Fort Casey Restoration – Whidbey Island, WA

Coastal artillery gun at Fort Casey State Park, Whidbey Island, Washington
Fort Casey Coastal Gun Battery – Whidbey Island, Washington

Project Name: The Fort Casey and Battery Moore Project

Fort Casey History

Located on Whidbey Island in Washington State, Fort Casey was one of 29 locations chosen for updated reinforcement. As a part of what was known as the “Triangle of Fire”, Fort Case, Fort Worden and Fort Flagler had to defend the entrance of the Puget Sound. Construction began in 1897 and ended in 1901 but the fort was equipped and used for training until the mid-1940’s.

In 1955, Washington State Parks acquired Fort Casey and opened it up for public use. With the help of some government funds, the fort grounds had regular maintenance but other parts of the Battery Moore section were in major need of some repairs. Most of the original concrete showed major signs of damage due to substantial corrosion of the reinforcing steel.

Finally in 2006, the Washington State Parks department made a budget of $600,000 to begin a full structural overhaul on the Battery Moore. The restoration was going to return the structure to its original glory while adding some modern elements along the way and with the use of batteries, lights and speakers it would turn the Battery into a live action example of how Fort Casey operated in the early 1900’s.

Phase 1 of the Repair

The engineering and architect team inspected and developed a scope of work for the impending repairs. After a full survey was performed, the focus was not only on repairing the existing structures but also about protecting against the brutal salt air from the Puget Sound. With all of this in mind, the design team put together a scope of work for Phase 1 that included repairs on gun emplacements 3 and 4 with gun emplacements 1 and 2 to be done in Phase 2.

During Phase 1, after the concrete preparation was completed, the repair work began with the cathodic protection on the existing square bar steel reinforcement. This was crucial to the project as the original concrete was mixed using local sand and aggregates directly from the sound. The existing concrete showed high levels of chloride so any materials used had to prevent future corrosion. All repair mortars were highly polymer modified and included integral corrosion inhibitors to protect the surrounding steel. There was also a significant amount of epoxy injections performed on many of the vertical surfaces while fiber-reinforced polymer (FRP) materials were used to strengthen the deteriorated columns.

Phase 2 of the Repair

Over the next 10 years, additional funding had to be secured to begin Phase 2, which came out to approximately $200,000 (a third of the Phase 1 budget). To repair 1 and 2 of the gun emplacements, the scope of work had to be paired down significantly. With another 10 years of deterioration to take into consideration, the focus of Phase 2 was mainly to restore the structural integrity of the Battery Moore.

When Phase 2 began, the team noted that there were areas with extreme cracking and some critical areas on the verge of collapse. While preparing the concrete, the source of existing concrete aggregate needed to be addressed. Large, rounded river rocks (some 4 inches in diameter) were used throughout the gun emplacements. In conjunction with this system, the existing concrete became extremely soft. As the crew removed the deteriorated concrete, some areas became so fragile that they would disintegrate on impact with an electric chipping hammer. No heavy equipment was used in the prep work due to the fragile structural capacity of the existing concrete. With most of the square steel reinforcement intact after sand blasting, the existing reinforcement was coated with epoxy rebar stirrups to support the repairs.

Sika® Product Solution

Both Phase I and Phase II of the Fort Casey restoration project used these Sika products:

  • SikaQuick® VOH and SikaTop® 123 for the vertical and overhead repairs
  • Sikagard® 705 L to permeate the concrete substrates using silane technology
  • Sikadur® 31 to bond concrete and seal cracks around injection ports
  • Sikadur 52 to seal concrete slabs and protect against water, chlorides and other elements that cause deterioration
  • Sikaflex® 1A to seal all vertical and horizontal joints.


Sika was honored to contribute products to help aid in the restoration of this historical landmark. Overall, the impact of both repair phases were very extensive but the contractor was able to restore the Battery Moore into a safe and education public area. People are now able to wander the grounds and begin to feel the sense of what it was like to work and live in Fort Casey during both World Wars.


Last Modified: January 27, 2019

Carlisle CCW Blindside Waterproofing White Paper

Carlisle Coatings & Waterproofing
Carlisle Coatings & Waterproofing

Construction design professionals or waterproofing contractors have the opportunity and responsibility to influence the success of a blindside waterproofing job. Blindside waterproofing or pre-applied waterproofing is a below-grade waterproofing system applied prior to the building construction. Ensuring the waterproofing manufacturer reviews the results of the subsurface investigation will help to drive success.

Geotechnical engineers or engineering geologists perform geotechnical investigations to obtain information about the physical properties of soil and rock around a building site. The investigation’s findings will help to determine foundation design, construction and verification, before concealment.

A white paper prepared by Carlisle® Coatings & Waterproofing (CCW) waterproofing experts discusses what to look for in a geotechnical report, as well as other tips for getting blindside waterproofing right.

Download Blindside Waterproofing White Paper!

Download White Paper


Last Modified: October 23, 2018

What Is Firestop, What Is Not?

Firestop Around Fire-Rated Assembly Penetrations and Pipes
Firestop Around Fire-Rated Wall Assembly Penetrations and Pipes

Over the last 33 plus years of selling firestop, I have heard firestop described in many ways. Some of these descriptions are unrepeatable, others nonsensical. This is the first in a series of articles clarifying what firestop is, its installation techniques, firestop project examples, what ‘UL® Tested Assembly’ means and basic terms used in the fire protection field.

Firestop Is Not Fireproofing

Fireproofing is typically the cementitious spray-on material you often see on the underside of steel fluted decks in multistory buildings. You might see fireproofing sprayed onto steel I-beams and structural support columns. It typically is grayish in color and has a rough texture. Other types of fireproofing can be white and look fluffy. New technologies recently have produced spray-on fireproofing in the form of intumescent paint, that expands when heated. These types of fireproofing protect steel structures by insulating them from a high temperature fire, thus preventing the steel from warping, preserving its shape and strength.

Specific Definitions for Firestop Through Penetrations and Joints

When we erect a building, there are national, state and local building codes that we need to follow. Almost all buildings have fire-rated wall and floor assemblies. These fire ratings range from 1, 2, 3 to 4 hours. That simply means that if a fire were to start on one side of the wall or floor, it will take the rated time to burn through the wall or floor assembly. Different buildings have different fire ratings, depending on their use.

Once we install these fire-rated walls and floors, we begin adding amenities like electricity, potable water, HVAC systems and cabling for telecommunications/Internet access. Adding these amenities requires us to make holes in our perfectly made, fire-rated walls and floors.

As soon as we make any size opening in a rated wall or floor, it is No Longer Fire-Rated!

Doug McNutt, Atlas Supply, Inc.

Firestop Materials Installation and Testing

This is where firestop materials enter the story. Firestops are installed around pipes, HVAC ducts, cables, etc. to bring a wall or floor back up to its original fire rating. These ‘Approved Methods’ meet the testing criteria of ASTM E814 – 13a(2017) Standard Test Method for Fire Tests of Penetration Firestop Systems. All firestop manufacturers must adhere to these criteria for testing their materials with specific penetrations, at a third-party laboratory, such as UL. A variety of sealant, devices and fasteners are used along with other materials such as Rockwool™ (also known as mineral wool or stone wool) insulation and backer rod.

The amount/depth of material or a combination of sealant/devices used depends on physical factors including:

  • Hour rating
  • Size of the opening
  • Annular space around the penetration
  • Size and type of the penetration.

Once installed in the lab, each penetration is put to the fire test. If the penetration passes, it is listed in the UL or third-party directory as an ‘Approved System’.

This is guidance architects and contractors use to specify and install the firestopping systems on their construction projects.

Construction Planning and Installation

Architects planning a new construction project have many fireproofing versus firestopping trade-offs. Contractors installing fireproofing and firestopping systems have specific questions under varying structural and environment conditions. Architects and contractors alike are welcome to consult Atlas Supply’s fire protection experts at 1-800-347-5767, whatever the phase of construction, whatever the questions might be. Call now!


Doug McNutt, Firestop Specialist

Doug McNutt, Firestop Specialist at Atlas Supply, Inc.
Doug specializes in selling 3M Fire Protection Products across the Pacific Northwest to Construction, Industrial, Building Owners, Medical Facilities and others. He attended Eastern Washington University and Antioch University Seattle.

Last Modified: July 15, 2018

Atlas Supply Expands Business, Opens New Stocking Warehouse in Mountlake Terrace, Washington

Atlas Supply, Inc. - Mountlake Terrace, WashingtonNew Location Will Serve Bellingham to North Seattle

SEATTLE, Washington, Feb. 16, 2018 — Getting the right specialty construction products when and where they are needed is the heart of Atlas Supply’s business. The company is raising the standard of customer-centric service with the opening of its new stocking warehouse in Mountlake Terrace, Washington.

Atlas Supply’s Mountlake Terrace warehouse, which opened in October 2017, is available to local architects, businesses and contractors, as well as commuters to construction projects in Seattle.

It’s a strategic investment we needed to make to better serve our customers. With the current construction climate and added traffic congestion, we want to provide options to our customers, said Jessica McIntosh, Atlas Supply Vice President, Operations.

Atlas Supply’s corporate offices are located in Seattle, Washington. The expansion northward into Mountlake Terrace greatly simplifies access for customers in Whatcom, Skagit, Snohomish and North King Counties. The new location adds to five existing warehouses in Seattle, Tacoma, Portland, Spokane and Boise.

About Atlas Supply, Inc.: Atlas Supply was founded in 1917 and is a wholesale supplier of Specialty Building Products for Construction and Industry. Atlas’ products and areas of expertise are New Construction, Remedial Projects, Glass and Glazing, Fenestration, Department of Transportation (DOT), Industrial and Aerospace. For more information about Atlas Supply, visit or the Atlas Supply, Inc. Facebook page.

Media Contact:

Jessica McIntosh
Altas Supply, Inc.
(206) 623-4697

Last Modified: March 7, 2018