Attachment 5 Design Analysis.pdf

DESIGN ANALYSIS

35% SUBMITTAL

(100% DESIGN DEVELOPED)

EDINBURG-KERRVILLE BLDG 4

DIP VAT REDESIGN – A-E

PREDESIGNAND DESIGN

SERVICES

PN: T.B.D.

MOORE FIELD EDINBURG, TX

Prepared For:

U.S. Department Of Agriculture

USDA APHIS

5601 Sunnyside Avenue

RM 3-2102

Beltsville, Maryland 20705

Contract No.

12805B23D0001

Task Order No.

1232SA25F03843

Prepared By:

The Johnson-McAdams Firm, P.A.

Greenwood, Mississippi

Tuesday, April 21, 2026 i

TABLE OF CONTENTS

Edinburg-Kerrville BLDG 4 Dip Vat Redesign

Executive Summary

1.0 Project Overview

2.0 Basis of Analysis

3.0 Project Requirements and Functional Intent

4.0 Existing Conditions and Site Constraints

5.0 Proposed Design Summary

6.0 Key Design Criteria

7.0 Discipline Review

7.1 Civil / Site / Concrete

7.2 Structural

7.3 Architectural / Operational Layout

7.4 Roofing and Envelope

7.5 Plumbing

7.6 Electrical

8.0 Budget and Phasing Considerations

8.1 Cost Estimate Review

8.2 Phasing

Edinburg-Kerrville BLDG 4 Dip Vat Redesign - Design Analysis

Executive Summary

The proposed redesign modernizes Building 4 and is appropriately focused on improving cattle-processing efficiency by activating the existing dip vat and drip pad. The design team has translated the core PRD requirements into a practical penning and circulation layout supported by modest but effective structural, plumbing, electrical, and concrete improvements. Selection of the insulated roof panel further strengthens the concept by responding appropriately to the hot, high-sun climate at Edinburg and by supporting a cooler covered environment for livestock operations and staff.

1.0 Project Overview

The Edinburg-Kerrville BLDG 4 Dip Vat Redesign project is intended to convert an existing experimental vat area that is currently not in use into a practical, higher-capacity cattle-processing facility for USDA ARS operations at Moore Field in Edinburg, Texas.

The Project Requirements Document states that Building 4 contains an experimental vat that was never used and an animal pen arrangement that is too small to process the number of cattle the research barn can hold. The redesign therefore focuses on making the existing dip vat and drip pad operational by enlarging the penning system, improving circulation, and providing the support systems necessary for daily use once the facility is returned to service.

The attached 35% design package reflects this intent through a covered penning layout, interior and exterior gates, maintenance access, a loading arrangement, water service, lighting, and convenience power. The specifications supplement the drawings by defining the administrative, structural, plumbing, electrical, and material requirements for a complete construction package.

2.0 Basis of Analysis

This design analysis is based on the following documents reviewed for this task:

Document Date Primary Use

FY 25 PRD Edinburg-Kerrville BLDG 4 Dip Vat Redesign 08/26/2025 Project purpose, budget, submittal requirements, and program criteria

35% Dip Vat Drawings 04/20/2026 Facility layout, discipline drawings, and project-specific details

Combined Specifications Ordered by Section Number 2026 issue set Technical requirements, submittals, materials, and execution criteria

3.0 Project Requirements and Functional Intent

The PRD establishes a clear operational goal: maximize the efficiency of the existing dipping vat and drip pad so the facility can process more cattle and better support the Cattle Fever Tick

Research Laboratory mission. The required features include larger pens, exterior gates for skid-steer access, gates between pens, alleys to and from the vat, access to a cattle chute from any pen, water in each pen, lighting, 120-volt receptacles, and a loading pen for trailer operations.

The 35% overall plan shows that the design team responded directly to that requirement by organizing the facility into eleven pens with associated feed troughs, water troughs, hose bibb drops, maintenance gates, internal movement gates, a holding/rotunda area, and improved circulation around the existing vat.

4.0 Existing Conditions and Site Constraints

The project is located within an active USDA ARS livestock research installation operating under biosecurity controls. While the existing Building 4 dip vat facility is currently not in use, the specifications still require the contractor to protect surrounding research operations, animal movement, and site access throughout construction. The existing dip vat and drip pad are specifically identified as integral facilities to be protected, except where contract modifications are shown.

The site is also constrained by the need to keep existing roads, pens, gates, and utilities functional during construction. Field verification of dimensions, grades, and utility locations is required before procurement or installation. This is especially important because the work interfaces with an existing vat, existing structural framing, and existing utility infrastructure.

Construction sequencing is therefore a major design consideration. The specifications require phasing that maintains Government operations, limits disruption, and coordinates utility extensions, pen construction, and electrical and water tie-ins to minimize downtime and temporary conditions.

5.0 Proposed Design Summary

The overall design concept is a practical, open agricultural handling structure built around the existing vat. The drawing set indicates eleven pens with areas ranging from approximately 200 square feet to 533 square feet, plus a rotunda/holding area, 42-inch circulation path, trailer loading relationship, and dedicated maintenance gates. The canopy and framing layout create a controlled environment for moving cattle through the dip process while still allowing service access and washdown operations.

Architecturally and operationally, the project is driven more by animal handling efficiency, durability, and maintainability than by conventional occupied-building criteria. That design approach is appropriate for the facility type and consistent with the PRD.

6.0 Key Design Criteria

Item Current Basis Observation

Programmed ECC $1,000,000 Base bid is to remain within 90 percent of the

ECC, with additives held within the overall programmed limit.

Pen Count 11 pens Pen areas shown on the overall plan range from approximately 200 SF to 533 SF.

Roof Slope 2:12 Consistent between the drawings and the metal building specifications.

Eave Height 8' - 5 1/2" Specified in the metal building system requirements.

Walkway Construction 6-inch concrete over 6-inch aggregate base

Reinforced with 4x4-W4xW4 welded wire mesh and heavy broom finish perpendicular to travel.

Water Service Connect to existing 3/4-inch line Overhead PEX distribution serves hose bibbs and float valves in the pens.

Electrical Service 100A, 120/208V, 3-phase, 4-wire, NEMA 3R panel Connected load is modest and consistent with lighting plus convenience receptacles.

Foundation Bearing 1,000 psf allowable bearing Conservative basis; verify against final delegated-design reactions and any geotechnical information obtained later.

Wind / Risk Criteria - drawings 134 mph ultimate, Risk Category I Shown in structural general notes on S001.

7.0 Discipline Review

7.1 Civil / Site / Concrete

The civil/site scope is limited but important because the project must operate in a wet, livestock-heavy environment. The walkway layout indicates 6-inch concrete reinforced with 4x4-

W4xW4 welded wire mesh over 6 inches of crushed aggregate base, finished with a heavy broom texture perpendicular to the path of travel. This is a practical assembly for washdown conditions, hoof traffic, and routine facility maintenance.

The specifications also emphasize maintaining existing drainage paths and preventing sediment, debris, concrete washout, and other contaminants from entering the vats, pads, drains, troughs, and adjacent livestock areas. Although the PRD marks erosion and stormwater items as not applying to the project scope, the narrative still describes erosion and runoff protection measures that should be carried forward as construction-phase controls.

7.2 Structural

The structural concept is a shallow-foundation system supporting a pre-engineered metal building or canopy frame. The structural notes establish a foundation design basis of 1,000 psf allowable soil bearing, with preliminary frame reactions shown for the new work. The drawings further state that if the final PEMB manufacturer loads differ by more than 10 percent, the contractor must resize the footings accordingly.

The specifications require delegated design by a professional engineer licensed in Texas and require signed and sealed calculations and shop drawings for the complete metal building system.

This is appropriate; however, the current document set should reconcile the structural note criteria with the edited specification criteria before the next submittal.

7.3 Architectural / Operational Layout

The architectural package supports the cattle-handling mission with a straightforward pipe-rail and gate layout. The enlarged plans show reverse swing gates, sliding gates, maintenance gates, rail infill at existing openings, and full-height blackout panels at the rotunda area. The overall plan also shows the holding area, truck/trailer relationship, and a new level concrete access surface above the existing vat access.

From an operational standpoint, the layout satisfies the PRD requirement for moving cattle between pens, to the vat, and back to pens while preserving outside access for equipment. The use of multiple gate types is deliberate and supports flexible movement control.

The A/E has had a full-scale working model of the reverse swing gate constructed and will schedule a time to bring it to the facility to demonstrate its use. The gate was developed to reduce the number of gates required and to aid in the safe movement of cattle for both the cattle and facility personnel. The gate can be opened from either gate post and creates a gentle angle to move cattle through the system, eliminating sharp ninety-degree turns.

7.4 Roofing and Envelope

The roof is a 2-inch insulated metal roof panel system using concealed clips and concealed fasteners as the roof basis of design, consistent with the edited metal building specification.

Use of the insulated roof panel is appropriate for this south Texas location because it reduces heat transfer through the canopy roof and helps provide a cooler environment for cattle and facility personnel during the hottest months of the year. The selected insulated system also establishes a single basis of design for detailing, loading, weather-tightness, warranty requirements, and cost control.

To support the roof selection, Table 7.4.A summarizes average monthly temperature and normal sunshine days for the project location. The climatic profile confirms extended warm-to-hot conditions and frequent sunshine, which reinforce the value of an insulated roof assembly over a non-insulated agricultural canopy roof.

Month Avg. Mean Temp. (°F) Normal Sunshine Days

January 62 19.2

February 67 18.4

March 72 19.0

April 78 17.9

May 83 18.1

June 87 17.3

July 88 22.2

August 88 23.1

September 84 11.0

October 78 18.6

November 70 17.0

December 63 18.2

Table 7.4.A Note. Average mean temperature values are based on climate averages reported for Miller International

Airport, approximately 10 miles from Edinburg. Sunshine-day values are reported for Edinburg and are included to illustrate the extent of solar exposure affecting roof heat gain and user comfort.

7.5 Plumbing

The plumbing scope is intentionally narrow and appropriate for the use. The plan shows a connection to an existing 3/4-inch water line, with overhead PEX distribution serving hose bibb drops and float-valve drops for the water troughs. The plumbing specification limits the work to potable cold-water piping, hose bibbs, manual mechanical float-operated tank valves, valves, fittings, supports, and related accessories for a complete installation.

This approach reduces conflicts with animal circulation and minimizes buried piping within the pen areas.

7.6 Electrical

The electrical scope provides basic but necessary utility support for operations within the covered work area. The power plan requires weatherproof GFI receptacles, galvanized rigid conduit above ground, and NEMA 3R rated equipment. The panel schedule identifies a new 100A, 120/208V, 3-phase, 4-wire panelboard with relatively modest connected and estimated demand loads.

The electrical demolition scope indicates removal of existing lighting, receptacles, and panelboard components with reuse and rerouting of existing conduit and conductors where acceptable. That is a cost-conscious approach and consistent with the project budget, but it will require careful field verification before final design and construction.

8.0 Budget and Phasing Considerations

8.1 Cost Estimate Review

The PRD establishes an Estimated Construction Cost (ECC) limit of $1,000,000 for FY 26 and requires the base bid to remain within 90 percent of the ECC. The current base bid cost estimate totals $897,906, indicating that the project is presently aligned with the programmed funding while leaving a limited balance for additives or market fluctuation.

Review Item Amount Percent of ECC Funding

Programmed ECC / Available Funding $1,000,000 100.0%

PRD Base Bid Ceiling (90% of ECC) $900,000 90.0%

Current Base Bid Cost Estimate $897,906 89.8%

Remaining Balance to Full ECC $102,094 10.2%

The estimate therefore represents approximately 89.8 percent of the total programmed ECC and approximately 99.8 percent of the PRD base-bid ceiling of $900,000. Stated differently, the estimate is about $2,094 below the permitted 90 percent base-bid threshold and leaves approximately $102,094, or 10.2 percent of the ECC, available within the overall funding limit. This indicates that the design is within funding, but only with a relatively modest remaining balance for additives, escalation, or scope growth.

8.2 Phasing

Phasing is also central to the design because the Government will continue to operate the surrounding research facility during construction. The specifications require coordination of disruptive activities, temporary barriers and fencing, end-of-day hazard control, and advance notice for utility interruptions and major operations. These requirements are consistent with the biosecurity nature of the site and should be reflected clearly in the final construction documents.