25-0709 OP-2 OBERSERVATION TOWER REPAIRS - SOW.pdf

OP-2 Tower Repairs Camp Lejeune, North Carolina

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Observation Tower OP-2 Repairs

Prepared by:

Project Manager for Training Systems

Marine Corps Systems Command

Date: 01/22/25

Approved by:

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OP-2 Tower Structure Description

Location and Site Description

The OP-2 Tower is located at the Marine Corps Base Camp Lejeune, NC, directly off Lyman Rd, approximately 3 miles east of Sneads Ferry Rd. The tower is situated on high ground and is supported by a 2'-6" thick concrete foundation.

Structural Description

The OP-2 Tower is a 9-floor level structure, approximately 81'-0" high, with an overall height of approximately 91'-0" including the sunshade structure. The tower's shell is composed of a pre-assembled wind panel assembly, featuring galvanneal siding over light-gage steel infill studs. The structure has a steel-framed system with mechanical connections throughout.

Floor Levels and Access

Access to all floor levels is possible through interior stairs from the ground level to the 3rd floor level, and interior ladder wells/exterior stairs from the 3rd floor level to the 9th floor level roof deck. Each floor level has steel checkered plating as flooring, and ceilings are made of galvanneal paneling over HSS steel framing.

Windows, Doors, and Observation Level

The south elevation of the 4th and 7th floor levels features window hatches, while the 9th floor level has commercial off-the-shelf (COTS) steel-framed horizontal sliding windows on all sides. COTS steel-framed hollow core steel doors are located on the 1st, 3rd, 4th, 7th, and 9th floor levels. The open 9th floor level roof deck serves as an observation level, with flooring consisting of bar grating over checkered plating and a HSS steel-framed handrail with metal parapet wall attached to the perimeter for fall protection.

Superstructure and Framing

The superstructure is a steel-framed system with mechanical connections throughout. Primary structural members in the bottom 8 floor levels include I-beam (W-section) columns and beams connected by a combination of bolted shear plates and welds. HSS steel cross-bracing, bolted to gusset plates that are welded to the structure's primary framing, is also found throughout the bottom 8 floor levels. The 9th floor level is framed with HSS steel columns and roof beams, without cross-bracing. Framing between each floor level consists of continuous C-channels that provide support for the floor decking.

Exterior Stair and Landing System

The exterior stair/landing and balcony system is completely framed by HSS steel members and topped with steel bar grate decking. The system is anchored to the structure's primary framing member and uses a series of angle braces and supports.

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Mechanical and Electrical Systems

The bottom 8 floor levels appear to have a ventilation system, although it is unclear whether ventilation was part of the original design intent, as information on the system was not included in the as-built drawings. The 9th floor level provides conditioned space and includes a thru-wall air conditioning unit.

The operating status of the mechanical systems was not investigated during the site survey. All floor levels include interior and exterior general-purpose lighting, as well as exit lighting and back-up emergency lighting. The tower also features red/blue notification lights, FAA warning lights, and convenience power receptacles on odd-numbered floor levels. An interior-mounted sub-panel is located on the 9th floor level, while all electrical distribution runs through the main distribution panel located on the exterior of the 1st floor level. The tower is grounded and includes a lightning protection system.

Figure 1 – Tower Location

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Figure 2 – OP-2 Tower

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1. POINTS OF CONTACT:

RTAM POC: Kevin Cagle michael.cagle@usmc.mil, Training Liaison Officer: Mrs. Gena Epley gena.epley@usmc.mil, 910-451-9374 PMTRASYS POC: Robert Rivera, PE robert.rivera12@navy.mil 787-645-7134

2. GENERAL:

2.1 The contractor shall provide supervision, labor, material and equipment required to perform all work for the following project: OP-2 Tower Repairs. Report any unforeseen findings to the attention of the Contracting Officer Representative (COR) assigned to the project. The COR is the individual designated as the authorized representative of the Contracting Officer. The COR is responsible for monitoring the performance and technical management of the effort required and should be contacted regarding questions or problems of a technical nature.

The COR will be the construction manager (CM), engineering technician (ET), and/or performance assessment representative (PAR) assigned to the project. Materials mentioned herein shall be the same or equal to specified manufacturer and or in quality.

2.2 All work shall be done in a manner to provide a complete, usable, and finished product. See paragraph “3.

WORK REQUIREMENTS” for an expanded and detailed scope of work.

2.3 A pre-proposal site meeting shall be held at the project site to review and discuss the scope of work and assess existing field conditions, prior to award of this task order. The contractor and other key personnel involved shall attend the site meeting with the Government. The contractor shall coordinate/schedule the date and time with the government COR.

2.4 Existing reference drawings are available in Attachments 5.2 & 5.3. Reference drawings shall be used for informational purposes only and may not accurately reflect current as-built conditions. The contractor is responsible for field verifying all measurements at the jobsite before ordering materials. All quantities are approximations and shall be verified by the contractor.

2.5 All work shall be performed in accordance with Unified Facilities Criteria (UFC’s), standard industry practices, local, state and federal codes, laws and regulations.

2.6 The contractor shall request a final acceptance inspection for project closeout with the COR. Any punch list shall be corrected prior to final payments.

mailto:michael.cagle@usmc.mil mailto:gena.epley@usmc.mil mailto:robert.rivera12@navy.mil

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3. WORK REQUIREMENTS:

3.1 SOW:

Repair of the Observation Tower OP-2 per user requirements to include the following features:

R1. Remove, refurbish re-install the sunshade structure located at the 10th Level. The refurbishment work shall be performed in accordance with the Corrosion Protection Procedures outlined in Attachment 5.1.

The scope of work includes:

• Refurbishing the FAA lights support columns

• Disconnecting and reconnecting all electrical components

• Replacing the FAA lights lightbulbs

• Testing the FAA lights for proper operation prior to re-installation

All work shall be completed in accordance with the specified procedures to ensure a safe and successful refurbishment of the sunshade structure. Provide all hardware, sealants, and materials necessary to reinstall the sunshade structure to its original condition as depicted in the as-built drawings.

R2. Remove and dispose the existing sunshade fabric and replace it with new equal fabric, ensuring a secure and proper installation. Dispose of the old fabric in accordance with applicable regulations and guidelines.

• Remove the existing sunshade fabric and replace it with new fabric, matching the original specifications and material composition."

• Remove the existing sunshade fabric and replace it with new fabric, ensuring that all hardware and fixtures are inspected and replaced as necessary to support the new fabric.

• Provide all hardware, sealants, and materials necessary to reinstall the sunshade structure to its original condition as depicted in the as-built drawings.

R3. Remove all protective railing at Level 10 and refurbish in accordance with the Corrosion Protection Procedures outlined in Attachment 5.1. Refer to Detail 9/S-501 of the drawings included in Attachment

5.2. As part of the refurbishment, replace all existing bolts, washers, and nuts with new ones.

Upon refurbishment completion, re-install the protective railing at Level 10, ensuring that all components are securely fastened and meet the specified requirements. Provide all hardware, sealants, and materials necessary to reinstall the sunshade structure to its original condition as depicted in the as-built drawings.

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Figure 3 – OP-2 Tower sunshade level

R4. Replace and dispose the existing 1-1/2” metal grating (identified as #1 in Figure 5) and ¼” checkered plate (identified as #2 in Figure 5) with new materials at the Level 10 floor. The new checkered plate shall be coated with a corrosion-resistant primer and paint to ensure durability and protection against the elements.

Prior to installing the new checkered plate, inspect and refurbish the checkered plate substructure, following the Corrosion Protection Procedures outlined in Attachment 5.1, where any signs of corrosion are visible. This refurbishment work shall include the removal of any corroded material, cleaning, and application of a corrosion-resistant coating to prevent further deterioration.

All new welding performed during this replacement and refurbishment work shall be coated with a corrosion-resistant primer and paint to ensure a durable and long-lasting finish. Ensure that all replacement and refurbishment work is completed in accordance with the specified procedures and guidelines to maintain the integrity and safety of the Level 10 floor. Provide all hardware, sealants, and materials necessary to reinstall the sunshade structure to its original condition as depicted in the as-built drawings.

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Figure 4 – OP-2 Tower level 10 Plan Figure 5 – OP-2 Tower sunshade level 10 section

Figure 6 – OP-2 Tower level 10 Figure 7 – OP-2 Tower level 10

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Figure 8 – OP-2 Tower canopy fabric Figure 9 – OP-2 Tower level 10

R5. Refurbish the steel wall supports for the outdoor stair landings' diagonal braces in accordance with the Corrosion Protection Procedures outlined in Attachment 5.1. This refurbishment work shall include the removal of any corroded material, cleaning, and application of a corrosion-resistant coating to prevent further deterioration. Any sealant between plate and wall shall be removed.

Upon completion of the refurbishment, apply a 3/8” bead of elastomeric sealant, equal to or similar to Sika Flex 1a, around the entire perimeter of the plate and wall interface. This sealant shall provide a watertight seal and help to prevent future corrosion.

As part of the refurbishment, replace all existing bolts, washers, and nuts with new ones, ensuring that all hardware is secure and properly tightened. The new hardware shall be compatible with the refurbished steel wall supports and the elastomeric sealant.

Ensure that all work is completed in accordance with the specified procedures and guidelines to maintain the integrity and safety of the outdoor stair landings and diagonal braces.

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Figure 10 – OP-2 Tower Steel Plates Supports Locations

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Figure 11 – OP-2 Tower Steel Plates Supports Figure 12 – OP-2 Tower Steel Plates Supports

Figure 13 – OP-2 Tower Steel Plates Supports Figure 14 – OP-2 Tower Steel Plates Supports

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R6. Refurbish the steel structure braces' gusset plates at each floor level, in accordance with the Corrosion Protection Procedures outlined in Attachment 5.1. The refurbishment work shall focus on the areas of the gusset plates that are exposed and in contact with the floor, and shall include the removal of any corroded material, cleaning, and application of a corrosion-resistant coating to prevent further deterioration.

The refurbishment shall extend 2 inches high from the floor level, as shown in figures 15 7 16, around the entire exposed lower perimeter of each gusset plate. This means that the refurbishment work shall be performed on the lower portion of the gusset plates, where they are in contact with the floor, and shall not include the areas of the gusset plates that are in contact with the ceiling.

Ensure that all refurbishment work is completed in accordance with the specified procedures and guidelines to maintain the integrity and safety of the steel structure braces and gusset plates

Figure 15 – OP-2 Tower Steel Middle Gusset Plates refurbishing area (provide refurbishing to back side as well)

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Figure 16 – OP-2 Tower Steel Corner Gusset Plates refurbishing area (provide refurbishing to back side as well)

R7. Replace all existing metal doors and frames, including all associated hardware, with new ones. The new doors and frames shall be constructed from 16-gauge galvanized steel, providing a durable and corrosion-resistant solution.

The replacement work shall include the removal and disposal of all existing metal doors and frames, as well as the installation of new doors and frames that meet the specified requirements. All new hardware, including hinges, latches, and locks, shall be provided and installed as part of the replacement work.

Ensure that the new metal doors and frames are properly sized, aligned, and secured to provide a secure and weather-tight seal. The new galvanized steel doors and frames shall be painted and free from defects and shall meet all relevant industry standards for quality and performance

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4. SAFETY:

4.1 All Safety and Hot Work contact information and procedures will be discussed at the pre-con meeting.

Hot Work Permits:

1) All welding and burning operations, or large grinding and cutting operations, require a Camp Lejeune Hot Work permit and the Fire Marshal will be called and notified by the GOV representative (PAR, ET, CM, FM or other) and or the KTR of the work location, type of work and dates for the work to be performed.

2) The Fire Marshal shall inspect and advise for the Hot Work conditions and limitations and the Hot Work Permit will be issued for the as needed time requirements to completer the work.

3) This also includes gas engine electric generators, gas engine pumps, refueling of gas / diesel fuel operated equipment and standalone refueling tanks.

4) The Fire Marshal will notify the Camp Lejeune base Explosive Safety office and both the Fire Marshal, and the Explosive Safety inspector will review the work location and site for approval of the Hot Work Permit.

4.2 All contract work shall be accomplished IAW manufacturer’s recommendations, industry standards, Unified

Facilities Criteria (UFC), Unified Facilities Guide Specifications Section 01 35 26, State and local governing authority, EM 385-1-1, Safety and Health Requirements Manual (current edition) and Occupational Safety and Health Administration requirements. If there is conflicting guidance the most stringent specifications shall apply.

4.3 The contractor shall submit an initial Activity Hazard Analysis (AHA) to identify actual or potential hazards associated with specific work activities to be performed and an Accident Prevention Plan(s) (APP) for preventative measures the contractor will take before beginning any work task, activity, or defined feature of work (DFOW). The AHAs shall define the steps being performed within the activity, task or DFOW and identify the work sequences. Specific anticipated hazards, site conditions, equipment, materials, personnel, and the control measures to be implemented; it shall also address life safety measures and personnel egress. The contractor must obtain government approval prior to starting any construction activities.

4.4 EM 385-1-1 dated November 2014 “Safety and Health Requirements Manual

4.5 29 CFR 1910 (OSHA) “2015” General Industry Regulations” and 1910.146 “Confined Spaces”

5. ATTACHMENTS:

5.1 Corrosion Protection Procedures

5.2 OP2 TOWER - MODULAR STEEL FRAME BLDG - Drawings

5.3 OP2 TOWER UCAS G8 - Drawings

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5.1 Corrosion Control Procedure

Preparation

To ensure a successful paint coating application, the metal surface must be properly prepared. The following steps must be taken:

Surface Cleaning: Thoroughly clean the metal surface to remove dirt, oil, grease, and other contaminants. Use a wire brush, sandpaper, or a cleaning solution to achieve a clean surface. The surface must be free of all substances that could interfere with paint adhesion.

Rust and Scale Removal: Remove any existing rust and scale using a wire brush, sandpaper, or a rust remover. This step is crucial to prevent further corrosion and ensure a strong bond between the paint and the metal surface.

Degreasing: Apply a degreaser to the surface and wipe it clean with a lint-free cloth. This step helps to remove any remaining contaminants and prepares the surface for painting.

Drying: Allow the surface to dry completely before proceeding with the paint coating application. This step is essential to prevent any moisture from interfering with the paint adhesion.

Paint Coating Application

The paint coating application process involves several steps:

Phosphating: Apply a phosphating treatment to the surface to create a conversion coating that enhances paint adhesion and corrosion resistance. This step helps to create a strong bond between the paint and the metal surface.

Primer Application: Apply a corrosion-inhibiting primer to the prepared surface. The primer must be compatible with the topcoat and suitable for the metal substrate. The primer helps to protect the metal surface from corrosion and promotes paint adhesion.

Topcoat Application: Apply two coats of the topcoat, which should be a high-build, corrosion-resistant paint. The topcoat must be compatible with the primer and intermediate coat (if used). The color of the topcoat must match the existing color.

Curing: Allow the paint to cure according to the manufacturer's instructions, which may involve air drying, baking, or using a curing agent. The curing process helps to ensure that the paint coating is fully bonded to the metal surface and provides the desired level of corrosion resistance.

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5.2 OP2 TOWER - MODULAR STEEL FRAME BLDG – Drawings

Including as a separate file attachment

5.3 OP2 TOWER UCAS G8 - Drawings

Including as a separate file attachment

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