The suburban neighborhood of Port Orchard, Washington is known for its dense, wooded surroundings full of natural beauty. Sitting up in the Pacific Northwest, it has been the home for human residents and a variety of wildlife. Residents of the area began to express concern about cellular connection in the area and the potential eyesore of a traditional tower. The solution? A 150-foot “monopine” - a cleverly designed structure that mimics a tall pine tree, native to this area of North America.

By June of 2024, a new communications tower was designed to provide critical cellular infrastructure while preserving the area’s natural beauty. While considering the best method of coating protection for the project, hot-dip galvanizing began to check all the boxes that the team was looking for: Long-term durability, aesthetics, corrosion performance, life-cycle costs and sustainability. No other coating protection was able to meet the demands of this towering structure compared to galvanizing.

On top of choosing galvanizing, the team also invested in a duplex coating system, which involved applying a paint coating over the galvanized steel that would more than double its expected 100-year lifespan. This beautiful combination of galvanizing and a painted topcoat not only achieved a natural, tree-like appearance, but also provided a level of weather resilience in the wet marine climate. Paint or epoxy solutions alone would have required frequent touch-ups and upkeep over the lifespan of the project to keep the tower in a safe, useable condition; galvanizing with a duplex façade minimized maintenance costs as well as disruptions to both flora and fauna.

The galvanizer chosen for the project worked alongside the contractor to ensure a seamless process from start to finish. This required frequent communication and the ability to adapt quickly to any changes along the way. The challenges in galvanizing this unique structure were considerable. There were multiple anchor points and attachments to embody the “branches” and “needles.” Careful attention to vent and drain hole placement was paramount in this project to ensure a quality finish. Each step of the galvanizing process (hanging, pre-processing, dipping, and cleanup) had to be meticulously planned and executed by the galvanizer to assure a finish that would provide excellent corrosion protection, meet all functional requirements, and provide a beautiful structure.

Standing tall as an example of how essential infrastructure can be designed to serve modern needs while respecting the natural aesthetics of the environment, the Monopine Communications Tower blends seamlessly into its environment and provides critical communication support to the area. For future generations, with a life-expectancy of more than 100 years, this project will continue to impact the people of Port Orchard by representing innovative design and thoughtful technology.