Bierlein Companies Demolishes
Powerhouse and 500 Foot Smoke Stack
Port Washington, Wisconsin

The Bierlein Companies, a nationwide demolition and environmental contractor, recently completed demolition activities at the Port Washington Generating Station located at the historic fishing harbor in Port Washington, Wisconsin. The coal-fired power plant, commissioned in 1935, was once the most efficient generating station in the world. The five coal-fired boilers are in the process of being replaced with two 545 MW gas-fired units. PWGS is an intermediate load plant, supplying electricity during periods of heavy demand. The rebuilt plant will provide the State of Wisconsin with new capacity to meet growing demand for power in the northern Milwaukee area.

Bierlein Companies was contracted in August of 2004 to perform the demolition, asbestos and lead abatement, as well as site remediation to the existing power plant. Bierlein responsibilities included demolishing three large remaining boilers and associated turbines, cleaning up the coal handling areas and abating and removing a 500-foot smoke stack. 

Historical preservation was one of the mandatory requirements of WE Energies on this high-profile project. The historical significance of the 1930’s architectural style needed to be maintained since the Port Washington Generating Station is the first site that greets pleasure boaters and fishermen as they enter the harbor. The northern and western portions of the 70-year-old facade of the station were left intact and untouched. The interior portions of the facility, including the 160’ high boilers, turbines and precipitators were carved out with surgical precision. Once all construction activities are completed in 2008, the powerhouse will appear nearly identical to the way it looked upon its original completion in 1935.

The demolition of the 500 foot smoke stack was another challenging aspect of the project. Since the stack was within 50’ of new construction activities, the use of explosives was not an option. The stack was dismantled by hand, first by removing the 3,000-ton inner liner – one brick at a time. Once the inner liner was complete, the solid concrete outer shell was broken into pieces utilizing hand-operated jackhammers. All materials were dropped into the interior of the stack and removed on a daily basis through an access cut into the base. In all, over 8,000 tons of brick and concrete was handled during the stack demolition.

Environmental stewardship was another prerequisite of WE Energies on the Port Washington Generating Station project. Extensive pre-cleaning, material segregation and tedious attention to detail were performed throughout the project to insure that a minimum of the demolition materials generated was sent to landfills. Upon completion of the project 22,000 tons of structural steel, 3,000 tons of specialty metals and 12,000 tons of concrete were processed and recycled. The remainder, which comprised less than 10% of the demolition materials, was land filled – a record for waste minimization on a Bierlein powerhouse project.

After the complete removal and excavation of the foundations the power company will rebuild another 545-MW, natural gas unit, which is expected to be operational in 2008. Bierlein will recycle a 100% of the materials hauled off site and wrap up the project with an on-time completion date.