Northrop Grumman, Blueberry Hill

Job Facts
Tons of steel: 41 tons
Owner: Northrop Grumman
Architect/Engineer: Morris & Richie Associates
Contractor: Henry H. Lewis & Sons
Project Manager: Glenn Tingle
Subcontractor: B&B Welding Company, Inc.
Erector: B&B Welding Company

At Northrop Grumman’s Linthicum headquarters, under the cloak of secrecy, the company tests some of its latest radar systems on a small peak dubbed Blueberry Hill. There, Grumman scientists beam radar waves from trailers anchored onto a two-level open-air steel platform. With a bird’s eye view, the scientists monitor and record data on the latest detection technology protecting our homeland.

At B&B, we’re proud to have played a major role getting those scientists perched high atop Blueberry Hill.

After winning a competitive bid, Grumman hired B&B to fabricate the steel and to help erect a two level platform on the site. The job included the additional fabrication of handrail, stairs, and a canopy. Each level contained walking surfaces with 1 ¼” serrated, bar grating. The framework consists of wide flange steel supports on each end like goal posts. Each platform is undergirded with I-beams and vertical and horizontal bracing, to provide lateral bracing for added strength. An open air structure, the two levels of framing house 10ft by 40ft trailers mated side by side, creating an elevated work area for the scientists to run their tests. The top platform contains two trailers with 20 by 40 feet of workspace. The bottom platform houses three trailers with 30 by 40 feet of workspace.

The architectural plans were clear: build the platforms first; then install the trailers second. During the early stages of the erection, however, our B&B field team — shaking their heads in sheer disbelief — realized the architectural plans were clearly wrongheaded. “Once the platform handrails and steps were in place,” says Dennis, “It would be a monumental task to install the trailers without dismantling some of the steel.”

At first, the Northrop Grumman project manager brushed aside the warnings, saying, “Ah let the riggers figure it out.” But after a quick walkthrough, he readily conceded the point. We could change things now at a small price, or the job would turn into a snafu of grand proportion.

So once again, the B&B team brainstormed on the fly. We took a look at the 3-D model and determined the most cost effective and timely remedy. Our solution: take out a small portion of the top level steel; set the trailers in the lower level; re-erect the top level, and lastly install the top trailer before erecting the canopy. Additionally, we coordinated the schedule and material delivery as well and brought in an extra crane and truck to do the job properly.

Never was a change order more quickly approved.

“Had we put in all the steel as planned, the trailer installation would have cost much, much more than our change order.” Dennis says, “I mean, they would have just had a rascal of a time putting in those trailers.”

With some quick thinking, a crisis was averted. And just as quick, another arose. After the trailer installation, our field guys — once again shaking their heads in disbelief — discovered that the trailers contained egress doors, which, hundreds of feet up, opened onto an area that did not have grating. A Grumman radar technician who opened the personnel door would have been in grave danger of finding their thrill on Blueberry Hill.

So, we went back to our model and designed new grating and handrail to safely protect the scientists from falling off the platform. “Our model gave us the ability to cost effectively and expeditiously make the change for them,” says Dennis.

The design glitches weren’t all for naught, though. By looking at the 3-D model, Dennis was able to provide for future expansion to Grumman’s radar testing stations. “We were able to provide for the future connections of the next bay over,” he says. “The 3-D model let us provide for future construction — whenever that may be.”

In the end, problem solving saved the day. B&B not only safely erected a platform for Northrop Grumman’s top scientists, but we’d like to think that in our own humble way, our work here helps keep the homeland safer as well.