Moving an antenna sounds like a relatively easy task for most people. However, when it is one of the most sophisticated radar research antennas in the world and is perched on a tower made of several tons of steel, things become complicated. Factor in a total of four antennas, no capability to move them and a tight timeline, the easy task becomes nearly impossible.
Moving four antennas and their towers fell on Rick Shaughnessy, chief of operations for the Sensors Directorate, Air Force Research Laboratory in Rome, N.Y. From the beginning, Shaughnessy knew the project would be daunting.
The Sensors Directorate consolidation, as directed by the Defense Department's 2005 Base Realignment and Closure recommendations to Congress, required the lab's sensor research to be relocated to Wright-Patterson Air Force Base, near Dayton, Ohio—specifically the surveillance facility consisting of four radar systems, the control room and calibration range. The four radar systems were an S-band, C-band, L-band and bi-static sensor array mounted on towers averaging 15,000 pounds.
Shaughnessy's first step was to secure bids from contractors, which came in ranging between $25 million to $30 million. The proposed cost to the Air Force was staggering, but Shaughnessy pressed on and began working to validate contractors' expertise in this type of project. The contractors provided resumes for engineers to supervise the highly technical removal and reinstallation of the radars, but none seemed qualified.
"One of the resumes was from an engineer for Microsoft operating systems, another was one from Honda that only worked on headlights," Shaughnessy said.
Shaughnessy quickly realized no company whom submitted bids was qualified to do the work, but he did have another available option.
"I had three tours with engineering installation squadrons in the Air Force and I knew they might have the expertise to help," Shaughnessy said.
During the spring of 2007, Shaughnessy visited the Air National Guard Bureau who was interested in the proposal. National Guard Bureau suggested he visit the 213th Engineering Installation Squadron at Stewart Air National Guard Base in Newburgh, N.Y. He presented an overview of the BRAC requirements affecting the move. During the meeting, he confirmed that this type of unit might be able do the job. He started working with Air National Guard units from around the country and confirmed they had the skills and manpower to do the work.
"There wasn't one EI unit that could do the entire job. We had to get expertise from around the country," he said.
In the end, six Air National Guard and one active-duty unit worked to complete the project. Once approved to use Air Force and Air National Guard EI units instead of contractors, the cost seemed more reasonable.
"Everyone laughed at me when I submitted the budget for an estimated $4.2 million," Shaughnessy said. "Other locations who did this type of project said it took them approximately $30 million to do the job."
Shaughnessy's concept ultimately cost the Air Force $3.6 million – 88 percent less than contractor estimates.
The 220th EIS, based in Zanesville, Ohio, was among the EI units committed to the multiyear project. Air National Guard engineering and installation units contributed resources and management teams. Those involved were the 212th from Milford, Mass., 213th from Newburgh, N.Y., 243rd from Portland, Maine, 219th from Tulsa, Okla., 211th from Fort Indiantown Gap, Pa., and the 85th the only active duty unit in the project from Keesler Air Force Base, Miss. This combination of Air National Guard and active units made it a total force effort. Shaughnessy also coordinated with local agencies for contract services to include heavy crane support and high-reach vehicles to save costs. Fabrication of specialized shipping containers and radar refurbishment by AFRL Information Directorate Fabrication Shop reduced costs also.
In spring 2010, after three years of planning, several units gathered at the Rome facility to initiate decommissioning operations. The 219th was the first to arrive and began the tedious task of removing the S-Band antenna which weighed more than 15,000 pounds. Each piece was taken down and meticulously labeled to ensure accurate reassembly. The 219th self-transported the tower back to Camp Gruber, Okla., where it will be used for training at a site that couldn't afford a new one. The antenna was refurbished and packaged at the lab for shipment to Wright-Patterson in a customized shipping container.
By the end of June 2010, the other antennas and their respective towers quickly followed the same process. Fort Indiantown Gap received the bi-static radar tower for use at the installation's Lightning Force Academy, and the antenna was prepared for installation at Springfield Air National Guard Base, Ohio. The C-band tower was shipped to Selfridge Air National Guard Base in Michigan, and the L-band tower was recycled.
Once all four radar antennas were completely decommissioned, inventoried and staged for relocation, structural assessments of all antennas were performed. Corrosion issues were mitigated on site and when the final pack-up was performed, each appeared brand new.
The antennas arrived at Wright-Patterson and the 220th began assisting with tower reconstruction. Critical to the success of the project were the Airmen's skills honed at their civilian jobs.
"A lot of the Airmen were only certified through the Air Force, and we were working on a contractor site—they recommended civilian certifications too," said Tech. Sgt. Robert Chaney of the 220th. "I had over 2,000 hours operating cranes for my civilian employer," Chaney said. With his civilian and military certifications, he was instrumental as a crane operator at Wright-Patterson. Chaney's unique skill set saved the project thousands of dollars.
The completion of work at Wright-Patterson in 2010 set the stage for completing the entire project during late spring 2011. Through the winter of 2010-2011, Springfield Air National Guard Base prepared for the construction of the last tower, which would receive the bi-static antenna. Once the concrete foundation for the tower was poured, the engineer units sent personnel to begin construction.
"The tower manufacturer did the foundation, and the EIS guys provided the labor, knowledge, expertise and experience to build the structure," said Staff Sgt. Keith Anderson from the 243rd, a team chief for the Springfield portion of the project. "This is what we would do in war, so this project is a training opportunity too."
Throughout the project, the Airmen were evaluated to receive annual certifications in hand tools, cabling, fiber optics and tower climbing. Rather than units holding specific training events or sending Airmen to schools, they were able to simultaneously use the project to meet training requirements.
As the project concluded, the original contractor estimates of $25 -30 million would not have covered all costs. The highly complex project saw several unforeseen tasks arise, but the EI units accomplished anything that came up and, at times, improved outcomes. EI units replaced rodent damaged cabling, and erected the three towers at Wright-Patterson higher than the original ones in Rome.
Upon completion, the Air Force benefited from an estimated 88 percent cost savings, and a more efficient product. The ANG and Air Force EI squadrons contribution limited the projects entire costs to approximately $3.6 million instead of the original estimates of up to $30 million for installation material, rental equipment and transportation. The end result: BRAC 2005 requirements met, four radar systems relocated with improved system performance and estimated cost savings of up to $26.4 million. In the end the best outcome of all was the pride in a job well done by all participating units. |
