Coastal Insulation Corp. Helps Restore Historic Building For Battery Park Pier A Project

New York, NY – December 28, 2012 – After sitting empty and exposed to the elements for more than a decade, a 126-year-old landmark building on New York City's Battery Park Pier A is undergoing a $10 million restoration and renovation project. The rotting landmark is located on the oldest surviving pier in New York City and was in desperate need of new roofing, siding, gutters and insulation. Coastal Insulation Corporation was called in to insulate the building with spray foam.

The historic building was originally headquarters for the New York Harbor Police before later serving as the FDNY fireboat station. It had suffered significant water damage, rot, and structural deterioration. In an attempt to preserve the pier, The Battery Park City Authority took it over from the city in 2008.

The goal of the restoration project was to create a first-class public destination for the pier. Plans included public amenities such as a visitor's center, over 30,000 sq. ft. of public plaza space, and a 12,500 sq. ft. public promenade. Lease agreements have been approved for an outdoor oyster bar restaurant, coffee shop, fine dining restaurant and two event and entertainment venues.

Coastal was the chosen contractor for the insulation job because they had the experience, most notably with LEED, and the resources to take on a high-profile job of this magnitude.

"Spray foam was one of those elements specified and particularly chosen due to the value it adds to overall structural integrity," said John Achille, Vice President of Coastal Insulation.

When they arrived at the project site, Coastal discovered the pier was just wide enough for their truck to fit alongside the building, but that it could not withstand the truck's weight. Therefore, crewmembers had to run a spray hose from nearby Battery Park across the water and into the building in order to spray. "The hose was suspended over the water," said Achille. "We threw a rope and pulled it over about 20 ft."

The project originally called for 3 inches of Demilec Heatlok Soy 200 to be applied in the bays, and 3.5 inches of it to be applied to the underside of the sloped ceiling. Coastal installed the initial application of foam, but the design changed when a new architect attached to the project specified that a vapor barrier coating would need to be applied to the existing foam and then topped with an additional layer of foam. Another contracting compny applied the vapor barrier coating, after which Coastal sprayed an additional 2 inches of Henry Permax 2.0 2 lb. closed-cell spray foam. The Permax foam was specified due to its compliance with the coating. The resulting application encased the studs and made the walls monolithic. 

Crewmembers used a Graco E-30 Reactor for this project and both scaffolding and lifts were employed. Although other tradesmen were at the site at the time, they were not present during the application process.

Three Coastal crewmembers worked on the job, which began in December of 2010 and was completed by September of 2012. The total spray area was 36,000 sq. ft.

Not long after the project was finished, the benefits of the spray foam application became evident. The building withstood the storm surge from Hurricane Sandy, which likely would have overcome the former structure.

"Spray foam definitely had its place in contributing to the overall positive result of this project," said Achille. "Most notably, of course, was its contribution in structural integrity. When Hurricane Sandy hit, I think it's pretty safe to say that spray foam lent its own hand in aiding this historic building to survive that storm."

About Coastal Insulation Corp.: Established in 1975 with only two employees, East Windsor-based Coastal Insulation Corporation is now one of the largest independent insulation contractors in the country. The organization serves the Northeastern U.S., currently spanning eight states and growing and works with clients in both the public and private sectors, counting several national new construction and commercial builders among their devoted clientele. For more information about Coastal Insulation Corp., please use the contact details and links provided below.