The Brooklyn Navy Yard is an historic site that is a central part of New York's long and colorful history. The Navy Yard dates back to 1625 and has built and hosted some of the most famous and infamous ships in our nation's history (USS Monitor 1857. USS Main 1895. USS Arizona 1915, USS Missouri 1944)
The building chosen to house the museum was building 92. It is considered by some to be the most important building on the site, as it will be the bridge from the old Navy Yard to the new 21st Century industrial park.
The new building is a modular structure annexed to one of the original brick structures. The architect's design made the modern modular feel as permanent and strong as the original building. To achieve this look and feel, they chose a polished micro-topping as their flooring solution. The topping has few score lines, giving the slab a sense of strength and permanence. The building incorporated modern architecture with the look, feel, and strength of the old brick and motor structures.
The pour and polish team had to overcome many challenges along the way. Precast concrete slabs were spec’d and transported to the site. During transportation, the slabs developed microscopic cracks throughout that could not be seen with the naked eye. These cracks appeared during the prep process. Everyone's first instinct was to blame the polishing crew’s heavy machines. The flooring team had to prove that it was not the weight of the grinders. With the help of a structural engineer, they were able to expose microscopic crack in the slabs that had not yet had grinders on them.
The knowledge and expertise of the TRU representatives was invaluable Kenny Vallens & Joe Zingale from TRU gave Matt Johnson and Patrick Mahoney the information they needed to keep the cracks from telegraphing on to the pour. The cracks were also injected with Roadwear 10 min mender and an epoxy primer with a washed sand broadcast was used to ensure maximum bond. Each floor was poured using a batch pump and screened from batch mixer to pump to ensure minimum powder spots and pitting.
TRU's quick set and cure time allowed for grinding process to begin the next day.
The topping was brought up to an 800-grit finish before stain guard was applied. Some saw cuts were installed to minimize cracking.
The client wanted a natural look which was achieved by leaving the TRU its natural color. In the end, the clients were very happy with the finished project. They said it was the look and feel they were wanted to achieve.