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Brownsville, Texas: Where old ships go to die
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 Posted: Wed Jul 25th, 2012 03:53 pm
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Bob Of Burleson
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When The Ship Comes In
To Brownsville, Rip it Up


by Wade Goodwyn
NPR.org


The ship recycling company Bay Bridge Texas recently moved to Brownsville, Tex., the center of the U.S. ship-breaking industry. Bay Bridge's scrapped metal is shipped to Mexico, where it is transformed into automobile parts.

This fall, the U.S. Navy will contract three Cold War-era aircraft carriers — the USS Forrestal, the USS Independence and the USS Constellation — for scrapping. Often called "supercarriers" due to their massive size, each ship contains nearly 60,000 tons of steel and other metal.

All three carriers will be sent to Bay Bridge Texas, LLC, a ship recycling firm near Brownsville, Texas, to be ripped apart.

Tearing up big ships can be a very lucrative business. It's also a messy one. Walk inside a ship that's being scrapped, and you'll find one of the nastiest places imaginable: filthy and rusty, with everything that's poisonous and salvageable torn out.

If it's rained, everything's all wet, too. Brush up against a bulkhead and you can kiss a white shirt goodbye.

But if you're a ship cutter, this is your office, and your cutting torch, your music to work by. Sixty welders are employed here at Bay Bridge Texas so far, but even more will be hired soon.

Bay Bridge Texas is the nation's newest ship recycling yard, says senior vice president Barry Chambers. The company, backed by Indian investors with deep pockets, just moved from to Brownsville from Chesapeake, Va.

The deepwater Port of Brownsville lies inland at the end of a 17-mile channel connecting to the Gulf of Mexico. The long channel provides unparalleled protection from hurricanes and tropical storms.

In the last two decades, this landlocked city has become the center of the U.S. ship recycling industry. Five of the nation's eight recycling companies are here. It's like Home Depot locating right next to Lowe's and Ace Hardware.

Chambers says the infrastructure, the deep water channel and the weather all make the Texas city particularly attractive for his company. But building the yard, he says, still required plenty of work.

"This land did not look like this," Chambers says. "I put in 175,000 cubic yards of fill, leveled and compacted it."

Now, the yard's piers are built to handle ships as large as air craft carriers. The pilings, made of steel cores, sink 60-feet deep.

From a distance, the tanker ship at the dock looks as though giant Post-It notes have been slapped onto the hull. But those squares are actually holes; the ship's been turned into Swiss cheese for ventilation and light.

Sergio Cazeres, who's been cutting ships since 1992, says the first cuts are made in the side of the ship. "In the hulls, we make cuts so the air can flow in," he says. "If it's too hot then we provide fans."

Recycled ships are typically scrapped from the top down and from front to back. As the steel is harvested, the bow lightens, and powerful winches begin to pull the ship out of the water and up a ramp.

Large white air bags, supporting 250 tons of weight, are rolled underneath.

Chambers says he moved Bay Bridge Texas from Virginia to Texas not just for the warm weather, but also for the labor pool. He pays between 10 and 13 dollars an hour for the recycling work.

"The Hispanic workforce that I found here is excellent," Chambers says. "It's attitude more than anything. Every day here is different. This is not an assembly line job, and everyday you have to use your wits."

In a nation hungry for working-class jobs, ship recycling is helping to drive Brownsville's economy — even at these relatively low wages. Nearly 1,000 welders scrap 80 percent of the ships recycled in the U.S.

After a ship is dismantled, the metal is shipped to Mexico. Chambers used to send much of his steel to the city of Monterrey in railroad cars — 20 boxcars per train, loaded with 60 tons of steel in each.

But that steel had a market value of 10 to 15 cents per pound. And eventually, the boxcars began showing up in Mexico empty.

Chambers has no idea how the bandits were doing it. "It's unbelievable," he says.

It was no small feat to rip the steel out, Chambers says. "We've even tried welding the steel in there. Then we tried welding bars across the top of it, but it still disappeared."

So now, the steel goes by barge, and the shipments arrive intact. A few months later, they come back into the U.S. as automobile frames, engines and parts to be assembled here.

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 Posted: Wed Jul 25th, 2012 09:33 pm
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redlt1
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Thanks for the post......my first ship,,,,,USS Independence CVA 62.

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 Posted: Thu Jul 26th, 2012 12:12 am
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Gopher
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Sad end for some mighty warriors.:frown:

Last edited on Thu Jul 26th, 2012 12:12 am by Gopher



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 Posted: Thu Jul 26th, 2012 01:07 am
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BigTex
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Alumni from each of those ships have no doubt looked into preserving them as museums, but it's an expensive process requiring private funds and you have to find a city willing to provide the pier space.



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