Unifying Jack System In Place
June 2, 1999
Cheryl Roberts
UPDATE
HATTERAS ISLAND, NC

The system of steel that supports the Cape Hatteras Lighthouse is nearing completion. It consists of layers of steel including three-foot high, yellow "strongback" beams that give rigidity to the lower portion of the tower, fourteen crossbeams, and seven duplex, wide-flange steel main beams with 100 hydraulic jacks.

Photos courtesy Bruce Roberts

The red control panel that will regulate the 100 hydraulic jacks is shown above.

In this image, Pete Friezen, conceptual designer of the unified (or unifying) jack system, explains to the media how the system will work. This system will lift the tower, keep it on a level plane while en route to the relocation site, and finally, lower the tower onto its new foundation 2,900 feet to the southwest. The new location positions the tower 1,600 feet from the Atlantic Ocean.

The unified jack system consists of sixty jacks that are individually pressurized along with forty "helper" jacks, all working on simple hydraulics (displacement of oil).

Over the next two weeks, the lighthouse will be lifted about five feet so the transport system can be installed. Gauges on the red control panel monitor pressure of all the jacks. When the correct pressure is reached in the hydraulic system's jacks, according to the pounds per square inch exerted on each jack, and all jacks have been locked off, the unified jack system valve is opened, and the lift of the tower will begin.

Each lift is done slowly, about one foot at a time, with all areas of the tower being lifted simultaneously. Movers then begin placing blocks of oak cribbing to support the area between the steel beam mat (ground level) and the base of the tower. Once all areas are supported, the next lift is executed. This is predicted to take about one week.

The tower is being lifted so the transport system can be inserted. Support is stepped out of the excavation around the lighthouse to meet the height of the transport system.

As a roll beam is installed under each main beam, encased Hilman rollers are placed under the jacks' postions. Hydraulic "push jacks" on the east side of the tower push on the main beams, causing the tower to slide on the sets of rollers about five feet per push (length of the push jacks' arms). The tower will glide along the main beams with the hydraulic jacks set in three-zone pressure, based upon the geometric principle that three points define a plane. If necessary, pressure in some jacks may be adjusted while the tower is moving to absorb the effects of any bumps along the way. The move corridor has been specially prepared for the gravel and steel mat upon which the transport system is laid to provide a smooth glide path to the new location.

The move is going well. The tower is predicted to begin its glide around June 20 and will take approximately six weeks to reach the relocation site.

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Feb 1, 1999
Staff Report

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Tower Prepared for Lift
May 20, 1999
Cheryl Roberts
UPDATE
HATTERAS ISLAND, NC

Photos courtesy Bruce Roberts

How the move will take place is really becoming apparent now. Main beams are being put in place with their hydraulic jacks. As the cross bracing is removed from the orange shoring towers, the seven main beams are threaded in between. These beams with their jacks will lift the lighthouse to allow roll beams to be put in place. Once the roll beams are in place, the slide will begin. Push jacks will push uniformly against the main beams from behind the lighthouse to move it to its new location and safety.

Lifting the tower takes 2-3 weeks. The most recent date for the slide to begin is the third week of June. The move process is not far behind schedule; most importantly, the process has progressed well and safely.

Both keepers quarters are on their new foundations and the recently poured lighthouse foundation awaits the tower at the relocation site.

Last Granite Moved
May 10, 1999
Cheryl Roberts
UPDATE
HATTERAS ISLAND, NC

On Wednesday May 5, 1999 at 12:46 PM, the last granite was removed from the Cape Hatteras foundation. The lighthouse now stands free of its rock foundation and rests on shoring towers; main beams with hydraulic jacks are being installed that will lift the tower. After lift, the roll beams, part of the transport system, will be installed. The lighthouse will slide on these roll beams to the new foundation. See May 4th Update for photos of the new foundation.

Photos courtesy National Park Service

This is the last of the 36 face stones of the granite plinth to be removed. (plinths 2-5 will move with the lighthouse)

Photos courtesy National Park Service

Removing this last granite leaves the lighthouse base free of its original foundation; work will proceed to install the lift system and then the transport system. Movers report work is proceeding well but they do each step with utmost concern for accuracy.

Updated Schedule of Events
UPDATE
May 4, 1999
Cheryl Roberts

The new lighthouse site is an area of 3.1 acres surrounded by natural growth. The light of the lighthouse will gain an advantage at a new height to put the beacon out across Diamond Shoals. A Notice to Mariners for light-out was issued for March 1st.

May until early June: installation of the main beams with hydraulic jacks that will lift the tower. The next step will be to install the roll beams upon which the tower will move.

Around mid-June (could be a lttle earlier or a little later) the slide should begin. It can take up to six weeks, moving about 50 feet per day. This is now predicted to last until mid-August.

August until mid-September the tower will arrive at the new foundation, be lowered onto the concrete pad, all steel removed, and concrete infill to complete its new foundation will be done.

Phase 2 will begin and work on details including parking, utilities and such begins.

Memorial Day 2000 reopening is planned. Nothing specific has been announced, but a ceremony will likely be in order.