Pennsylvania Station – Moynihan Train Hall
Project Description
Property History
The Moynihan Train Hall expands the nation’s busiest train station, Pennsylvania Station, New York across 8th Avenue into the historic James A. Farley Post Office Building, part of a mixed-use redevelopment of the entire block. The imposing century-old Post Office Building was designed by the same architecture firm, McKim, Mead, and White, as the original, iconic Pennsylvania Station. The Moynihan Train Hall will offer enhanced passenger facilities for Amtrak’s Northeast Corridor (NEC) and long distance travelers, including accessibility for passengers with disabilities, all within a grand Train Hall featuring a sky lit atrium approximately the size of the Grand Central Terminal’s Main Hall.
Project Scope
Grand Light was brought in to restore the large exterior lanterns located on the facade of the historic post office.
Extensive repairs were required including replication and replacement of all steel structural mounting components. Of the fixtures’ existing bolts, 70% required complete replacement, retapping, and adjustment to ensure stability and longevity. Bent components, scrolls, and spikes were straightened while new door latches were fabricated to replace those missing.
Each lantern was partially disassembled and soda and/or walnut blasted to remove excessive corrosion, dirt, and tarnish. From there, Grand Light artisans worked tirelessly to enhance the existing verdigris finish with our beautiful, custom patina “Liberty” finish, inspired by the distinguished color of one of our nations most famous monuments. Applying the custom hot patina finish involved heating up the fixture’s bronze surfaces before applying the patina solution. The heated metal initiates a chemical reaction when it interacts with the patina, yielding the desired “Liberty” green coloration. The applied patina is then meticulously hand burnished to accentuate the component detailing and aesthetic elements. Multiple application coats of UV resistant protective coating of lacquer were applied to seal and protect the newly restored surfaces.
The existing Flemish glass diffusers were retained through ultrasonic and hand-cleaning when possible, and any missing or broken panels were replaced with similar-in-kind replicas. The fixtures’ electrical components were all fully replaced and rewired with UL listed components and tested in accordance with UL 1598 standards.
Once restored, our artisans returned to Penn Station’s Moynihan Train Hall to hand deliver the lanterns and assist with their reinstallation.
Services Performed
On-Site Disassembly, Assembly, & Testing
Our restoration artisans are trained to safely remove and disassemble fixtures and components, labeling and photographing fixture components in sequence of its removal and as a section. Work areas are left in the same condition it was found prior to leaving the site.
For documentation our technicians inspect and note any electrical deficiencies on every lighting fixture prior to any electrical component replacement and rewiring, to ensure the fixtures can be wired in accordance with UL listed products, UL standard 1598 and hi-pot tested, with UL label (LED retrofit kits utilize manufacturers listing).
On-Site Packing, Crating, & Transportation
Grand Light frequently transports lighting fixtures using our own box trucks, flatbeds, and custom-built trailers that are designed specifically for safe transport. Our team packs all components with custom-built crates catered to each fixture in our factory. Each crate is packed and properly labeled with all necessary information per fixture type, including loose components, damages/deficiencies, and proper component placement/alignment.
Lighting Design & Engineering
Our process begins with reviewing existing documentation including sketches, architectural drawings, historical photographs, and an on-site inspection to gather the full scope of the project requirements. From there, Grand Light will develop a detailed proposal. As required Grand Light conducts research to assure the historical accuracy of all historic projects.
The creation of Custom Drawings, Modeling, Simulation, and Rendering is an important part of the process when it comes to the production of custom lighting. Whether it be a replication or modification of an existing lighting fixture, the client’s design, or a creation by Grand Light’s engineering team, our designs will serve as the blue print for our production process.
Our designs and subsequent mock-ups address the smallest of detail, allowing our clients to fully visualize the fixture before it goes into production, which reduces the possibility of error, and allows Grand Light to fulfill its commitment of delivering high quality lighting fixtures on schedule.
Material Fabrication
Grand Light has created custom lighting fixtures of every style and for every application. Our team of professional metal workers excel in Forming, Forging, Spinning, Stamping, and Hydroforming various materials such as Steel, Aluminum, Stainless Steel, Brass, Bronze, and Copper.
Grand Light’s production process in machining and manufacturing custom lighting fixtures and components in both large and small quantities; from minor components to the complete fabrication of full sized lanterns or other custom lighting fixtures, our artisans can accommodate any client specification or deadline.
With our automated lathes, stamping, and welding equipment aid in our ability to craft metal components to project specification with unparalleled design, quality, and durability. Our custom lighting team stands confidently behind their work with years of experience and dedication to quality craftsmanship.
Glass Cleaning & Fabrication
Grand Light’s Crystal, Glass, & Acrylic Studio specializes in the cleaning, repair, fitting, custom fabrication, replacement and replication of crystal, glass, and acrylic components of varying types, sizes, and color.
Our extensive cleaning solutions include hand cleaning, abrasive, micro-abrasive, and ultrasonic cleaning technology. Our artisans utilize a proprietary cleaning solution before each component is rinsed and hand polished. We have extensive experience pinning and stringing crystal components on historic and custom lighting fixtures. Utilizing time proven techniques, our artisans install pinning wire, clips, and connecting rings on crystal components in a wide variety of sizes, shapes, and designs.
Our specialists will identify and research any missing crystal or glass component on a historic lighting fixture and offer up a similar or exact grade, size, tint, color, and shape to maintain a fixtures historical integrity.
Grand Light offers a wide variety of custom, high quality architectural glass and acrylic diffusers, available in an array of styles, types, and sizes. Our high quality architectural diffusers are available by custom order and offer unique, one-of-a-kind pieces or replications of an existing design.
Cleaning Systems
Grand Light specializes in commercial luminaire cleaning services, including the utilization of state-of-the-art Ultrasonic, Micro-Abrasive, and Hydrosonic Molecular Impact System (HSMI) Cleaning Technologies. Using our engineered cleaning systems, our artisans are able to eliminate decades of accumulated debris from any lighting fixture or surface.
Grand Light’s Industrial Ultrasonic Cleaning Tanks provide high-frequency sound waves transmitted through liquid to scrub clean the surface of immersed parts. The high-frequency sound waves, typically 40 kHz, agitate the liquid solution of water or solvent, and cause the cavitation of solution molecules.
Our Micro-Abrasive process utilizes fine abrasive media to generate an accurate, precise, and controllable abrasive jet to target and remove material (on the micron level). Our system is so precise it can remove ink from a business card without damaging the card’s surface.
HSMI is Grand Light’s unique, proprietary system includes powerful continuous super high steam production up to 369 degrees Fahrenheit with an integrated wet vacuum system insuring residual moisture and debris extraction. Purified dry vapor steam and integrated vacuum system guarantees spot free crystals and fixture frames.
Finish Application & Top Coatings
As a part of the restoration process, our artisans explore the intricate details of preserving the historical integrity of lighting fixtures including color matching and sheen of the original finish. Custom lighting finishes are available in custom painted colors, sheen, and textures as well as custom patina colors on bronze, copper, and brass components.
Our artisans can match any color or finish utilizing a variety of processes involving Powder Coat, Spray, Hot or Cold Patina Custom Recipes and Color Blending an existing finish.
Grand Light exercises meticulous techniques that are unparalleled in the application of Protective Top Coatings including binders, rust, and UV resistant protective metal oils, waxes, and lacquers with various customized sheens and tints.
NRTL Testing & Listing
Utilizing only UL listed products, Grand Light’s OSHA NRTL Certified Manufacturer’s Testing and Listing Laboratory strives to ensure only the highest quality of standards go into finalizing each lighting fixture; from the rewiring of luminaires, to the installation of modern lamp technology, and the custom conversion of gas powered fixtures to electric.
Grand Light’s technicians inspect and document any electrical deficiencies on every lighting fixture prior to any electrical component replacement and rewiring. We also offer comprehensive retrofit kits for upgrading existing historic luminaire to take full advantage of modern induction lamping technology. Grand Light’s practice is to perform multiple UL tests on all electrical components and systems to ensure compliance with UL Standards for luminaires.
Featured Products
Media
Project Updates
A “Monumental” Install – Historic Moynihan Lanterns Return Home
Grand Light restored and delivered large exterior lanterns located on the historic James A. Farley Post Office Building for the Pennsylvania Station Moynihan Train Hall redevelopment and renovation project.
Custom “Liberty” Finish Reinvigorates Moynihan Train Hall Lanterns
Grand Light is restoring the large exterior lanterns located on the historic James A. Farley Post Office Building for the Pennsylvania Station Moynihan Train Hall redevelopment and renovation project.
Preserving A Landmark – The Penn Station Project
Grand Light recently removed and transported numerous historic exterior lighting fixtures from the Moynihan Train Hall restoration project which project which expands the nation’s busiest train station, Pennsylvania Station, New York across 8th Avenue into the historic James A. Farley Post Office Building
Project Case Study
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