2025-04-08T14:06:33Z

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The immense structure of a cooling tower becomes almost surreal when it stands next to you, casting a shadow over the landscape. This was my first thought as I approached Satsop Business Park, located about an hour and a half from Seattle. Known as the site of the Washington Nuclear Projects 3 and 5 (WNP-3 and WNP-5), these towering concrete relics were originally intended for nuclear energy production but now serve a unique purpose as an advanced acoustics testing facility.I made my visit on a drizzly March day, eager to meet Ron Sauro, the owner and operator of NWAA Labs, a company specializing in sound testing. Over the years, their lab has assessed everything from sound-dampening materials to the noise levels of household appliances, including washing machines, and even the crew cabin of an airplane. When manufacturers need precise measurements of how much sound their products emit, they turn to Ron for expertise. Upon arriving, I noticed a sign warning that entering the premises was at my own risk, a reminder of the site's complex history and the unfinished structures surrounding it.The auxiliary building meant to house WNP-3's reactor is now a bustling hub for acoustics testing. The background of this site is quite telling; the Washington Public Power Supply System, or WPPSS, which sounds alarmingly like “whoops,” began construction on WNP-3 and WNP-5 in 1977. Unfortunately, the projects faced severe budget overruns, and the infamous Three Mile Island accident in 1979 dampened enthusiasm for nuclear energy nationwide. By 1982, construction on both plants was halted, even though WNP-3 was nearing completion.In the following decade, WPPSS sought potential buyers in vain, as no one wanted to invest in a defunct nuclear facility. Ultimately, the land and buildings were acquired by the Port of Grays Harbor, which now manages Satsop Business Park. Over the years, this unique complex has hosted a variety of enterprises, including film productions, a now-closed Overstock.com call center, and even thousands of Volkswagen vehicles recalled due to an emissions scandal.Today, much of the office space remains largely vacant, and it seems the anticipated business boom has yet to materialize. Nonetheless, Ron Sauro and his wife Bonnie saw potential in the remnants of the nuclear plant and opened NWAA Labs in 2010, after persuading the management that they could establish their acoustics lab in just five months as a proof of concept. Fast forward fifteen years, and their operations thrive within the one-of-a-kind setting at Satsop.Acoustic testing is a meticulous process that necessitates a controlled environment. Organizations such as the American National Standards Institute (ANSI) and the International Organization for Standardization (ISO) set forth stringent guidelines for conducting various acoustic tests, specifying everything from the allowed ambient noise levels to the precise instruments needed for testing. The integrity of these tests relies on maintaining consistency across different laboratories. Therefore, if Sauro tests a soundproof material in his lab, similar results should emerge from other accredited facilities, providing clients with reliable data that informs their design choices and ensures compliance with noise regulations.As I followed Sauro through the expansive building, he drew attention to the massive exterior walls, which are five feet thick and reinforced with robust rebar. We meandered along a path marked in yellow, carefully avoiding the dark, padlocked entrance to the reactor housing. A sudden rustling sound startled me, and I noticed a large bird nestled in a crevice above the door. It was a stark reminder of how nature has begun to reclaim this once-bustling industrial site. During our tour, Sauro recounted a tragic incident involving a careless visitor who fell 500 feet down an unfinished elevator shaft, emphasizing the need to tread carefully in this labyrinth of unfinished structures. I remained vigilant, ensuring I stayed within the safety markers as we approached the building's operational elevator.Sauro's journey to this point began with his search for an ideal location for his acoustics lab after relocating to Washington from California. Initially, he and Bonnie considered constructing their facility into a hillside quarry, but upon learning that the former nuclear power plant was being redeveloped into a business park, they turned their attention to the reactor building. As Sauro aptly put it, “If you can’t find a mountain, you make a mountain,” and that’s precisely what he did by transforming WNP-3 into a sound testing sanctuary.Acoustic testing, as I discovered, is part science and part artistry. “You have to be better than the thing you’re testing,” Sauro explained, emphasizing the importance of creating an environment free from external noise interference. The remote location of Satsop provides an added advantage, as it is relatively isolated from urban disturbances. Furthermore, the thick concrete walls of the facility absorb sound and contribute to the lab's soundproofing capabilities.Temperature and humidity control also play a crucial role in acoustics research, as they impact sound behavior. Within the reactor building, Sauro maintains a consistent temperature of around 54 degrees Fahrenheit, a setup that would have cost millions to replicate elsewhere. With these natural advantages, the lab is well-equipped for rigorous testing.We ascended to the second floor, which once housed the control room, where the couple has ingeniously converted two adjoining rooms into reverberation chambers. The unique design features a 12-by-10-foot opening between the two, allowing them to evaluate materials for soundproofing and transmission loss. Sound is generated in one chamber, and measurements are taken in the adjacent space to determine how much sound is absorbed or transmitted. The receive room is designed as a floating structure, with its ceiling suspended by springs, and its floor and walls separated from the rest of the building. Sauro claims this room is the quietest non-anechoic chamber in the world, stating that even a simple breath can raise sound levels significantly.During my visit, I observed a test panel set up between the two chambers, which was part of an evaluation for a SCIF (Sensitive Compartmented Information Facility). SCIF structures are designed to be impervious to sound and electromagnetic waves, utilized by government officials for confidential discussions in the field—a detail that adds a hint of intrigue reminiscent of spy thrillers.While the WNP-3 building provides notable advantages for acoustic testing, it has also posed challenges. The two reverberation rooms lacked an opening between them, so Sauro hired a contractor to create the necessary passageway. The initial estimate for the project was about $1,500, but the complexity of cutting through thick rebar extended the job into a week-long endeavor, ultimately costing around $15,000—an unexpected financial burden that added to the lab's operational challenges.Adjacent to the turbine building, Sauro has set up a free field speaker testing rig. The turbine building itself spans over 600 feet and once housed the equipment necessary to convert steam generated by the reactor into electrical power. The testing rig is positioned on the turbine deck, which was a bit damp during my visit due to the persistent rain, revealing the age and wear of the facility.Describing the testing rig, Sauro likened it to something out of a Lovecraftian tale. The structure features a tall arm that extends forward and is adorned with numerous microphones, poised to capture audio data as speakers are tested. This innovative setup allows for three-dimensional assessments of sound performance.Sauro reminisced about the challenges they faced when they shared the building with another tenant who operated diesel tank construction equipment around the clock. To avoid interference during audio tests, he often had to work late into the night. Now, with that tenant gone, he expresses skepticism about the likelihood of attracting another business, citing the high costs of repairs needed for the building's aging roof.“Nobody’s ever come back and I don’t think anybody’s ever going to,” he lamented. The anticipated repairs would run over a million dollars, a daunting figure for any potential tenant. While he manages to work around the weather-related obstacles, including using sound-absorbing foam on wheeled carts, he remains hopeful that the facility can continue its unique operations.In summary, the transformation of WNP-3 into an acoustics lab is a testament to innovation and adaptability. Sauro remarked on the nature of the structure: “You work around it. It doesn’t work around you.” The building's original design for housing a nuclear reactor makes it a formidable presence, one that is likely to stand for centuries to come. Sauro mused, “This building is gonna be around 1,000 years from now.”As I prepared to leave, I took a moment to appreciate the massive reactor housing once more. While the bird I had spotted earlier was gone, I noticed signs of wildlife, a reminder that nature is slowly reclaiming this abandoned industrial site. With so much unused space and an abundance of shadowy corners, it’s only logical that local fauna would take advantage of the shelter offered by these colossal structures. In the end, it is not just the human capacity for innovation that shapes the future of Satsop, but also the resilience of nature itself.