfactory condition 
with members exhibiting some minor section loss and minor deterioration. 
The steel pipe piles, steel bracing, and the primary steel girders and W 
Sections that provide the load resisting system for the structure exhibited 
minor to moderate deterioration above the splash zone. Loss of paint 
coating, corrosion, and pack rust was evident on most structural elements 
exposed to the marine environment. No significant loss of steel section was 
observed on these components. Within the splash zone, the piles exhibited a 
thick layer of corrosion and rust nodules. This area was inaccessible for a 
hands-on view at the time of the inspection and the extent and severity of 
the deterioration on the piles between the splash zone and the channel 
bottom was unable to be evaluated. 

In general, the Helicopter Deck was in satisfactory condition with only 
minor surface corrosion throughout and moderate corrosion isolated to areas 
around the exterior door opening and Light Tower stairway in the Generator 
Room. The Light Tower stairway was in satisfactory condition with failing 
paint and minor surface corrosion. The Helicopter Deck walkways have some 
minor to moderate deterioration of the support beams, channels, and grating 
with isolated areas of advanced loss of section. When compared to the 
available plans from Chesapeake Light, the Helicopter Deck framing is similar 
but not identical. 

The Machinery and Quarters Deck was generally in satisfactory 
condition. The columns, wall panels, and wall framing that were visible had 
some minor deterioration such as failure of paint coatings and minor surface 
corrosion. The interior floors felt stable with no visible signs of excessive 
deformations or movement during the inspection. The Machinery and 
Quarters Deck walkways had some minor to moderate deterioration of the 
support beams, channels, and grating with isolated areas of advanced loss of 
section. The main beams and girders supporting the Machinery and Quarters 
Deck were observed from the Maintenance Deck. These structural elements 
were exposed to the marine environment and exhibited significant corrosion 
and pack rust. Due to the limited access to the deck support members, the 

i 



extent and severity of this deterioration could not safely be evaluated during 
this inspection. From the limited accessible areas, this deterioration appeared 
to have some minor section loss which does not appear to have affected the 
structural capacity of the members. 

The Maintenance Deck was completely exposed to the marine 
environment and had the most significant deterioration. Due to the advanced 
deterioration of the access walkways, an evaluation of this deck could only 
be made from the North and South stairwells leading from the Machinery and 
Quarters Deck. Overall, the Maintenance Deck was in serious to poor 
condition. The storage tanks hanging below the Quarters Deck exhibited 
significant corrosion with some section loss. A majority of the walkway had 
advanced section loss of the beams, channels, grating, and handrails which 
has seriously affected its structural capacity and safety. This deck was 
unsafe and access to this area should be restricted. 

Due to limited access, the main structural legs and jackets supporting 
Frying Pan Shoals Light were inspected from the Maintenance Deck. The 
piles were generally in fair condition. The main piles, jackets, and diagonal 
bracing appeared to have light to moderate corrosion with concentrated 
corrosion around the splash zone. There were no signs of distortions or 
abnormal deformations of these members. The boat landing was completely 
deteriorated and all access ladders, stairs, and walkways near the water 
were unfit for use. Access by boat was not possible. 

Recommended repairs to the structure would include thoroughly 
cleansing and reapplying a protective coating suitable for marine 
environments, rebuilding the entire walkways for the Maintenance Deck, and 
replacing the support members for the walkways at specific locations 
throughout the Helicopter and Machinery and Quarters Deck. 

After completion of the above recommendations, it is recommended 
that the Frying Pan Light Station be inspected to insure proper 
implementation of the corrective measures. It is also recommended that the 
above water portions of the Light Station be inspected at an interval not to 
exceed 24 months. An underwater inspection of the portions of the piles 
and pile bracing members below the surface of water should be performed 
prior to implementation of any significant superstructure repairs. 

The estimated cost to provide the recommended repairs is $1,375,000. 
A detailed cost estimate for the repairs is located in Appendix C. 

ii 



TABLE OF CONTENTS 


Page 

EXECUTIVE SUMMARY ..........................................................................i 
TABLE OF CONTENTS .......................................................................... iii 


1.0 INTRODUCTION .......................................................................... 1 


1.1 Purpose and Scope ............................................................... 1 


1.2 General Description of the Structure ....................................... 1 


1.2.1 Description of Helicopter Deck .......................................... 1 


1.2.2 Description of Machinery and Quarters Deck....................... 2 


1.2.3 Description of Maintenance Deck and Piles......................... 2 


1.3 Method of Investigation ........................................................ 3 


1.4 Data Collection .................................................................... 3 


2.0 OBSERVED CONDITIONS ............................................................. 3 


2.1 Helicopter Deck.................................................................... 4 


2.2 Machinery and Quarters Deck ................................................ 4 


2.3 Maintenance Deck and Piles .................................................. 5 


3.0 ASSESMENT.............................................................................. 6 


3.1 Helicopter Deck.................................................................... 6 


3.2 Machinery and Quarters Deck ................................................ 6 


3.3 Maintenance Deck ................................................................ 7 


4.0 RECOMMENDATIONS................................................................. 7 


4.1 Helicopter Deck.................................................................... 7 


4.2 Machinery and Quarters Deck ................................................ 7 


4.3 Maintenance Deck ................................................................ 8 


4.4 Piles.................................................................................... 8 


4.5 Re-Inspection Frequency ....................................................... 8 


5.0 COST ESTIMATE........................................................................ 9 


iii 



Appendix A – Figures 
Figure 1. Location Map 
Figure 2. General Elevation 
Figure 3. Helicopter Deck Plan 
Figure 4. Machinery and Quarters Deck Plan 
Figure 5. Maintenance Deck and Piles Plan 
APPENDIX B – PHOTOGRAPHS 
Photograph 1. Overall View of Light Station, Looking West. 
Photograph 2. Overall View of Light Station, Looking East. 
Photograph 3. Overall View of Light Station, Looking North. 
Photograph 4. Overall View of Light Station, Looking South. 
Photograph 5. View of the Helicopter Deck from the Light Tower, 
Looking Northwest. 
Photograph 6. Floor-Level View of the Helicopter Deck, Looking East. 
Photograph 7. View of Typical Support Beam of the Helicopter Deck. 
Note the Minor Coating Failure and Surface Corrosion at 
the Beam/ Decking Interface. 
Photograph 8. View of Support Beam of the Helicopter Deck Walkway 
with an Isolated Area of Section Loss. 
Photograph 9. View of Support Structure of the Helicopter Deck 
Walkway showing Typical Overall Condition. 
Photograph 10. View of the East Fascia of the Helicopter Deck Walkway, 
Looking North. 
Photograph 11. View of the West Fascia of the Helicopter Deck 
Walkway, Looking South. 
Photograph 12. View of the Light Tower Looking Up from the Base. 
Photograph 13. View of the Stairway in the Light Tower Looking Up. 

iv 



Photograph 14. 

Photograph 15. 

Photograph 16. 
Photograph 17. 
Photograph 18. 

Photograph 20. 

Photograph 21. 
Photograph 22. 

Photograph 23. 
Photograph 24. 
Photograph 25. 
Photograph 26. 
Photograph 27. 
Photograph 28. 
Photograph 29. 

Photograph 30. 

Photograph 31. 

View of the Stairway in the Light Tower Looking Up 

showing Protective Coating Failing on the Stairs. 
Overall View of the Light Tower from the Helicopter 
Deck, Looking South. 

View of the Light Tower Stairway, Looking Down. 
View of the Light inside of the Light Tower. 
View of the Light Tower Windows with several broken or 


intact with bullet holes. 


View of the Generator Storage Area with Floor 
Delamination. 
View of Typical Floor Delamination near the access door. 
View of the Electrical Cabinets and Fuel Storage in 


Generator Room. 
View of the Recreation Room, Looking Northeast 
View of the Recreation Room’s main area, Looking West. 
View of the Galley, Looking North. 
View of the Galley, Looking South. 
View of the General Storage, Looking North. 
View of the General Storage, Looking East. 
View of the Living Quarters Bathroom from Hallway, 


Looking Northeast. 


View of the Living Quarters Bathroom, Looking 
Northwest 
View of the Radio Room from the Living Quarters 

Hallway, Looking East. 

Photograph 32. View of the Radio Room, Looking Southeast. 


v 



Photograph 33. View of an Office adjacent to the Radio Room, Looking 
East. 
Photograph 34. View looking into Room No. 1 with Paint Failing on the 
Walls, Looking West. 
Photograph 35. View looking into Room No. 2 with Paint Failing on the 
Walls, Looking West. 
Photograph 36. View of the East Fascia and Exterior Platform and 
Generator Access Door, Looking North 
Photograph 37. View of the East Fascia at the East/West Hallway 
Access, Looking North 
Photograph 38. View of the West Fascia looking toward the Southwest 
Corner at the East/West Hallway, Looking South. 
Photograph 39. View of the Access Platform Aligned with the East/West 
Hallway, Looking South 
Photograph 40. View of the Maintenance Level, Looking South. 
Photograph 41. View of the Maintenance Level, Looking East. 
Photograph 42. View of Protective Coating Loss that is Typical on all 
support members. 
Photograph 43. View of Floor Pan of the Living Quarters with Heavy 
Pitting. 
Photograph 44. View of the Underside of the Storage Tanks with Severe 
Corrosion. 
Photograph 45. View of the Maintenance Level Walkway with Section 
Loss. 
Photograph 46. View of the Maintenance Level Walkway with New 
Grating over Deteriorated Grating. 
Photograph 47. Close-up View of Severely Deteriorated Floor Grating that 
has given way. 

vi 



Photograph 48. View of Severely Corroded Stairway from the Machinery 
and Quarters Deck to the Maintenance Deck. 
Photograph 49. View of the Piles and Diagonal Braces on the Southwest 
corner of Structure. 
Photograph 50. View of the Piles and Diagonal Braces on the Southeast 
corner of Structure. 
Photograph 51. View of the Piles and Support Beams on the Northeast 
corner of Structure. 
Photograph 52. View of the Piles and Access Stairs on the Northwest 
corner of Structure. 
Photograph 53. View of Severely Deteriorated Walkway on the Cross-
Bracing near the Waterline. 
APPENDIX C – COST ESTIMATE 
APPENDIX D – REFERENCED DESIGN PLANS 

vii 



1.0 INTRODUCTION 
1.1 Purpose and Scope 
The purpose of this project was to perform a condition assessment of 
the existing condition of the above water portions of Frying Pan Shoals Light 
Station, located 32.5 miles southeast of Cape Fear, North Carolina. Collins 
Engineers, Inc. (Collins) conducted the site inspection for the USCG Civil 
Engineering Unit, Cleveland (CEU Cleveland) on January 5, 2010. The point 
of contact at CEU Cleveland was LT Neil Orlich at (216) 902-6249. 

The scope of work included an inspection of the structural elements 
supporting the structure. Photographs, video and field notes were taken to 
record the condition of the structural elements at the time of inspection. 
Design plans were not available for this structure; however, design plans 
dated August 3, 1964 were available for the Chesapeake Light Station. The 
plans were typically consistent with the Frying Pan Shoals Light Station 
layout. Based on the inspection findings, repair recommendations, which 
included the type, estimated cost, and suggested timetable of repair work 
were included. 

1.2 General Description of the Structure 
The US Coast Guard Frying Pan Shoals Light Station is located in the 
Atlantic Ocean at approximately 32.5 miles southeast of Cape Fear, North 
Carolina. The coordinates of the light are 35°29'00”N, 77°35'00"W. The 
structure was constructed with a design which is commonly referred to as a 
“Texas Tower”. The structure consists of a light tower, Helicopter Deck, 
Machinery and Quarters Deck, and Maintenance Deck. The decks are 
supported by four steel pipe piles with intermediate horizontal bracing. The 
structure was originally designed and constructed with a boat landing, which 
is no longer in place. Refer to Photographs 1 through 4 in Appendix B for 
typical views of the structure. Refer to Figure 1 in Appendix A for location 
map of the facility, and Figures 2 and 3 in Appendix A for a general elevation 
view of the structure. 

1.2.1 Description of the Helicopter Deck 
The Helicopter Deck is approximately a 77-foot by 77-foot square with 
a 7-foot by 7-foot by approximately 30-foot tall tower located at the 
southeast corner of the structure. A steel grating walkway extends around 
the entire Helicopter Deck. The Helicopter Deck is comprised of a steel plate 

1 



deck which is supported by ST-shape floor stingers on W-shape floor beams. 
The Helicopter Deck floor beams are welded to 8-inch by 8-inch hollow 
structural steel columns. The columns are generally ordered in 6 rows of 6 
columns, with additional columns located around the tower section in the 
southeast corner. Columns extend from the Machinery and Quarters Deck 
(base of column) to the Helicopter Deck (top of column). 

1.2.2 Description of the Machinery and Quarters Deck 
The Machinery and Quarters Deck is located below the Helicopter 
Deck. Based on similar plans from Chesapeake Light the Machinery and 
Quarters Deck consists of steel plates supported by ST-shape floor stingers 
on W-shaped floor beams. The Machinery and Quarters Deck floor beams 
are supported by plate girders. There are four 5-foot deep plate girders 
oriented east-west which span the entire width of the structure. Large 
storage tanks are connected to these girders. There are a total of eleven 4foot-
deep plate girders oriented north-south which span between the 5-foot 
deep plate girders. The ends of the plate girders are welded to four W-shape 
girders which span from pile cap to pile cap. Columns extend from the 
Machinery and Quarters Deck (base of column) to the Helicopter Deck (top 
of column). 

1.2.3 Description of the Maintenance Deck and Piles 
The Maintenance Deck lies below the Machinery and Quarters Deck. 
It primarily consists of a steel grating floor supported by various steel W-
shapes and channels. Two sets of stairs, one at the northwest corner and 
one at the southwest corner, connect this deck with the Machinery and 
Quarters Deck. A third set of stairs extends down to the Maintenance Deck 
from the main passageway in the Machinery and Quarters Deck. Only the 
upper portions of a spiral staircase on the northwest pile remain intact. 

The piles are constructed of steel pipe sections. From the available 
plans, the piles are labeled 1, 2, 3, and 4 clockwise starting at the northeast 
pile. Horizontal bracing members, consisting of steel pipe sections, were 
located approximately 10 ft above the waterline at the time of the 
inspection. Diagonal foundation bracing members, also consisting of steel 
pipe sections, span vertically from the piles to the horizontal braces as well 
as horizontally from horizontal brace to horizontal brace. 

2 



1.3 Method of Investigation 
A detailed visual and tactile inspection was conducted to 
determine the physical condition of the above water portions of the light 
station. A three-person team consisting of licensed professional engineers 
performed the inspection. The station was accessed via a chartered 
helicopter (Bell Long Ranger) through Helo Air, Inc. 

The inspection consisted of a Level I visual and tactile examination of 
all accessible components of the structure. Particular attention was given to 
any noted areas of excessive deterioration or apparent distress. For 
inspection documentation, the structure was divided into the Helicopter 
Deck, the Machinery and Quarters Deck, and the Maintenance Deck. The 
Helicopter Deck includes the Light Tower and the Helicopter Deck supporting 
floor beams, girders, and columns. The Machinery and Quarters Deck 
includes the supporting Quarters Deck floor beams and girders, the 
superstructure plate girders, and the top-of-pile girders. The Maintenance 
Deck, includes the Maintenance Deck walkway, the walkway supporting 
members, the above water portions of the four piles, and the pile bracing 
members. 

1.4 Data Collection 
A biennial inspection dated June 1996 was available during the 
inspection. Design plans were not available for the Frying Pan Shoals Light 
Station; however, the plans for the Chesapeake Light Station were very 
similar to the construction of the Frying Pan Shoals Light Station. The 
following design drawings were obtained from CEU Cleveland: 

Plans Drawing Number Sheets 
Chesapeake Light Station (Design) 109001 1-50 

Refer to Appendix D for copies of the design drawings referenced for 
the assessment report. 

2.0 OBSERVED CONDITIONS 
The following criteria govern the assessment ratings of the structural 
components of the light station: 

-Very Good Condition – no problems noted. 

3 



-Good Condition – some minor problems. 
-Satisfactory Condition – structural elements show some minor 
deterioration. 
-Fair Condition – all primary structural elements are sound but may have 
minor section loss, cracking, or spalling. 
-Poor Condition – advanced section loss, deterioration, or spalling. 
-Serious Condition – loss of section, deterioration, or spalling has seriously 
affected primary structural components. Local failures are possible. 


2.1 Helicopter Deck 
Overall, the structural elements of the Helicopter Deck were in 
satisfactory condition. The top of the Helicopter Deck exhibited minor 
coating failure with minor corrosion covering approximately 20 percent of 
the surface area. The underdeck support members were in satisfactory 
condition with minor surface corrosion in sporadic areas. Moderate surface 
corrosion with some minor loss of section was primarily isolated to areas 
around the external door openings and on the stairway to the Light Tower in 
the Generator Room. The walkway extending around the perimeter of the 
Helicopter Deck exhibited light to moderate corrosion and was in fair 
condition. The walkway grating was typically intact and exhibited light to 
moderate corrosion. The steel support members for the Helicopter Deck 
walkway exhibited a loss of protective coating with moderate corrosion and 
random isolated areas of section loss. 

The Light Tower located on the Helicopter Deck was in satisfactory 
condition. Light to moderate corrosion was observed on all exposed steel 
surfaces and covered approximately 90 percent of the surface area. There 
was no significant sign of distress or section loss on the structural members 
of the Light Tower. Refer to Photographs 5 through 118 in Appendix B for 
views of the deficiencies observed on the Helicopter Deck. 

2.2 Machinery and Quarters Deck 
Overall, the primary structural elements within the Machinery and 
Quarters Deck were in satisfactory condition. The visible structural elements 
including the exterior wall tube members, the wall panels, and the interior 
columns exhibited minor deterioration in the form of paint failure and light to 
moderate surface corrosion. The exposed steel plate floor in the Generator 
Room had light to moderate corrosion throughout with rust nodules up to 1 

4 



in. in diameter and minor delamination of the plate. In the other locations 
the deck had a raised sub floor with linoleum tiles. Furniture, tools, and 
equipment still remained throughout the entire Machinery and Quarters Deck. 

Access was limited on the Maintenance Deck because the walkways 
were unsafe, therefore, only isolated portions of the steel support members 
for the Machinery and Quarters Deck could be inspected. Parts of the 
underside of the Machinery and Quarters Deck were accessed by the 
walkway stairs on the north and south fascias and other portions were 
visible from the interior stairs in the main passageway. The accessible 
portions of the deep plate girders and W sections typically exhibited a loss of 
protective coating with moderate to heavy corrosion and scale with minor 
loss of section. 

The walkway surrounding the Machinery and Quarters Deck was in 
fair condition. The walkway grating was typically intact and exhibited light to 
moderate corrosion. The steel support members for the Machinery and 
Quarters Deck walkway exhibited a loss of protective coating with moderate 
corrosion and random isolated areas of section loss. Refer to Photographs 
19 through 40 in Appendix B for views of the deficiencies observed in the 
Machinery and Quarters Deck. 

2.3 Maintenance Deck and Piles 
Overall, the accessible structural elements within the Maintenance 
Deck were in poor to serious condition. Due to the heavy deterioration of 
the steel grating for the Maintenance Deck, a majority of these elements 
were inaccessible. The inspectors were able to view the Machinery Deck and 
Piles from the bottom of the exterior stairwell on the north and south faces 
of the structure and from the interior stairwell located in the center of the 
structure but did not attempt to walk on the gratings with considerable loss 
of section. The steel grating was heavily deteriorated and exhibited up to 
100 percent loss of section. Several sections of grating were missing and 
temporary grating was installed in isolated locations. The steel support 
members for the walkway were heavily deteriorated and exhibited up to 100 
percent loss of section. 

Since walkways to the lower portions of the piles were no longer 
present, only the upper portions of the piles were accessible for close 
inspection. With a zoom lens, all four piles were observed to have a loss of 
protective coating and minor surface corrosion on up to 100 percent of the 
surface areas above the splash zone. Within the splash zone the piles 
exhibited heavier corrosion with rust nodules and scaling. The diagonal pile 
bracing members above the waterline exhibited a loss of protective coating 

5 



and minor surface corrosion on up to 100 percent of the surface area. The 
spiral stairwell on the Pile No. 2 was heavily deteriorated with up to 100 
percent loss of section. Refer to Photographs 41 through 52 in Appendix B 
for views of the deficiencies observed on the Maintenance Deck and Piles. 

3.0 ASSESSMENT 
3.1 Helicopter Deck 
Overall, the Helicopter Deck was in satisfactory condition. The areas 
of coating loss and surface corrosion on the members supporting the 
Helicopter Deck are generally minor with no appreciable loss of section, and 
as a result, are not structural concerns at this time. From the observed 
conditions, there were no indications that the Helicopter Deck should be 
restricted from its intended use. The walkway surrounding the Helicopter 
Deck showed some signs of distress with moderate corrosion only in isolated 
locations of the floor grating and support members. 

The Helicopter Deck transfers load down through the 8x8 columns to 
the W24 beams in the Machinery and Quarters Deck. The load is then carried 
down to the structural legs through the 5 foot deep girders. There were no 
observed deficiencies in the Helicopter Deck that would result in a reduction 
in the designed load capacity. However, these loads are transferred down to 
the W24 beams which ultimately support the entire Helicopter Deck in the 
Machinery and Quarters Deck. Due to the significant deterioration of the 
Maintenance Deck walkways, the extent and severity of the deterioration of 
the underside of the Machinery and Quarters Deck, including the W24 
beams, could not be fully documented. 

Based on the observed conditions of the assessable areas of the W24 
beams, the minor to moderate deterioration should not have reduced the 
structurally capacity significantly. However, without a structural load rating 
and positive confirmation of the extent of the deterioration of the W24 
beam, we cannot definitively determine that a helicopter could land on the 
Helicopter Deck. The inspection team landed a Bell Long Ranger weighing 
approximately 4000 pounds fully loaded. The pilot kept the helicopter fully 
running in order to reduce the weight applied to the deck. 

3.2 Machinery and Quarters Deck 
The corrosion on the girders and beams supporting the Machinery and 
Quarters Deck has probably been accelerated by the members’ close 
proximity to salt water spray and the corrosive air environment. The loss of 

6 



protective coating observed on a majority of the members has also 
accelerated this corrosion. The majority of the members supporting the deck 
exhibited loss of protective coating and minor to moderate surface corrosion. 
Heavy corrosion was observed in the bottom flanges of the majority of the 
inspected girders. The walkway surrounding the Quarters and Machinery 
Deck showed some signs of distress with moderate corrosion only in isolated 
locations of the floor grating and support members. 

3.3 Maintenance Deck and Piles 
Overall, the Maintenance Deck was unusable at the time of the 
inspection. The heavy deterioration of the steel support members and steel 
grating has rendered the Maintenance Deck unsafe for use. 

The corrosion on the upper portions of the piles and pile braces 
appeared to be limited to the surface, with no appreciable loss of section. 
Given that the heaviest corrosion was observed near the waterline, an overall 
structural assessment of the piles cannot be determined until the piles are 
closely inspected at and below the waterline. The spiral staircase located on 
the northwest pile was deteriorated to the point where it was unsafe for use. 

4.0 RECOMMENDATIONS 
4.1 Helicopter Deck 
All exposed steel surfaces including the decking, the deck support 
members, and Light Tower support members should be thoroughly cleaned 
and recoated with a coating manufactured specifically for marine 
environments. As part of this process, any areas of surface corrosion should 
be blasted clean to bare metal prior to the application of the protective 
coating. 

The random isolated areas of section loss in the grating and support 
members should be replaced prior to returning the Light Station to service. 

4.2 Machinery and Quarters Deck 
All of the exposed steel surfaces located on the internal portions 
of the Machinery and Quarters Deck should be thoroughly cleaned and 
recoated using a coating specifically manufactured for marine environments. 

7 



Primary deck and structural support members should be thoroughly 
cleaned and recoated using a coating specifically manufactured for marine 
environments. 

The random isolated areas of section loss in the grating and support 
members should be replaced prior to returning the Light Station to service. 

4.3 Maintenance Deck 
Due to the significant deterioration it is recommended that a 
complete replacement of the Maintenance Deck be performed before 
returning the Light Station to service. This would include a complete 
replacement of the steel grating support members, the steel grating, and the 
steel handrails. As part of this repair, consideration should be given to 
installing a new stairwell below the Maintenance Deck and a boat landing so 
that the structure is accessible from the water. 

4.4 Piles 
Because there was no documentation of a previous underwater 
inspection available, a thorough inspection of the piles and pile bracing 
members below water should be performed prior to any repair or 
rehabilitation work being performed on the superstructure. The purpose of 
the inspection should be to document the condition of the piles and bracing 
members and determine if the piles provide adequate support for the 

superstructure and its anticipated loads. Pending the underwater 
investigation, consideration should be given to installing a cathodic 
protection system on the piles to prolong their serviceable life. 

The portions of the piles and pile bracing above the waterline should 
be thoroughly cleaned and recoated with a coating manufactured specifically 
for marine applications. 

4.5 Re-Inspection Frequency 
It is recommended that the above water structural steel elements be 
inspected at an interval not to exceed 24 months. It is also recommended 
that an underwater inspection of the piles and pile bracing be performed 
within the next six months, and at intervals not to exceed 5 years. 

8 



5.0 COST ESTIMATE 
The following figure is a rough order of magnitude cost estimate to be 
used for planning purposes and to identify preliminary budgetary numbers 
only. This cost does not represent a specific detailed scope of work, 
timetable, escalation pricing, or specific prevailing wage rates. A detailed 
scope of work and completed structural drawings are required to determine 
more accurate construction costs. 

It is estimated that the total cost to perform the recommended repairs 
is approximately $1,375,000. Refer to Appendix C for a detailed cost 
estimate. 

Respectfully submitted, 

COLLINS ENGINEERS, INC. 

Thai G. Trinh, P.E. 

9 



APPENDIX A – FIGURES 



APPENDIX B – PHOTOGRAPHS 



Photograph 1. Overall View of Light Station, Looking West. 


Photograph 2. Overall View of Light Station, Looking East. 


Photograph 3. Overall View of Light Station, Looking North. 


Photograph 4. Overall View of Light Station, Looking South. 


Photograph 5. View of the Helicopter Deck from the Light Tower, Looking Northwest. 


Photograph 6. Floor-Level View of the Helicopter Deck, Looking East. 


Photograph 7. View of Typical Support Beam of the Helicopter Deck. Note the Minor 
Coating Failure and Surface Corrosion at the Beam/ Decking Interface. 


Photograph 8. View of Support Beam of the Helicopter Deck Walkway with an Isolated 
Area of Section Loss. 


Photograph 9. View of Support Structure of the Helicopter Deck Walkway showing 
Typical Overall Condition. 


Photograph 10. View of the East Fascia of the Helicopter Deck Walkway, Looking North. 


Photograph 11. View of the West Fascia of the Helicopter Deck Walkway, Looking 
South. 


Photograph 12. View of the Light Tower Looking Up from the Base. 


Photograph 13. View of the Stairway in the Light Tower Looking Up. 


Photograph 14. View of the Stairway in the Light Tower Looking Up showing Protective 
Coating Failing on the Stairs. 


Photograph 15. Overall View of the Light Tower from the Helicopter Deck, Looking 
South. 


Photograph 16. View of the Light Tower Stairway, Looking Down. 


Photograph 17. View of the Light inside of the Light Tower. 


Photograph 18. View of the Light Tower Windows with several broken or intact with 
bullet holes. 


Photograph 20. View of the Generator Storage Area with Floor Delamination. 


Photograph 21. View of Typical Floor Delamination near the access door. 


Photograph 22. View of the Electrical Cabinets and Fuel Storage in Generator Room. 


Photograph 23. View of the Recreation Room, Looking Northeast 


Photograph 24. View of the Recreation Room’s main area, Looking West. 


Photograph 25. View of the Galley, Looking North. 


Photograph 26. View of the Galley, Looking South. 


Photograph 27. View of the General Storage, Looking North. 


Photograph 28. View of the General Storage, Looking East. 


Photograph 29. View of the Living Quarters Bathroom from Hallway, Looking Northeast. 


Photograph 30. View of the Living Quarters Bathroom, Looking Northwest 


Photograph 31. View of the Radio Room from the Living Quarters Hallway, Looking East. 


Photograph 32. View of the Radio Room, Looking Southeast. 


Photograph 33. View of an Office adjacent to the Radio Room, Looking East. 


Photograph 34. View looking into Room No. 1 with Paint Failing on the Walls, Looking 
West. 


Photograph 35. View looking into Room No. 2 with Paint Failing on the Walls, Looking 
West. 


Photograph 36. View of the East Fascia and Exterior Platform and Generator Access 
Door, Looking North 


Photograph 37. View of the East Fascia at the East/West Hallway Access, Looking North 


Photograph 38. View of the West Fascia looking toward the Southwest Corner at the 
East/West Hallway, Looking South. 


Photograph 39. View of the Access Platform Aligned with the East/West Hallway, Looking 
South 


Photograph 40. View of the Maintenance Level, Looking South. 


Photograph 41. View of the Maintenance Level, Looking East. 


Photograph 42. View of Protective Coating Loss that is Typical on all support members. 


Photograph 43. View of Floor Pan of the Living Quarters with Heavy Pitting. 


Photograph 44. View of the Underside of the Storage Tanks with Severe Corrosion. 


Photograph 45. View of the Maintenance Level Walkway with Section Loss. 


Photograph 46. View of the Maintenance Level Walkway with New Grating over 
Deteriorated Grating. 


Photograph 47. Close-up View of Severely Deteriorated Floor Grating that has given way. 


Photograph 48. View of Severely Corroded Stairway from the Machinery and Quarters 
Deck to the Maintenance Deck. 


Photograph 49. View of the Piles and Diagonal Braces on the Southwest corner of 
Structure. 


Photograph 50. View of the Piles and Diagonal Braces on the Southeast corner of 
Structure. 


Photograph 51. View of the Piles and Support Beams on the Northeast corner of 
Structure. 


Photograph 52. View of the Piles and Access Stairs on the Northwest corner of Structure. 


Photograph 53. View of Severely Deteriorated Walkway on the Cross-Bracing near the 
Waterline. 


APPENDIX C – COST ESTIMATE 



COST ESTIMATE 
DATE PREPARED 
January 19, 2010 
SHEET OF 
1 1 
ACTIVITY AND LOCATION 
United States Coast Guard 
Frying Pan Shoals Light Station Repair (Texas Tower Platform) 
DESIGN/ENGINEERING CONTRACT NO. 
HSCG83-07-D-3WF172 
IDENTIFICATION NUMBER 
0 
ESTIMATED BY 
TGT 
CATEGORY CODE NUMBER 
PROJECT TITLE 
USCG Frying Pan Shoals Light Station Structural Assessment 
General Conditions 
STATUS OF DESIGN 
Planning Level Estimate 
JOB ORDER NUMBER 
HSCG83-10-J-PCU004 
ITEM DESCRIPTION QUANTITY MATERIAL COST LABOR COST EQUIPMENT COST ENGINEERING ESTIMATE 
NUMBER UNIT UNIT COST TOTAL UNIT COST TOTAL UNIT COST TOTAL UNIT COST TOTAL 
Mobilization 
Jack-Up Vessel 
Helicopter Deck 
Clean & Coat Steel 
Demolish Portion of Walkway 
Replace Portion of Walkway 
Machinery & Quarters Deck 
Clean & Coat Steel 
Demolish Portion of Walkway 
Replace Portion of Walkway 
Machinery & Quarters Deck 
Demolish Walkway 
Clean & Coat Steel 
Replace Walkway 
Replace Boat Landing 
Cathodic Protection 
1 LS 
75 Days 
7333 SF 
1 LS 
2260 LBS 
7100 SF 
1 LS 
2260 LBS 
1 LS 
3870 SF 
40000 LBS 
27000 LBS 
8 EA 
34,000 34,000 
10,000 750,000 
$4.50 32,999 
10,000 10,000 
$2.50 5,650 
$4.50 31,950 
10,000 10,000 
$2.50 5,650 
35,000 35,000 
$4.50 17,415 
$2.50 100,000 
$2.50 67,500 
3,000 24,000 
Subtotal $0.00 $0.00 $0.00 $1,124,163.50 
Profit @ 10% 
Contingencies @ 10% 
$112,416.35 
$112,416.35 
Total $1,348,996.20 
Bonding @ 2% 
Total 
$26,979.92 
$1,375,976.12 



APPENDIX D – REFERENCED DESIGN PLANS