Statement of Work.pdf

FEDERAL AVIATION ADMINISTRATION AUGUST 27, 2018

JOT VOR ROOF REPLACEMENT – Single-Ply PVC Roof at Joliet, IL

00 01 10 – TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 10 00 SUMMARY OF WORK

01 31 00 S PROJECT MANAGEMENT AND COORDINATION

01 33 00 SUBMITTAL PROCEDURES

01 50 00 TEMPORARY FACILITIES

01 60 00 S PRODUCT REQUIREMENTS

01 71 33.10 PROTECTION OF WORK AND PROPERTY

01 77 00 CLOSEOUT PROCEDURES

DIVISION 02 – SITE WORK

02 10 00 EQUIPMENT REMOVAL

02 20 00 ANTENNA SHELTER

02 30 00 AZIMUTH POSITIONER BRACKETS

02 40 00 COUNTERPOISE REPLACEMENT

DIVISION 06 – WOOD

06 20 00 DECKING AND NAILERS

DIVISION 07 – THERMAL AND MOISTURE PROTECTION

07 54 2 THERMOPLASTIC MEMBRANE ROOFING

APPENDIX – ATTACHMENTS

ATTACHMENT 1 EOSH Impacts CSA EOSH Checklist Form 3900-17 Form 3900-18 Form 3900-19

ATTACHMENT 2 DRAWINGS

END OF SECTION 00 01 10

DIVISION 01 – GENERAL REQUIREMENTS

SECTION 01 10 00 SUMMARY

PART 1 – GENERAL

1.1 SUMMARY

A. Furnish the labor, materials, and tools required to remove and replace existing single-ply membrane, fully adhered, Polyvinyl Chloride (PVC) roofing membrane, insulation, roof board, flashing, and vinyl soffit for the VOR roof at Joliet, IL in accordance with specification, contract drawings, codes and standards.

1.2 WORK COVERED BY CONTRACT DOCUMENTS

A. Project Identification: JOT VOR

1. Project Location: 11500 McKanna Rd, Minooka, IL 60447.

B. FAA POC: Sary Sancen, 847-294-7100

C. The work consists of, but not limited to the following:

1. Remove and replace ceiling panels inside the building. Match existing materials. For bidding purposes only, assume 15% of ceiling material needs replacement. For any additional material, contractor shall provide a per square foot cost in the proposal.

2. Carefully remove TACAN Antenna fiberglass shelter from the roof and store at approved location. (VOR Antenna Equipment will be removed by FAA). A new base gasket kit will be provided as government furnished material.

3. Mark all sixteen (16) existing monitoring antennas and carefully remove along with supporting brackets. Store at approved location. (See Division 2)

4. Remove all existing roofing material including but not limited to roofing membrane, insulation, ladder supports, flashing, and nailer board around perimeter and cone.

5. Remove and replace all rotted and deteriorated wood decking including nailers and spacers. For bidding purposes only, assume 25% of decking needs replacement.

Contractor shall provide a per square foot cost in their proposal for any additional decking.

6. Inspect for water damaged counterpoise and substrate. For bidding purposes only, assume 15% (in quantity of each specific material) of the mesh counterpoise and grounding material needs replacement. Install grounding plates and copper wire mesh counterpoise, as necessary. Before the roof is covered, test for the continuity of the counterpoise in the presence of the FAA COR.

7. Furnish and install new pressure-treated nailer board under cone and around roof perimeter. Paint to match adjacent materials.

8. Furnish and install 1½” thick polyisocyanurate insulation over counterpoise roof excluding area within the fiberglass shelter.

9. Furnish and install new PVC roof system including ½” Densdeck Prime Roofboard, a fully adhered, 80-mil single-ply, PVC membrane, and PVC coated metal edge flashing.

10. Furnish and install single-ply, PVC walkway treads and match existing layout.

11. Re-establish Antenna fiberglass shelter and provide liquid flashing around base of cone.

12. Reposition monitor antennas. The contractor is responsible for providing licensed surveyor to determine new locations based on survey readings.

13. Clean project site and work areas daily. Dispose of debris at approved waste site and in accordance with local regulations. Restore all areas disturbed by construction activity or vehicles per specifications.

14. Participate in CAI and address punch list items if any.

1.3 SITE VISIT

A. Bidders are encouraged to visit the site and carefully examine the areas in question as to conditions that may affect execution of work. All dimensions and quantities should be verified.

B. A minimum of 24 hour notice is required prior to a site visit.

1.2 FAA-FURNSIHED

A. FAA will furnish products indicated.

1. FAA will arrange and pay for delivery of FAA-furnished.

2. If FAA-furnished items are damaged, defective, or missing, FAA will arrange for replacement.

3. Contractor shall review Shop Drawings, Product Data, and Samples noting discrepancies or anticipated problems in use of product.

4. Contractor is responsible for receiving, unloading, and handling FAA-furnished items at

Project site.

5. Contractor is responsible for protecting FAA-furnished items from damage during storage and handling, including damage from exposure to the elements.

6. If FAA-furnished items are damaged as a result of Contractor's operations, Contractor shall repair or replace them.

B. FAA-Furnished Products: VOR Cone Gasket Kit including base gasket.

C. Report to COR immediately and contractor is responsible for repair of any damage on building or damage to any Government Furnished Products caused by construction operations. Protect all products during construction.

1.4 USE OF PREMISES

A. General: Contractor will have full access to the construction site.

B. Ingress and egress to work area: Ingress and egress to the work areas and contractor parking will be discussed at the preconstruction meeting. Keep all vehicles, working equipment and materials within the area designated by the COR.

1.5 WORK RESTRICTIONS

A. On-Site Work Hours: Work shall be generally performed during normal business working hours of 7 a.m. to 5 p.m., Monday through Friday, except otherwise indicated.

1. No work will be performed on weekends and federal holidays.

2. Work shall be performed during a scheduled work week of 40 hours.

3. Any work outside of the shift will be considered overtime work. The Contractor may work overtime provided the Contractor notifies the COR a minimum of 48 hours in advance of any weekend, holiday, or overtime work.

4. The start and stop times shall typically be coordinated with the schedules of the FAA COTR or facility personnel to minimize or prevent the need for overtime work by FAA personnel.

B. Expected job duration: Fifteen (15) business days.

C. Nonsmoking Building: Smoking is not permitted within the building or within 25 feet of entrances, operable windows, or outdoor air intakes.

END OF SECTION 01 10 00

SECTION 01 31 00 - PROJECT MANAGEMENT AND COORDINATION

1.1 COORDINATION

A. Key Personnel Names: Within 14 calendar days of Notice To Proceed, submit a list of key personnel assignments, including superintendent and other personnel in attendance at Project site. Identify individuals and their duties and responsibilities; list telephone numbers where they can be reached during work hours.

1. Provide COTR with list and keep list current at all times.

B. Requests for Information: Immediately on discovery of the need for additional information or interpretation of the Contract Documents, Contractor shall prepare and submit an RFI in the form specified to the COR.

C. All correspondence between the contractor and FAA must be through the FAA’s Contracting Officer (CO) or the Contracting Officer’s Representative (COR).

D. At no expense to the FAA, procure all construction and working permits required by local and state agencies.

E. Pre-Construction Conference: The contractor shall attend a pre-construction conference when required by the contracting officer. The contractor shall abide by all agreements reached at the conference regarding safety practices, access to site, deference to air traffic if necessary, and any other operational procedures.

F. Safety Meeting: Contractor shall hold a tailgate safety meeting prior to commencement of work each day, in the presence of the COR to discuss possible safety hazards and mitigation.

G. All work must be accomplished by experienced workers in accordance with the highest stand-ards of the various work trades involved. Workers must abide by safety requirements, set forth by OSHA, that correspond to the type of work being performed. See EOSH documents in the Appendix.

I. Contractor’s Warranty: The contractor shall supply the FAA with a two-year workmanship warranty. In the event any work related to roofing, flashings, or metalwork is found to be de-fective or otherwise not in accordance with the contract documents within two years of comple-tion, the roofing contractor shall remove and replace at no cost to the FAA.

J. Manufacturer’s Warranty: The manufacturer’s materials shall be guaranteed against defects and be leak free for a period of 15 years after completion. This warranty shall be a No-Dollar-Limit Warranty, and identifying the FAA as the owner of the facility. The location of the facility and the effective starting date of the warranty shall be indicated on Warranty documents.

END OF SECTION 01 31 00

SECTION 01 33 00 – SUBMITTAL PROCEDURE

1.1 SUBMITTALS PROCEDURES

A. Contractor shall submit list of materials for FAA approval prior to the commencement of construction.

B. In making a formal request for substitution, the Contractor represents that they have investigated the proposed product and have determined that it is equal to or superior in all respects to that specified.

C. As-Built Drawings: Contractor shall maintain a complete set of construction drawings at the site, and make daily annotations to document as-built conditions. At project completion, and prior to final payment, the contractor shall submit red-lined as-built drawings to COR.

D. Processing Time: Allow 15 days for submittal review. A resubmittal would require additional time. No extension of the Contract Time will be authorized because of failure to transmit submittals enough in advance of the Work to permit processing, including resubmittals.

E. Procurement Before Approval: The contractor is advised not to procure any item for which submittal approval is required but not yet granted. If approval is denied, the contractor will be prevented from installing the disapproved item(s). The contractor must transmit a new submittal package for the new items replacing the disapproved items, and must procure only approved items. The contractor shall take responsibility for the delivery and installation of any items installed before submittal approval is granted. The FAA reserves the right to discontinue field work on any item furnished without submittal approval. Procuring and/or installing material which is later disapproved could result in substantial losses of money and time for the contractor.

END OF SECTION 01 33 00

SECTION 01 50 00 – TEMPORARY FACILITIES

1.1 STORAGE CONTAINER

A. Contractor shall provide a Conex Box which will provide temporary safe storage of the equipment that will be removed from the VOR roof and replaced.

B. The location of the storage container will be decided by the FAA.

1.2 COORDINATION

A. Coordination of the delivery and pick-up of the storage container is essential.

B. The container may not be on site prior to the VOR Antenna being shut off for construction.

C. The container is required to be picked up and removed from the site immediately post construction. The VOR Antenna CAN NOT return to service without its removal.

END OF SECTION 01 50 00

SECTION 01 60 00 S – PRODUCT REQUIREMENTS

1.1 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. Deliver, store, and handle products using means and methods that will prevent damage, deterioration, and loss, including theft and vandalism. Comply with manufacturer's written instructions.

B. Delivery and Handling:

1. Schedule delivery to minimize long-term storage at Project site and to prevent overcrowding of construction spaces.

2. Deliver products to Project site in an undamaged condition in manufacturer's original sealed container or other packaging system, complete with labels and instructions for handling, storing, unpacking, protecting, and installing.

3. Inspect products on delivery to determine compliance with the Contract Documents and to determine that products are undamaged and properly protected.

1.2 ASBESTOS FREE CERTIFICATION

A. The contract shall provide the Contracting Officer (CO) a signed statement stating that to the best of his/her knowledge; no asbestos-containing building materials were used during the renovation, and modernization of this facility.

B. If the FAA suspects the presence of asbestos, the FAA will sample the suspect material to verify that no asbestos-containing material was utilized. This testing shall be performed at the expense of the FAA. If asbestos-containing material is subsequently found during the sam-pling of the building materials, the Contractor shall remove and replace the product or materi-al at his/her expense. In addition, the Contractor shall incur the costs of the original testing and/or any re-testing that may be necessary.

C. The Contractor shall submit to the CO Material Safety Data Sheets (MSDS), prior to con-struction, for all materials and/or products to be utilized during the course of the project ac-complishment. During the course of the project, both the COR and the Contractor shall rou-tinely check products utilized on-site to ensure only products which have had MSDS submit-ted are utilized. Copies of all MSDS shall be turned over to the local FAA office for their records.

D. If the Contractor does not submit the required information described above, the FAA shall have a complete building survey performed by a qualified testing firm prior to acceptance.

The cost of the survey and any subsequent removal/replacement of any asbestos-containing material shall be deducted from the Contractor's payment.

1.3 HAZARDOUS MATERIAL AND SAFETY

A. The Contractor shall provide workers protection per OSHA 29 CFR 1926.62.

B. The Contractor shall be responsible for safety on the work site. It is the responsibility of the Contractor to eliminate hazards which may result in tripping, electrical shock, fire, falling ob-jects, environmental hazards, vehicular accidents, etc. The Contractor shall comply with all safety precautions required by OSHA. The Contractor shall have two l5 lb. Class B and C fire extinguishers at the work area through the progress of welding, metal cutting, or any other pro-cess involving a spark or fire hazard.

END OF SECTION 01 60 00 S

SECTION 01 71 33.10 – PROTECTION OF WORK AND PROPERTY

1.1 PROTECTION AND RESTORATION OF PROPERTY AND LANDSCAPE: The contractor shall be responsible for the preservation of all public and private property. The Contractor shall be responsible for all damage or injury to property of any character, during the prosecution of the work, resulting from any act, omission, neglect, or misconduct in its manner or method of executing the work, or at any time due to defective work or materials, and said responsibility will not be released until the work is completed and accepted. When or where any direct or in-direct damage or injury is done to public or private property by or on account of any act, omis-sion, neglect, or misconduct in the execution of the work, or in consequence of the nonexecu-tion thereof by the Contractor, the Contractor shall restore, at its own expense, such property to a condition similar or equal to that existing before such damage or injury was done, by repair-ing or otherwise restoring as may be directed by the COR, or it shall make good such damage or injury in an acceptable manner, at no additional cost to the Government.

END OF SECTION 01 71 33.10

SECTION 01 77 00 – CLOSEOUT PROCEDURES

1.1 GENERAL

A. Contractor shall participate in Contractor Acceptance Inspection (CAI) and shall address all punch list items generated by FAA. For first two subparagraphs below, see Evaluations.

B. Prepare and submit redline drawings, Deliver tools, spare parts, extra materials, and similar items to location designated by FAA. Label with manufacturer's name and model number where applicable.

C. Complete final cleaning requirements.

PART 2 – EXECUTION

2.1 FINAL CLEANING

A. General: Provide final cleaning. Conduct cleaning and waste-removal operations to comply with local laws and ordinances and Federal and local environmental and antipollution regulations.

B. Cleaning: Employ experienced workers or professional cleaners for final cleaning. Clean each surface or unit to condition expected in an average commercial building cleaning and maintenance program. Comply with manufacturer's written instructions.

1. Complete the following cleaning operations::

a. Clean Project site, yard, and grounds, in areas disturbed by construction activities, including landscape development areas, of rubbish, waste material, litter, and other foreign substances.

b. Remove tools, construction equipment, machinery, and surplus material from Project site.

c. Sweep floors broom clean in unoccupied spaces.

C. Comply with safety standards for cleaning. Do not burn waste materials. Do not bury debris or excess materials on FAA's property. Do not discharge volatile, harmful, or dangerous materials into drainage systems. Remove waste materials from Project site and dispose of lawfully.

END OF SECTION 01 77 00

DIVISION 2 – SITE WORK

SECTION 02 10 00 – EQUIPMENT REMOVAL

PART 1 – GENERAL

1.1 SCOPE OF WORK

A. The fiberglass antenna shelter and azimuth positioner brackets shall be removed from the build-ing roof prior to installation of the new single-ply membrane roof. The VOR antenna shall be removed by the FAA.

B. Remove all existing terne-coated metal pan roofing material, rosin paper, and base felt down to tongue & groove decking and properly dispose of.

C. Temporary covering over the roof shall be provided until new roof is installed and antenna shelter has been reinstalled. The temporary roof covering shall be the tarpaulin specified within this document which shall be supplied by the contractor.

SECTION 02 20 00 – ANTENNA SHELTER

PART 1 – GENERAL

1.1 SUMMARY

A. This section covers the requirements for removing, refurbishing, and replacing the VOR fiber-glass antenna shelter. The contractor is cautioned that the existing VOR fiberglass antenna shel-ter can be damaged with rough handling. Care must be exercised when working with the shelter to maintain its structural integrity.

B. The work includes but is not limited to:

1. Remove the existing hold down nuts and sealant around the base of the cone. Using a crane (100’ max height), remove the existing cone from the VOR roof and set next to building. Remove the existing base gasket from the roof and clean the membrane sur-face.

2. Refurbish existing antenna shelter at base: Remove caulking, gasket and sand chipped ar-eas prior to re-installation.

3. Install the refurbished shelter onto the building roof with the new base gasket after new membrane installation. Secure with existing hold down nuts or furnish new ones if the existing ones are damaged.

4. Reseal the vertical and horizontal seams (including base) with non-sag, polyurethane sealant from the exterior side of the cone.

5. Install door gasket around the entire perimeter of the cone door and provide watertight seal.

C. Sealant Removal

1. Replace all seams in the fiberglass cone and between the cone and the roof.

2. All seams between individual segments of the fiberglass antenna shelter shall be resealed.

Replace the gasket (or install new if there is not one).

3. All caulking and sealant shall be removed until the surface of the fiberglass is exposed.

4. Use scrapers, wire brushes, wire wheels, sandpaper, and any other method approved by the COR to remove all old sealant and caulking from fiberglass surfaces upon which the new sealant will be adhered as detailed. Use sandpaper as final removal agent and re-move all residue and dust with XYLOL, or “TOLUOL” or similar solvent, approved by the COR.

PART 2 – PRODUCTS

2.1 MATERIALS

A. Caulking: Caulking shall be premium grade high-performance moisture cured, non-sag, polyurethane-base elastomeric sealant.

1. Products:

a. Vulkem Number 116 manufactured by Tremco International

b. Sonolastic NP-1" manufactured by Sonneborn Division of Contech, Inc.

c. Tremco Dymeric, as manufactured by Tremco, Inc.

B. Primer:

1. Products

a. Primer for caulking Vulkem No. 116 shall be Vulkem Primer No. 181.

b. Primer for caulking Tremco Dymeric shall be Tremco Primer No. 1.

c. Primer for caulking Sonolastic NP-1 shall be Sonolastic Primer No. 773.

C. Sealant materials shall be delivered to the job in sealed containers with manufacturer's original label attached. Materials shall be used according to manufacturer's printed instructions. Color shall be white. Materials shall not have exceeded shelf-life. Sealant materials are available from Glenrock Company.

D. Gasket: The shelter base gasket, shelter top gasket and shelter door gasket will be government furnished.

E. Lag Bolts: To secure antenna shelter. Contractor shall furnish new 3/8" x 3" long hex head stainless steel lag bolts and washers.

F. Abrasives:

1. Sandpaper: Use aluminum oxide 100, 120, 160, and 200 grit.

2. Nylon Abrasive Pads: Medium grit aluminum oxide abrasive mat, 3M or Bear-Tex.

G. Solvent Cleaners: Naphtha, Toluol, Xylene or MEK

H. Epoxy Patch Resin: (If cone is damaged in the removal or installation, use this patch) Use any of the following:

1. Epoxy patch, resin, polyester, low pressure laminating, fire resistant MIL-R-21607, MIL- R-7575

2. Hetron 32A with catalyst and activator, EPON 815 resin with EPON V-25 curing agent.

3. A suitable one gallon kit No. L9002 of epoxy resin for repairing reinforced fiberglass can be purchased from General Fiberglass.

I. Fiberglass Reinforcing: Ten ounce per square yard fiberglass cloth shall be used as reinforce-ment with the epoxy resin. This material can be purchased in small quantities from the same supplier as the epoxy resin noted above.

J. Safety Equipment: The equipment used by the contractor to perform the required work shall meet the Occupational Safety and Health Act Standards for this type work.

PART 3 – EXECUTION

3.1 FIBERGLASS ANTENNA SHELTER REMOVAL

A. The antenna shelter position shall be precisely indexed by scribe lines to the building roof be-fore removal and in the field to assure reinstallation in the same relative position.

B. In addition to the lag bolts holding the antenna shelter to the roof, waterproofing material at the base may be incorporated in the original construction that will contribute to difficulty in remov-ing the shelter. Such materials will include a circular gasket under the antenna shelter, flashing materials adhered to the roof and antenna shelter, and various caulking and sealant beads at this juncture. Carefully cut such materials free from the antenna shelter using knives and flush-cut surface saws, in such a manner that the shelter is in no way damaged. Carefully remove all residues from the shelter down to bare fiberglass by scraping, sanding, and cleaning with a solvent.

C. Hoist cables shall be secured to the antenna shelter system before hold-down bolts are removed to insure that shelter will not blow over in the wind. Shelter shall be carefully hoisted in an ap-proved manner from building roof to temporary storage on grade. Place antenna shelter on wood blocking and boards of sufficient area such that the weight of the antenna shelter is dis-tributed over at least 50% of the area of the base flange to preclude damage to the relatively brittle shelter.

D. Immediately after placement of antenna shelter on grade, it shall be anchored with at least four guy wires or ropes and posts driven into the ground to preclude this shelter from being blown over by the wind. This precaution is emphasized due to its occurrence in the past at substantial cost for replacement.

3.2 SHELTER SURFACE PREPARATION

A. Strip and Decaulk: The fiberglass reinforced shelter is constructed from layers of fiberglass cloth and resins laminated together. The side walls are approximately 3/16 inch thick and the base flange is approximately 1/4 inch thick.

1. Remove all caulking from around shelter base and roof flange by scraping and sanding.

2. Remove existing coating that is blistered, rough, flaked, loosened or has deteriorated.

Use scrapers, sanding discs, wire brushes or similar tools.

3. Feather the edges of all existing paint that is well adhered and is to remain intact. If need be or if directed by the COR, roughen the existing coating surface with a nylon abrasive scouring pad to break the surface glaze. Rinse off this area with clean water and let dry thoroughly. Any damaged areas will require repairing.

3.3 SEALANT REPLACEMENT FOR EXPOSED SURFACES

A. Sealant shall be non-sag caulking as specified in Part 2 of this Section.

B. Install sealant according to manufacturer’s instructions. Every attempt should be made to satis-fy joint design recommended by the manufacturer. In general, joint width should be twice joint depth. Depth can be governed by amount of gasket material removed. Width can be varied by how far the sealant surface is depressed within the groove.

C. Install caulking in shelter joint with two passes. The first layer shall be tooled without a lubri-cant. The outer laying shall be sealed to the walls when applying the second pass.

D. Finished sealant joints shall be tooled smooth and uniform. A soapy water solution may be used to lubricate the final finish after sealant is in place. Excess waste sealant on adjacent sur-faces shall be removed using methods recommended by the manufacturer.

E. For clean-up of Vulkem No. 116 or TREMCO Dymeric use XYLOL or TOLUOL. The joint requiring sealant removal and replacement as above is between the 10 foot diameter antenna shelter and single-ply membrane roof. CAUTION must be taken for the following:

1. Between 10 foot diameter antenna shelter and single-ply membrane roof, use "Tremco" monolastic one-part acrylic sealant to seal antenna base gasket to single-ply membrane.

2. Between antenna shelter and the 4 foot diameter top mounting fixture gasket (both sur-faces).

3. Between 4 foot diameter top-mounting fixture top gasket and top mounting fixture (bot-tom side of gasket only). TACAN antenna has to be removed for maintenance.

4. Estimated lineal feet of sealant required for the above is 158 feet.

3.4 SHELTER REPAIR IF DAMAGED DURING REMOVAL

A. All holes, cracks, damaged areas or areas where the protective resin coatings have worn away and has left the fiberglass surface exposed and weathered shall be repaired.

1. Cut away all ragged edges and corners from the damaged area of the panel to form an oval or round hole by using a router, rasp or other acceptable tool.

2. Feather the edge of the hole on the interior and exterior surface of the panel to a smooth, sloping contour approximately 3 inches beyond the edge of the hole.

3. Clean all abraded areas with solvent cleaner.

4. Cut fiberglass cloth patches approximately 2 or 3 inches larger than the hole formed in Step 1.

5. Apply premixed epoxy resin with a paint brush or spatula to the abraded surface and the feathered edge of the hole.

6. Position fiberglass cloth patch on exterior surface of panel, and brush resin on outside of patch and around edges to produce a filled surface free of air bubbles.

7. On the interior side of the panel, cut a fiberglass cloth patch to fit the dimensions of the hole. Cut a sufficient number of additional patches, in increasing sizes (in 1/2 inch in-crements) to obtain a patch thickness (when impregnated with resin) of slightly greater thickness than the original pane. Finally, cut and apply one patch 2 inches larger in di-ameter than the preceding patch.

8. After the resin has completely dried, sand the repaired areas smooth with a fine grit sand paper.

3.5 RESIN APPLICATION (IF NEEDED FOR REPAIR OF DAMAGED AREA)

A. Combine and mix resin in accordance with the manufacturer's instructions. Use extreme cau-tion in handling the catalyst and accelerator as they are toxic and highly reactive. Catalyst and accelerator ratios depend upon many factors, including application method (two-part pressure spray, roller, or brush), ambient temperature, and humidity.

B. The resin may be applied by means of a two-part pressure pot, rollers, or brushes. Apply one coat of uniform thickness to entire surface to be refurbished. Where the fiberglass is exposed and loose glass fibers stick out of the surface, apply the resin in a manner which will cause the fibers to lie flat on the surface and become embedded in the resin coating.

C. Required final coating shall be five to six mils in thickness on surfaces which are not deterio-rated to the point where the fiberglass is exposed. Do not apply resin to surfaces which are evi-dently damp, or have had insufficient drying time at lower humidity levels to assure evapora-tion of moisture from cracks and porous areas. Allow at least 20 hours of curing time for resin coating on any particular area of the surface before sanding.

3.6 INSPECTION

A. The COR shall inspect the antenna shelter prior to storage, during, and after reinstallation of the fiberglass shelter.

3.7 ANTENNA SHELTER BASE GASKET

A. The Government furnished base gaskets are furnished in four segments, each approximately 7 '- 8 1/4" in arc length by 3/8" thick and 2 1/2" in width. It is a closed cell neoprene foam material.

The contractor shall install the gasket as follows:

1. Prior to installing the gaskets, the contractor shall mark a 5' - 0 1/2" radius (10' - 1" diam-eter) circular ring around the center of the roof with a felt tip ink pen in order to center the antenna shelter.

2. After the centering reference circle has been marked, set the antenna shelter inside the circular marked line and center it as well as orienting the shelter in the same azimuth as it was before it was removed from the roof.

3. After the shelter has been accurately positioned and approved by the COTR, the contrac-tor shall mark each bolt hole location on the single-ply roofing membrane with a suitable marker. The marks shall be in a circular pattern outlining each bolt hole. After all bolt holes have been marked, the shelter shall be moved in order to install the base gasket ma-terial.

4. Pre-drill a 1/4" hole in the center of each bolt hole 1 1/2" deep. Apply a smooth even coat of caulking on the bottom side of the base gasket and set the gaskets in place. Keep the outer edge of the gasket approximately 1/4" from the edge of the antenna shelter to al-low for a bead of caulking.

5. The gasket may need to be trimmed on the outer edge by 1/4". Be extremely careful when trimming gasket to prevent cutting the single-ply membrane roof material. A strip of 20 gauge galvanized sheet metal can be placed under the gasket to prevent cutting the single-ply membrane.

6. DO NOT CAULK THE TOP SURFACE OF THE GASKET except a small bead at each joint in the gasket. Use "Tremco" monolastic one-part acrylic sealant to seal antenna base gasket to single-ply membrane.

3.8 ANTENNA SHELTER INSTALLATION

A. Upon antenna shelter removal, old gasket material, mastic and sealant shall be removed from shelter to bare fiberglass material by scraping, sanding, and other approved methods. Remove all dust and residue by compressed air or by wiping down with a solvent cleaner such as dena-tured alcohol "101" or "EMK". Final cleaning shall be with XYLOL or TOLUOL.

B. The antenna shelter shall be reinstalled in precisely the same location and orientation that exist-ed before removal.

C. Carefully hoist, align, and reset the antenna shelter on the roof. Install new stainless steel 3/8" x 3 inch long lag bolts and the existing hold-down straps. Torque bolts equally to only such tightness to provide a watertight seal and not to an extent where fiberglass will shatter or the gasket deforms excessively. Tool the caulking around the outer and inner edges of the antenna shelter. Apply additional caulking if required to make a nice smooth bead.

END OF SECTION 02 20 00

SECTION 02 30 00 AZIMUTH POSITIONER BRACKET

PART 1 – GENERAL

1.1 SCOPE

A. The following shall be conducted by the contractor:

1. Re-install existing supports for azimuth positioner brackets.

2. The bracket bolt assemblies shall be installed before the roof edge flashing is installed.

3. The existing aluminum azimuth positioner brackets shall be reused.

B. Subsequent to removal of the 16 or more azimuth positioner brackets, the dipole antennas and connecting cables will be disconnected and removed by the FAA. The antenna brackets consist of 5" x 5" x 3/8" x 6" long aluminum angles fastened to the roof deck with four mechanical fas-teners. Trapezoidal face plates are attached to the azimuth positioner brackets which support the antennas by a wedging action. Sixteen of these azimuth positioner brackets will be reused.

PART 2 – PRODUCTS. NOT USED

PART 3 – EXECUTION

3.1 GENERAL

A. Upon removal of the antenna shelter, the contractor shall have a licensed surveyor set a transit over the building center point and project a line through the center of the north azimuth posi-tioner bracket to a mark on a wood hub driven flush with the ground approximately 200 feet north of the VOR building. Guard the hub with a 1" x 2" x 5'-0" (+/-) wood stake with a red flag tied to the top of the stake. This work shall be performed with care and the COR shall check and approve the reference point before the azimuth positioner brackets are to be re-moved. Upon installation of 2" x 8" wood nailers around the perimeter of the roof, the transit is then set up, as previously referenced, to the wood hub, and scribe reference lines 22.5 degrees apart are placed near the edge of the roof at each of the 16 bracket locations using the transit to certify the proper reference for true north and angles. After turning the transit scope 360 de-grees, the cross hair must align precisely with the wood hub starting mark. The azimuth posi-tioner brackets must be evenly spaced at 22.5 degrees apart on centers.

B. Each azimuth positioner brackets shall be covered with padding after they are installed to pro-tect the tarpaulin roof covering from puncturing on the exposed sharp edges of the brackets dur-ing construction.

C. The azimuth positioner bracket bolt assemblies must be mortised into the 2" x 8" wood nailers prior to installing the edge flashing and single-ply roofing material. The existing bracket bolt assembly will be left in place if verified location is accurate.

3.2 AZIMUTH POSITIONER BRACKET

A. Install all 16 brackets at the same elevation in reference to each other (plus or minus 1/4").

B. "Keystone brackets" shall be centered on the same radial lines through the center of the build-ing as the existing brackets.

C. Keystone brackets and mounting aluminum clip angles shall be oriented at right angles to the radial lines as detailed.

D. Azimuth positioner brackets and antenna supports shall be vertical and plumbed in each direc-tion with a carpenter's level.

E. Re-check antenna supports for plumb after tightening hold down/mounting bolts.

F. Install strut supports on each monitor antenna mast as shown on drawings.

G. The monitor antennas coaxial cables and connectors will be installed by the FAA.

END OF SECTION 02 30 00

SECTION 02 40 00 – COUNTERPOISE REPLACEMENT

PART 1 – GENERAL. NOT USED

PART 2 – PRODUCTS

2.1 COPPER WOVEN WIRE MESH

A. Copper wire mesh shall be 16 x 16 square mesh fabricated from 0.011" diameter wire size.

B. Copper mesh shall be delivered to the job site in at least 36" wide sheets cut to length. Sheets dropped on their edges or bent out of shape to the extent that the mesh can not be laid smooth and flat will be rejected by the COTR.

C. Two sources for the copper woven wire mesh is:

1. McMaster – Carr 200 Aurora Industrial Pkwy. Aurora, OH

2. Direct Metals, Kennesaw, GA

2.2 COPPER JOINT STRIP

A. Backing strips to be used for soldering the mesh joints together shall be 2 inches wide, fabricat-ed from at least 12 oz. (0.016") copper sheets (Alloy 110 cold rolled).

B. Strips shall be cut from sheets 8 or 10 foot in length.

C. Copper shall be bright and shiny, free from oxidation, when delivered to the job site.

D. One source for this material is Chris Industries Inc. Northbrook, IL

2.3 SOLDERING

A. Solder: Solder shall be solid core 50-50 type, wire bar stock. All solder shall be fresh stock ma-terial.

B. Solder Flux: Solder flux shall be "Lonco" RF460 Kwickflo 50-WA-6 manufactured by the "London Chemical Co.", or approved equal. Any substitutions of flux requires approval by the COR which shall only be given after the contractor has demonstrated that the substitute flux will do the job adequately. The recommended flux mentioned above has been tested and has worked well for soldering copper woven wire mesh to copper. Solder, flux and neutralizer can be purchased from the London Chemical Co., Inc., Bensenville, Illinois.

C. Flux Residue Neutralizer: Flux neutralizer shall be "Lonco" Neutralizer No. 2051-B-3. If a substitute flux neutralizer is used, it must be of a type recommended by the flux manufacturer.

D. Soldering Equipment

1. Copper soldering irons weighing a minimum of 4 pounds per pair shall be used (each iron weighing 2 pounds each, normally marked with a number 4).

2. Soldering equipment that applies flame directly to the materials to be soldered shall not be used. The galvanized coating on the wire mesh shall not be burned off.

3. Gas fired soldering irons that direct the flame on the soldering coppers with absolutely no flame striking the materials to be soldered are acceptable.

2.4 MISCELLANEOUS

A. Copper Grounding Segments: The antenna pedestal mounting plate shall be grounded to the wire mesh with four copper semi-circle segments fabricated from 12ox (0.016”) copper (allow 110 cold rolled).

1. Material can be purchased from Chris Industries, Inc.

B. Roof Ground Connector: #6 copper ground wire & Burndy Type KC17B1 connector shall be used to ground the outside roof edge perimeter detail. See Roof Edge Flashing drawing for more information.

PART 3 – EXECUTION

3.1 SOLDERING

A. Wire Mesh Fasteners:

1. Staple the wire mesh in place as shown on the project drawings. Leave a 12" width of wire mesh edge free from staples in order to slip a heat barrier sheet under the joint to be soldered, to protect the vapor barrier membrane from heat generated by the soldering process.

2. Non-asbestos sheet millboard 42" x 48" x 1/8" thick, capable of withstanding 1000 de-grees F makes a good temporary heat shield. Any type of heat barrier that will protect the vapor barrier is suitable. The heat barrier used must be approved by the COR. The barri-er must be removed after the area under the barrier has been soldered and moved to the next area to be soldered. Non-asbestos sheet millboard can be purchased from "McMas-ter-Carr", Catalogue number 9362K1.

3. After each joint is soldered, remove the heat barrier and staple wire mesh in place.

B. Joint Seams: The wire mesh shall be butt joined with approximately 1/4" separation. The wire mesh shall be centered over the copper joint strips. Do not lap the mesh over the copper strips.

All joints shall be soldered with a continuous seam of solder with no gaps.

C. Soldering: After the mesh is in place and temporarily weighted down flat against the copper strips, the materials shall be coated with flux. Sweat a coat of solder over the entire width of the copper strip and wire mesh. The solder joints not acceptable to the COR shall be corrected before additional wire mesh is placed. The mesh shall be soldered to the copper antenna pedes-tal mounting plate grounding segments and the four grounding points at the counterpoise edge in the same manner.

D. Neutralizer: Thoroughly rinse soldered joint with plain clean water to remove all flux residues and apply "Lonco" #2051-B-3 neutralizer or equal after rinsing with water to prevent corrosion.

E. Safety Protection: Solder flux is corrosive and can cause permanent eye damage if it comes in contact with the eye. Use chemical goggles or face shield when using the flux. If accidentally splashed into the eye, immediately flush the eye with plenty of clean water and get medical at-tention immediately. Swallowing the flux can cause severe damage to the esophagus and pylo-rus and requires immediate medical attention. Follow all safety procedures provided by the manufacturer when using the flux. Dispose of all unused flux following all federal, state and local regulations. Store flux in cool, well-ventilated area away from strong alkaline materials.

END OF SECTION 02 40 00

DIVISION 6 – WOOD

SECTION 06 20 00 – DECKING AND NAILERS

PART 1 - GENERAL

1.1 SUMMARY

The contractor is to replace all deteriorated wood decking, wood framing, and fascia material.

All

PART 2 – PRODUCTS

2.1 MATERIALS

A. Lumber: Lumber shall be pressure treated with preservative Chromate Copper Arsenate (CCA) such as “Osmose K-3” or “Wolmanized” and dried after treatment. Retention of preservative shall not be less than 0.40 lbs./cubic foot.

B. Nails: Nails for decking shall be 16 penny hot dipped galvanized

C. Fasteners: The wood nailers shall be attached to existing decking with 302, 304, or 410 stainless steel fasteners or fasteners specially coated to be used in CCA treated lumber. Furring strips shall be affized to existing nailers, fascia, and one to another utilizing ¼” Dia x 2 ½” Long “Zinc-Plated Steel” Lag Screws, McMASTER-CARR Catalog Stock No. 91478A552 or equal.

PART 3 – EXECUTION

3.1 REPLACEMENT DECKING

A. If the repair in any area is more than one board wide, the length of repair boards shall be at least twice the width.

B. When a tongue or a groove has to be trimmed to fit new boards, use construction adhesive to bond new decking to old decking along the full length of the joint.

C. Install ½” plywood decking in the area inside the cone between the antenna shelter wood nailers.

END OF SECTION 06 20 00

DIVISION 7 – THERMAL & MOISTURE PROTECTION

SECTION 07 54 2 - THERMOPLASTIC MEMBRANE ROOFING

PART 1 - GENERAL

1.2 SUMMARY

A. Section Includes:

1. PVC membrane roofing system.

2. Vapor retarder.

3. Roof insulation.

1.3 PERFORMANCE REQUIREMENTS

A. General Performance: Installed membrane roofing and base flashings shall withstand specified uplift pressures, thermally induced movement, and exposure to weather without failure due to defective manufacture, fabrication, installation, or other defects in construction. Membrane roofing and base flashings shall remain watertight.

B. Roofing System Design: Provide a membrane roofing system that is identical to systems that have been successfully tested by by a qualified testing and inspecting agency to resist uplift pressure calculated according to ASCE 7.

1. Field-of-Roof Uplift Pressure: 60 lbf/sq. ft.

2. Perimeter Uplift Pressure: 80 lbf/sq. ft.

3. Corner Uplift Pressure: 108 lbf/sq. ft.

C. Material Compatibility: Provide roofing materials that are compatible with one another under conditions of service and application required, as demonstrated by membrane roofing manufacturer based on testing and field experience.

1.4 SUBMITTALS

A. Product Data: For each type of product indicated.

B. Shop Drawings: For roofing system. Include plans, elevations, sections, details, and attachments to other work.

1. Base flashings and membrane terminations.

2. Tapered insulation, including slopes.

3. Roof plan showing orientation of membrane roofing and

C. Maintenance Data: For roofing system to include in maintenance manuals.

D. Warranties: Sample of special warranties.

E. Inspection Report: Copy of roofing system manufacturer’s inspection report of completed roofing installation.

1.5 QUALITY ASSURANCE

A. Manufacturer Qualifications: A qualified manufacturer that is UL listed and FM Approvals approved for membrane roofing system identical to that used for this Project.

B. Installer Qualifications: A qualified firm that is approved, authorized, or licensed by membrane roofing system manufacturer to install manufacturer's product and that is eligible to receive manufacturer's special warranty. Installer shall have minimum 5 years experience in similar project size, complexity and system to conduct testing indicated.

C. Source Limitations: Obtain components including roof insulation and fasteners for membrane roofing system from same manufacturer as membrane roofing or approved by membrane roofing manufacturer.

1.6 PROJECT CONDITIONS

A. Weather Limitations: Proceed with installation only when existing and forecasted weather conditions permit roofing system to be installed according to manufacturer's written instructions and warranty requirements.

B. When inclement weather forces a work stoppage or when the contractor leaves the work site for the night, over the weekend, or any other time the roof shall be covered with the specified tarpaulin securely tied down and weighted with sand bags or similar means to prevent the wind from blowing the tarpaulin off. It shall be the responsibility of the contractor to insure the tarpaulin is leak free. Roofing materials damaged from wind or rain during construction shall be replaced at the contractor’s expense.

1.7 WARRANTY

A. Special Warranty: Manufacturer's standard or customized form, without monetary limitation, in which manufacturer agrees to repair or replace components of membrane roofing system that fail in materials or workmanship within specified warranty period.

1. Special warranty includes membrane roofing, base flashings, roof insulation, fasteners, cover boards, roofing accessories, and other components of membrane roofing system.

2. Warranty for roofing system shall be a no dollar limit for labor and materials.

3. Warranty Period: 20 years from date of Substantial Completion.

PART 2 - PRODUCTS

2.1 GENERAL

A. The components of the fully adhered single-ply roof system are to be products of one manufacturer.

B. Components to be used that are other than those supplied or manufactured by the roof membrane manufacturer shall be submitted for review and acceptance. Roof membrane manufacturer’s acceptance of any other product is only for a determination of compatibility with products and not for inclusion in the membrane manufacturer’s warranty. The specifications, installation, instructions, and/or restrictions of the respective manufacturer’s must be reviewed by the FAA COR for acceptability for the intended use with membrane manufacturer’s product.

C. Polyethylene film sheeting to protect equipment inside building.

1. Thickness: 6 mils thick

2. Color: transparent

3. Size: width suitable to adequately cover the equipment

2.2 PVC MEMBRANE ROOFING

A. Membrane shall conform to ASTM D4434, “Standard for Polyvinyl Chloride Sheet Roofing”.

1. Classification: Type II, Grade 1.

2. Thickness: 80 mils, nominal.

3. Exposed Face Color: White (Energy Smart), initial reflectivity of .83, initial emissivity

0.90, solar reflective index (SRI) of > 104.

4. Wind uplift: 120mph

B. Membrane shall be a fiberglass-reinforced flexible PVC sheeting, such as G410-20 as manufac-tured by Sarnafil, Inc. or approved equal.

1. The proposal of another manufacturer's product requires the following: Membrane man-ufacturer's Catalog and Specification Data including descriptions and detailed application instructions, standard installation detail drawings, product characteristics, physical prop-erties, a copy of the 20 year warranty and a list of 10 projects completed with the pro-posed product at least five years prior to the bid opening date.

C. PVC membrane used for flashing and roofing shall be fully adhered with hot air welded joints.

1. Product: G410-12, 48 mil (1.2 mm), thermoplastic membrane with fiberglass reinforce-ment.

D. Roof membrane typical Physical Properties:

2.3 AUXILIARY MEMBRANE ROOFING MATERIALS

A. General: Auxiliary membrane roofing materials recommended by roofing system manufacturer for intended use, and compatible and approved by membrane roofing manufacturer.

B. Flashing:

1. Membrane coated flashing material shall be Sarnaclad, G410-L, 25 gauge galvanized steel, coated with 0.02 inch thick coating of PVC film or approved equal. This material shall be used for edge flashing around the perimeter of the counterpoise roof and bottom retaining strip.

2. Flashing for the antenna supports withing the fiberglass antenna shelter shall be made from Sarnafil G410 PVC membrane or approved equal.

C. Bonding Adhesive:

1. Sarnafil Sarnacol 2170 solvent-based, elastomeric adhesize or approved equal. Shall be used to attach membrane, polyester felt, and Sarnatred protection mat to the substrates specified.

2. Sarnafil 11FC and Primer 449. The 11FC is one-component polyurethane construction adhesive. The primer is clear, solvent base primer. This product shall be used in the installation of eight ladder anchor plates, A/C electrical receptacle, and flashing to inside of cone. Use PVC G459 membrane when using the 11FC.

D. Caulking for PVC Membrane: Caulking will be used on the flashing and setting the A/C receptacle in the fiberglass antenna shelter, between the antenna shelter base gasket and the single-ply membrane and installing the ladder deck supports to the roof surface. The following caulking/sealants are accepted based on chemical compatibility with PVC membranes:

1. Monolastomeric, one-part acrylic, as manufactured by Tremco.

2. Silpurf, one-part silicone sealant, as manufactured by General Electric Company, or equal by Dow Corning.

3. GACO AS-3, one-part silicone sealant, as manufactured by Gates Engineering Company.

E. Fasteners:

1. Fasteners for attaching the insulation board and overlayment board shall be "Buildex"

Roofgrip fasteners, #14 diameter with Climaseal coating or approved equal. Fasteners shall be 3" long.

2. Any screws, nails or miscellaneous hardware for attaching flashing, ladder deck supports, etc., shall be 302, 304, or 18-8 stainless steel alloy.

3. Any screws, fasteners, etc., to attach the treated wood nailers to counterpoise deck shall be stainless steel or similar corrosion resistant fasteners designed to be used in treated wood as shown in the drawings.

F. Distribution Plates: The distribution plates shall be three inch diameter plastic plates manufactured by "Buildex", TRU FAST or approved equal. Metal distribution plates will not be allowed.

2.4 OVERLAYMENT BOARDS

A. Overlayment Board: ASTM C 1177/C 1177M, glass-mat, water-resistant gypsum…