U.S. Army Corps of Engineers tackles demolition challenges at Brookhaven National Laboratory

The U.S. Army Corps of Engineers (USACE) New York District continues to demonstrate its unique engineering and construction capabilities in providing tangible, real-world solutions for some of the nation’s toughest challenges. The latest example involves the demolition of the Brookhaven National Laboratory in Brookhaven, New York.

Over the years, the lab has been on a mission to remove old buildings on its property that contain legacy radioactive material that was a result of past work at the site. Many structures have been removed or decommissioned over the years, but one high-profile structure has remained—a sizeable smokestack. Now, using the latest in demolition technologies, it is being safely removed by the USACE New York District.

To perform this work, the USACE is partnering with contractor Olgoonik-FPM, which was formed as a joint venture; its subcontractor ICC Commonwealth; and the U.S. Department of Energy’s (DOE) Office of Environmental Management, which is responsible for the environmental remediation of the High Flux Beam Reactor (HFBR) stack at Brookhaven National Lab.

Since 1947, the Brookhaven National Lab has been a multipurpose research institution known for its seven Nobel Prize-winning discoveries. Throughout its tenure, workers have performed research in physical, biological and environmental sciences as well as in energy technologies, computation, and national security.

The lab’s 5,300 acres of property sit on the former site of the U.S. Army’s Camp Upton. Near the center of the site is a 320-foot-tall, red and white concrete stack. The stack has a tapered cone shape, its interior base diameter is almost 27 feet and the interior top diameter is almost 19 feet. The stack marks where the 13-acre HFBR complex sits that was used for research purposes up until 1996.

The complex includes two research reactors—the HFBR and the Brookhaven Graphite Research Reactor (BGRR). The BGRR was decommissioned and dismantled over a decade ago; the HFBR has been similarly dismantled except for the reactor vessel, which will be removed in the future.

These reactors performed significant work in their day. The HFBR is known for many accomplishments including being a dependable source of neutrons—the subatomic probes crucial to an array of scientific research programs. This site is also known for work helping discover new uses for radioactive isotopes for treating cancer, cardiovascular disease, arthritis, and other medical conditions.

The BGRR had its share of achievements including being the world’s first reactor built solely to perform scientific research on peaceful uses of the atom after World War II.

Exhaust air from these reactors was transported by lines and ducts through filters to the stack. The stack was used to discharge cooling air from the BGRR and later to ventilate equipment and rooms in the HFBR and other support buildings on the complex. This exhaust included radioactive material.

This hazardous material contaminated the interior of the stack up to three-fourths of an inch in depth. In addition, the red and white paint on the stack’s exterior contained asbestos and lead. Removal of the stack is one of the last remaining actions related to the cleanup plan for the complex. USACE offered the lab and DOE a safe and efficient alternative solution to do this using the latest demolition technology.

First, the contractors removed the contaminated paint. A hydroblasting technique was applied that uses high-pressure water to remove the paint from the concrete. The paint is then vacuumed up at the point of removal from the stack’s surface and contained in a closed system. This procedure minimized the release of any hazardous material and eliminated the need for workers to directly handle the contaminated waste.

Next, the contractors began dismantling the stack using what is called the MANTIS Demolition System, which is an unmanned, remote-operated hydraulic machine used to dismantle large chimneys.

“With this system, the equipment actually sits on top of the stack and walks its way down as it chips away. Each piece of concrete is broken out, the rebar supports are cut, and it all falls inside the stack for removal. By the stack collecting its own waste, it keeps workers and the surrounding area protected from hazardous material,” Matthew Creamer, project manager for USACE’s New York District, says. “The system also produces limited vibration, which protects nearby lab equipment from being damaged.”

Additional safety measures are in place to protect workers and the surrounding environment. Water sprayers were installed on the MANTIS equipment and at the bottom of the stack to suppress dust from the concrete. In addition, air monitoring samples are being continually taken to make sure there are no contaminants in the work area, and silt fencing was set up around the work area to prevent any contaminated water from running off the site.

All contaminated soil, debris and material is being removed and transported to approved off-site waste disposal sites. When the project is completed, a final survey of the site will be performed, and the land will be graded with clean soil. The project is expected to be completed this summer.

“Removing this stack is a significant milestone for Brookhaven National Lab’s overarching environmental restoration program that supports the health and wellbeing of our community and environment,” Peter Genzer, manager of the media and communications office at the Brookhaven National Laboratory, says.

“This project is another example of the exceptional work New York District does on a daily basis. I couldn’t be prouder of our team because they are addressing unique challenges, working closely and transparently with contractors and our partners at the Department of Energy, and ensuring safe and effective execution of the work,” Col. Matthew Luzzatto, commander of the USACE New York District, says.