Technical Specifications.pdf

March 15, 2019

Submitted By:

Engineering Services AJW-2E15J Project Engineer …………………………………………Shane C. Harvey, PE

FAA-HLI -1505562

Specification For

“REPLACEMENT OF THE EXISTING ROOF WITH A

NEW SINGLE-PLY MEMBRANE

ON THE HLI VORTAC

FACILITY ROOF WOOD DECK”

Holly Springs, MS

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

TABLE OF CONTENTS

DIVISION 1 - GENERAL REQUIREMENTS --------------------------------------------------------- 1

SECTION 1A - SUMMARY OF THE WORK ---------------------------------------------------------------------------- 1 1A.1 General --------------------------------------------------------------------------------------------------------------------------- 1 1A.2 Scope of Work------------------------------------------------------------------------------------------------------------------ 1 1A.3 Coordination -------------------------------------------------------------------------------------------------------------------- 2 1A.4 Sanitary Facilities -------------------------------------------------------------------------------------------------------------- 2 1A.5 Materials ------------------------------------------------------------------------------------------------------------------------- 2 1A.6 Material Storage --------------------------------------------------------------------------------------------------------------- 3 1A.7 Ingress and Egress to Work Areas --------------------------------------------------------------------------------------- 3 1A.8 Cleaning -------------------------------------------------------------------------------------------------------------------------- 3 1A.9 Pre-Construction Meeting --------------------------------------------------------------------------------------------------- 3 1A.10 Project Drawings --------------------------------------------------------------------------------------------------------------- 4 1A.11 Site Visit -------------------------------------------------------------------------------------------------------------------------- 4 1A.12 Contractor’s Warranty -------------------------------------------------------------------------------------------------------- 4 1A.13 Manufacturer's Warranty----------------------------------------------------------------------------------------------------- 4 1A.14 Contractor's Liability ---------------------------------------------------------------------------------------------------------- 5 1A.15 Workmanship ------------------------------------------------------------------------------------------------------------------- 5 1A.16 Work Permits ------------------------------------------------------------------------------------------------------------------- 5 1A.17 Asbestos Free Certification ------------------------------------------------------------------------------------------------- 5

1A.18 Hazardous Material and Safety -------------------------------------------------------------------------------- 7

DIVISION 2 - SITE WORK -------------------------------------------------------------------------------- 7

SECTION 2A - EQUIPMENT REMOVAL -------------------------------------------------------------------------------- 7 2A.1 Scope of Work --------------------------------------------------------------------------------------------------------------------- 7 2A.2 TACAN Antenna Removal ------------------------------------------------------------------------------------------------------ 7 2A.3 Fiberglass Antenna Shelter Removal ---------------------------------------------------------------------------------------- 8 2A.4 Azimuth Positioner Brackets --------------------------------------------------------------------------------------------------- 9 2A.5 Protection of Roof During Construction ----------------------------------------------------------------------------------- 10

DIVISION 6 - WOOD ------------------------------------------------------------------------------------- 11

SECTION 6A - DECKING -------------------------------------------------------------------------------------------------- 11 6A.1 Scope of Work ------------------------------------------------------------------------------------------------------------------- 11 6A.2 Materials --------------------------------------------------------------------------------------------------------------------------- 11 6A.3 Replacement Decking --------------------------------------------------------------------------------------------------------- 11

DIVISION 7 – THERMAL & MOISTURE PROTECTION --------------------------------------- 13

SECTION 7A - EQUIPMENT PROTECTION -------------------------------------------------------------------------- 13 7A.1 Scope of Work ------------------------------------------------------------------------------------------------------------------- 13 7A.2 Materials --------------------------------------------------------------------------------------------------------------------------- 13 7A.3 Installation ------------------------------------------------------------------------------------------------------------------------ 13

SECTION 7B - OVERLAYMENT/RECOVER BOARD --------------------------------------------------------------- 13 7B.1 Scope of Work ------------------------------------------------------------------------------------------------------------------- 13 7B.2 Materials --------------------------------------------------------------------------------------------------------------------------- 13 7B.3 Installation ------------------------------------------------------------------------------------------------------------------------ 14

SECTION 7C - SINGLE-PLY PVC ROOFING MEMBRANE ------------------------------------------------------- 15 7C.1 Scope of Work ------------------------------------------------------------------------------------------------------------------- 15 7C.2 Materials: -------------------------------------------------------------------------------------------------------------------------- 15 7C.3 Caulking for PVC Membrane------------------------------------------------------------------------------------------------- 17 7C.4 Weather Limitations ------------------------------------------------------------------------------------------------------------ 17 7C.5 Quality Assurance -------------------------------------------------------------------------------------------------------------- 17 7C.6 Product Delivery and Storage ----------------------------------------------------------------------------------------------- 20 7C.7 Membrane Installation --------------------------------------------------------------------------------------------------------- 21 7C.8 Weather Protection ------------------------------------------------------------------------------------------------------------- 25 7C.9 Field Quality Control------------------------------------------------------------------------------------------------------------ 26

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

Table of Contents, Continued

DIVISION 10 – SPECIALTIES ------------------------------------------------------------------------- 27

SECTION 10A - ANTENNA SHELTER --------------------------------------------------------------------------------- 27 10A.1 Scope of Work ---------------------------------------------------------------------------------------------------------------- 27 10A.2 Inspection ---------------------------------------------------------------------------------------------------------------------- 27 10A.3 Materials ----------------------------------------------------------------------------------------------------------------------- 27 10A.4 Shelter Repair ---------------------------------------------------------------------------------------------------------------- 29 10A.5 Resin Application------------------------------------------------------------------------------------------------------------- 29 10A.14 Inspection ---------------------------------------------------------------------------------------------------------------------- 29 10A.15 Antenna Shelter Base Gasket -------------------------------------------------------------------------------------------- 30 10A.16 Antenna Shelter Installation ----------------------------------------------------------------------------------------------- 30

SECTION 10B - TARPAULIN---------------------------------------------------------------------------------------------- 31 SECTION 10C - AZIMUTH POSITIONER BRACKETS ------------------------------------------------------------- 31 SECTION 10E - COUNTERPOISE REPLACEMENT --------------------------------------------------------------- 32

10E.1 Scope of Work ---------------------------------------------------------------------------------------------------------------- 32 10E.2 Removal of Existing Terne-Coated Metal Roofing ------------------------------------------------------------------ 32 10E.3 Replace Damaged Wood -------------------------------------------------------------------------------------------------- 32 10E.4 Counterpoise Materials----------------------------------------------------------------------------------------------------- 32 10E.5 Soldering Equipment ------------------------------------------------------------------------------------------------------- 34 10E.6 Soldering Procedures ------------------------------------------------------------------------------------------------------ 34

10E.1A STAINLESS STEEL MESH COUNTERPOISE(ALTERNATE)--------------------------------------------36

VORTAC Roof Assembly System (pictures)-----------------------------------------------------------------38

Note: Divisions 3, 4, 5, 8, 9, 11 through 14, 15 and 16 are not used.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

DIVISION 1 - GENERAL REQUIREMENTS

SECTION 1A - SUMMARY OF THE WORK

1A.1 General This specification, along with project drawings, codes and standards specifies the technical requirements of the Federal Aviation Administration’s (FAA) project to replace the existing EPDM membrane with a new single-ply, fully adhered, Polyvinyl Chloride (PVC) roofing membrane, on the VORTAC facility at Holly Springs, MS.

1A.2 Scope of Work The work consists of, but is not limited to, the following:

1) Remove, clean the bottom seam, and securely store at location (for future loading) the existing 16’ tall fiberglass antenna cone shelter from atop the roof.

2) Mark, remove and preserve for reinstallation the 16 antenna Azimuth brackets. All 16 brackets and supports will be reused. Final location shall be determined by the local FAA coordinating work with the contractor surveyor and established and installed by the contractor.

3) Remove and dispose of the existing 2124 sqft, membrane, tern-coated metal pan roofing material, edge gravel stop, rosin paper, and base felt down to the wood decking of the 52’ diameter, single-story, flat roof.

4) Inspect, remove and replace any existing, rotted 2” x 8” decking board. For bidding purposes, plan 10% (212 Sqft) of 2” x 8” decking will be replaced with new treated decking. Engineer shall check the dormer condition.

5) Install vapor barrier, counterpoise mesh and grounding plates. ( Copper Mesh, Stainless steel wire mesh or steel sheeting)

6) Install ½” x 8" pressure treated plywood nailers around the perimeter of the counterpoise and ¾” x 12” pressure treated plywood nailers around the perimeter of the fiberglass antenna shelter. The existing outlets inside the shelter shall be removed.

7) Furnish, install, 16 base support bracket, 16 strut bracket and clean, reinstall the 16 azimuth positioner brackets at a location determined by the local FAA.

8) Mechanically fasten 5/8” Dens Deck prime board on the entire roof surface between the perimeter ½” plywood and the ¾” shelter plywood with plastic washer and xp self-drill fasteners.

9) Install a single-ply, fully adhered, PVC roofing membrane over entire roof surface up to the antenna plate, located inside the fiberglass antenna shelter.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

10) Install metal flashing band with single-ply PVC membrane factory coating around perimeter of roof counterpoise.

11) Install single-ply, PVC membrane flashing around the antenna supports and other areas as shown on the drawings.

12) Off load the new GFM 16’ tall fiberglass cone and cover cone from the FAA-supplied delivery truck. Install the new fiberglass cone, base & cone gaskets atop the roof. Install sealant between the exterior of the cone base, and the roof membrane. Load and secure the old fiberglass shelter and tacan onto the FAA-supplied delivery truck.

13) Install and flash the inside and outside of the fiberglass cone base with liquid flashing PMMA membrane.

14) Furnish and install Brundy KC17B1 grounding connector with #6 solid bare copper wire around the entire fascia of the roof edge outside perimeter.

15) Furnish and install one ladder support for the main access on counterpoise roof edge.

16) Install single-ply, PVC walkway treads from the ladder support at the roof edge to the antenna shelter, at the base of the 16 antenna Azimuth, the positioner brackets around the roof perimeter, around and inside the shelter as indicated on the drawings.

17) Supply and install one tarpaulin 56 feet in diameter to cover the roof during inclement weather during construction.

18) The counterpoise shall be grounded at four locations as shown on the drawings (reattach four existing #2 bare conductors to the new ground plates).

1A.3 Coordination All coordination between the contractor and the FAA shall be through the Contracting Officer or his designated Representative COTR.

1A.4 Sanitary Facilities Sanitary facilities are not available at the site. The contractor shall provide temporary toilet facilities as required for his workers. Temporary toilet facilities shall be of the type approved by the local governing body. The location of the toilet facilities shall be as directed by the COTR.

1A.5 Materials The contractor shall furnish all materials, equipment, and labor to complete all contract requirements, except material shown on the Government Furnished Property List in Section J of the contract. The use of brand names or equal products in this specification does not constitute a requirement that they are the only materials which meet the specifications in this contract. They are used as an illustration of known acceptable sources or products.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

If a brand name product is used in the drawings or Specifications, it should be regarded as a “known acceptable source". The use of the term “known acceptable source” and “brand name or equal” in referencing a specific product or manufacturer is not intended to indicate a preference for the products mentioned, but indicates the quality and characteristics of products that will meet the Government requirements. Should the contractor decide to use a product other than that identified as a “known acceptable source” or “brand name or equal”, the contractor shall provide a submittal for this product. This does not relieve the contractor from providing submittals for products or materials required in other sections of this Specification.

1A.6 Material Storage The contractor shall store all materials in a manner to protect them from all elements of the weather. No contractor furnished materials shall be stored inside the FAA equipment building or engine generator room.

1A.7 Ingress and Egress to Work Areas Ingress and egress to the work areas shall be as directed by the COTR. Security precautions against unauthorized site and building entrance shall be maintained. The contractor shall keep all vehicles, working equipment and materials within the leased boundaries of the access road and site plot.

1A.8 Cleaning

1) Working Area: The contractor shall keep the working area in a clean and proper condition. All rubbish and waste resulting from the execution of the work shall be removed at the end of each day or as directed by the COTR.

2) Waste Packing Material: Immediately after unpacking, all packing material, case lumber, excelsior, or other rubbish, flammable or otherwise, shall be removed from the building and the premises.

3) Final Clean-Up: Upon completion of work, and before final inspection, the contractor shall remove his working tools, equipment, debris, rubbish, and unused materials from the building site.

4) Disposal: Disposal of rubbish, debris, and gravel will be off the site at the contractor's expense or as directed by the COTR

1A.9 Pre-Construction Meeting-See Contract Clause 3.2.2.3-62 in Section I The contractor shall attend a Pre-Construction Meeting prior to starting work at a location agreed upon between the contractor and the Contracting Officer.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

1A.10 Project Drawings The following drawings of the issue specified form a part to this specification and are applicable to the extent specified herein. If any conflict exists between drawings and the specifications, the specifications shall govern.

Drawing Title

1A.11 Site Visit Bidders are encouraged to visit the site and carefully examine the areas in question as to conditions that may affect proper execution of the work. All dimensions and quantities shall be determined or verified by the contractor. No claims for extra costs will be allowed because of lack of full knowledge of the existing conditions. To arrange for a site visit contact the facility, GWO SSC Manager, Greg Vaughan, (662) 451-5000. The CO will set up a one day meeting in which prospective bidders can visit the site.

1A.12 Contractor’s Warranty

Legal Counsel had made the determination in the past that our standard is one year material and workmanship, except for extended warranties (20 Years); i.e., roofs. See Contract Clause 3.10.1- 20 in Section I.

1A.13 Manufacturer's Warranty The single-ply roofing membrane material shall be guaranteed against defects by the manufacturer and be leaking free for a period of 20 years after completion. This warranty shall identify the FAA as the owner of the facility and shall protect the FAA from all costs of repairing leakage resulting from defects in the membrane. The location of the facility and the effective starting date of the warranty shall be indicated. Final contract payment will not be released until receipt of the written warranty by the FAA.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

1A.14 Contractor's Liability Damage to existing facilities and equipment caused by the contractor shall be reported to the COTR without delay. The contractor will be responsible for repairing, or having repaired, all damage of the building or equipment at the contractor's expense. All repairs shall be accomplished to the satisfaction of the COTR. See Contract Clause 3.2.2.3-49 for additional requirements.

1A.15 Workmanship All work shall be accomplished by experienced workers in accordance with the highest standards of the various work trades involved.

1A.16 Work Permits The cost of all construction and working permits required by local and state agencies shall be included in the contractor’s cost proposal.

1A.17 Asbestos Free Certification The Contractor shall provide to 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. See Contract Clause 3.6.3-12 in Section I.

If the FAA suspects the presence of asbestos, the FAA will sample the suspect material prior biding 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 sampling of the building materials, the Contractor shall remove and replace the product or material 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.

The Contractor shall submit to the CO Material Safety Data Sheets (MSDS), prior to construction, for all materials and/or products to be utilized during the course of the project accomplishment. During the course of the project, both the COTR and the Contractor shall routinely check products utilized on-site to ensure only products which have had MSDS submitted are utilized. Copies of all MSDS shall be turned over to the local FAA office for their records.

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.

1A.18 Hazardous Material and Safety Terne-coated metal roof solder contains lead. The contractor shall provide workers protection per OSHA 29 CFR 1926.62. See Contract Clauses for additional requirements.

The contractor shall be responsible for safety on the work site. It is responsibility of the contractor to eliminate hazards which may result in tripping, electrical shock, fire, falling objects, Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562 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 process involving a spark or fire hazard.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

DIVISION 2 - SITE WORK

SECTION 2A - EQUIPMENT REMOVAL

2A.1 Scope of Work The fiberglass antenna shelter shall be removed from the building roof by the contractor prior to installation of the new single-ply membrane roof. The VOR antenna and DME antenna (both located inside the fiberglass shelter) and the 16 roof perimeter-mounted VOR monitor antennas shall be removed by FAA personnel, prior to commencing roof work. The contractor shall remove all existing aggregate, terne-coated metal pans, cleats, nails, rosin paper, edge gravel stops and base felts from the existing wood deck and dispose of. 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 in this specification, which shall be supplied by the contractor.

2A.2 TACAN Antenna Removal

1) Before the TACAN antenna is removed, all antenna cables will be disconnected by the FAA and pulled back into the building. Likewise, the VOR antenna system will be removed by the FAA from the antenna pedestal mounting support and placed in storage and crate within the building.

2) The TACAN antenna system is approximately 4 feet in diameter by 7 feet high and is mounted on top of a 4 feet inch diameter by 2 feet high steel top mounting fixture which sets on top of the fiberglass antenna shelter. The TACAN antenna weighs approximately 800 pounds.

3) The TACAN antenna assembly shall be removed first using a special sling provided by the FAA. The assembly rests on a gasket and is bolted to the top mounting fixture with eight bolts through an internal base flange. The gasket shall be removed and

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562 mating surfaces cleaned position shall be indexed by scribe lines to the top mounting fixture before removal. Carefully remove hold-down bolts after sling is in position and lower the TACAN assembly to grade for safe storage on site. The entire removal operation is to be accomplished under the direction of the FAA electronics specialists who will be on site for these operations. Two days advance notice for removal shall be given the COTR. The location of the upper ladder support on the TACAN enclosure should be noted before removal as this information will be needed when installing the lower cone ladder anchors on the roof deck.

4) The TACAN antenna assembly shall be stored on site where directed by the COTR.

The antenna assembly shall be temporarily bolted to a wood frame and crate provided by the contractor. The assembly shall remain attached to the crane until bolting to the wood frame is accomplished. These procedures are necessary to prevent the assembly from being blown over in the wind, which has occurred in the past at great cost for replacement.

2A.3 Fiberglass Antenna Shelter Removal

1) Before the antenna shelter is removed, all antenna cables will be disconnected by the

FAA and pulled back into the building. The VOR/DME antenna system and 16 monitor antennas will be removed by the FAA from their supports and placed in storage.

2) The antenna shelter position shall be precisely indexed by scribe lines to the building roof before removal and into the field to assure reinstallation in the same relative position.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

3) In addition to the lag bolts holding the antenna shelter to the roof, waterproofing material at the base was also incorporated in the original construction that will contribute to difficulty in removing the shelter. Such materials will include a circular gasket under the antenna shelter, flashing materials adhering 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 manner that the shelter is in no way damaged. Carefully remove all residues from the underside base of the old shelter down to bare fiberglass by scraping and sanding as necessary.

4) 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 approved manner from the 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 distributed over at least 50% of the area of the base flange to preclude damage to the relatively brittle shelter.

5) Immediately after placement of the 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.

6) The shelter shall remain in storage until the new shelter is delivered, which will not occur until the roof is ready to accept the new fiberglass shelter. The old shelter shall be loaded by the contractor onto the delivery truck. Close coordination will be required for this step as the roof needs to be ready and the contractor’s crane needs to be available.

2A.4 Azimuth Positioner Brackets

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

2) The contractor shall set a transit over the building center point and project a line through the center of the magnetic north azimuth positioner 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 COTR shall check and approve the reference point before the azimuth positioner brackets are to be removed. This will be preserved as a control point for possible future reference. Upon installation of the ½” x 8” wood nailers around the perimeter of the roof, the transit shall be set up atop the building center point. The contractor shall then establish and reference magnetic north which, as of May, 2014, is 7 degrees west of true north.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

Mark this point along the roof edge, as this line establishes not only the magnetic north VOR monitor antenna, but establishes the baseline for all other monitor antennas. Continue surveying, establishing 15 more reference points and lines 22.5 degrees apart, each, from magnetic north, until the circle is closed. After turning the transit scope 360 degrees, the transit cross hairs must align precisely with the wood hub starting mark. The azimuth positioner brackets must be evenly spaced at 22.5 degrees apart on centers. Equal variance to these marks may be necessary at this time, to correct for magnetic declination, based on instruction from the local FAA, who will coordinate with the contractor the final marks, prior to attaching the brackets.

3) Reinstall the sixteen azimuth positioner brackets with new, similar stainless-steel hardware and cover the brackets with padding after it is installed to protect the tarpaulin roof covering from puncturing on the exposed sharp edges of the brackets during construction.

4) The azimuth positioner bracket bolt assemblies must be mortised into the ½” x 8” wood nailers prior to installing the edge flashing and single-ply roofing material.

2A.5 Protection of Roof During Construction 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 in this document which shall be supplied by the contractor.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

DIVISION 6 - WOOD

SECTION 6A - DECKING

6A.1 Scope of Work After the old roofing has been removed, the contractor shall replace all deteriorated decking, wood framing and fascia material as directed by the COTR.

6A.2 Materials

1) Lumber: Lumber shall meet AWPA standards and shall be pressure treated with preservative ACQ, CA-B or CA-C. Above-ground retentions are as follows:

ACQ: 0.15lb/cf CA-B: 0.10lb/cf CA-C: 0.06lb/cf

2) Decking: Decking and trim shall be nominal 2” x 8” treated lumber (decking replacement), ½” x 8” treated plywood (roof perimeter) and ¾” x12” treated plywood (shelter perimeter). Two dormer Boards are 6” X 6”X 10’ (Custom cut to match the slope of the deck)

3) Nails: Nails for decking shall be 16 penny hot dipped galvanized nails.

4) Fasteners: The wood nailers shall be attached to the existing decking with 302, 304, or 410 stainless-steel fasteners or fasteners specially coated to be used in CCA treated lumber as indicated on the drawings. Furring strips shall be affixed to existing nailers, fascia, and one to another utilizing 1/4"dia x 2 1/2" Long “Zinc-Plated Steel” Lag Screws, or equal.

6A.3 Replacement Decking

1) All rotted or deteriorated decking shall be replaced as determined necessary by the

COTR.

2) For bidding pricing purposes, the contractor shall assume replacement of 212 sqft

(10% of the total square footage of roof: 2124 sf) of wood decking. This amount of material shall be included in the offer amount.

Inspect all the dormers before the project start replace.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

3) If the repair in any area is more than one board wide, the length of repair boards shall be at least two spans long.

4) Install ½” x 8" treated plywood nailers around the counterpoise roof edge and ¾” x 12” treated plywood nailers to support the fiberglass antenna shelter as shown on the drawings.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

DIVISION 7 – THERMAL & MOISTURE PROTECTION

SECTION 7A - EQUIPMENT PROTECTION

7A.1 Scope of Work Provide a protective moisture barrier plastic cover over all electronic equipment, control panels, and power panels.

7A.2 Materials

1) Polyethylene film sheeting, six mils thick, transparent, and in width suitable to adequately cover the equipment.

2) Duct tape used to attach the polyethylene film sheeting shall be waterproof sealing type.

7A.3 Installation Carefully cover the equipment so that no water can enter the cabinets and damage the equipment.

Equipment in service which generates heat and requires ventilation shall have a wood frame constructed above the equipment and covered with polyethylene membrane. All temporary polyethylene covering shall be approved by the COTR.

SECTION 7B – OVERLAYMENT/RECOVER BOARD

7B.1 Scope of Work Install Prime Dens Deck duraguard overlayment board 5/8” thick on the roof deck between the plywood nailers at the outer roof perimeter and the plywood nailers under the fiberglass antenna shelter.

7B.2 Materials Fasteners and insulation boards shall be approved by the membrane manufacturer.

1) Fasteners: Fasteners for attaching the Overlayment Board shall be "Buildex" Roof grip fasteners, #14 diameter with Climaseal coating or approved equal. Fasteners shall be 3" long.

2) 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.

3) Overlayment Board: DensDeck® Prime Fire-tested, gypsum hardboard with glass-mat facers and a pre-primed surface on one side. DensDeck Prime is provided in a 4 x 8 ft (1.2 x 2.4 m) board size and in thicknesses of 1/4, 1/2 and 5/8 inch (6, 13 and 16 mm). Consult Product Data Sheet for size, thickness and additional information.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

7B.3 Installation

Install overlayment sheets using two inch long fasteners and distribution plates as specified in this document. The fastener pattern is shown on the drawings. A minimum of one fastener per two square feet will be required. Overlayment sheet joints shall not be wider than 1/8". When overlayment sheets are cut to fit irregular shapes, the board shall be cut to fit the desired shape accurately with true square edges.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

SECTION 7C - SINGLE-PLY PVC ROOFING MEMBRANE

7C.1 Scope of Work The work covered by Section 7C is for a fully adhered, 0.080 inch thick, single-ply Polyvinyl Chloride (PVC) membrane with hot air welded seams.

7C.2 Materials:

1) Single-Ply Membrane:

Membrane shall be a fiberglass-reinforced flexible PVC sheeting, 0.080 inches thick, such as G 410 as manufactured by Sarnafil, Inc., (Tel. 1-800-451-2504), or approved equal. PVC membrane used for flashing and roofing shall be fully adhered with hot air welded joints. Color shall be white. The proposal of another manufacturer's product requires the following: Membrane manufacturer's Catalog and Specification Data including descriptions and detailed application instructions, standard installation detail drawings, product characteristics, physical properties, a copy of the 20 year warranty. Acceptable Alternate Manufacturers

For Flashing: G410-12, 48 mil and 60 mil (1.2 mm), thermoplastic membrane with fiberglass reinforcement.

For The ROOF: G410-20, 80 mil (2.0 mm), thermoplastic membrane with fiberglass reinforcement.

Certified Polymer Thickness

Membrane manufacturer is to certify that the polymer thickness is of the polymer thickness specified. Certification is to be signed by the membrane manufacturer’s quality control manager. ASTM +/- tolerance for membrane thickness is not accepted.

Color of Membrane

Energy Smart (white), initial reflectivity of 0.83, initial emissivity 0.90, solar reflective index (SRI) of >104.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

Typical Physical Properties (1)

Parameters

ASTM

Test Method Minimum ASTM

Requirement Sarnafil Typical

Physical Properties

Reinforcing Material - Fiberglass Overall Thickness, min., inches (mm) D638 0.0805 (1.14) [0.08 inches)] Tensile Strength, min., psi (MPa) D638 1500 (10.4) 1600 (11.1) Elongation at Break, min. (machine x tranverse) D638 250% / 230% 270% / 250% Seam strength(2), min. (% of tensile strength) D638 75 80 Retention of Properties After Heat Aging D3045 - - Tensile Strength, min., (% of original) D638 90 95 Elongation, min., (% of original) D638 90 90 Tearing Resistance, min., lbf (N) D1004 10 (45.0) 14 (63.0) Low Temperature Bend, -40º F (-40º C) D2136 Pass Pass Accelerated Weathering Test (Xenon Arc) D2565 5,000 Hours Pass Cracking (7x magnification) - None None Discoloration (by observation) - Negligible Negligible Crazing (7 x magnification) - None None Linear Dimensional Change D1204 0.10 % 0.02% Weight Change After Immersion in Water D570 ± 3.0% 2.5% Static Puncture Resistance, 33 lbf (15 kg) D5602 Pass Pass Dynamic Puncture Resistance, 7.3 ft-lbf (10 J) D5635 Pass Pass

*Failure occurs through membrane rupture not seam failure.

2) Flashing Material:

a) Membrane coated flashing material shall be "PVC coated metal ", G 410-L, 25 gauge galvanized steel, coated with a 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.

b) Flashing for the antenna supports within the fiberglass antenna shelter shall be made from Sarnafil, Inc. G 410 PVC membrane or approved equal.

3) Protection Mat:

a. SarnaTred polyester-reinforced PVC protection mat, or approved equal, shall be installed where shown on the project drawings to protect the roofing membrane in high traffic areas.

4) Adhesives:

a) 2170 solvent-based, elastomeric adhesive or approved equal shall be used to attach the membrane, polyester felt and tred protection mat to the substrates specified.

b) 2121 water-based dispersion adhesive or approved equal shall be used to apply a silica sand non-slip surface to the walkway membrane. This product must be protected from freezing.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

c) 11FC and Primer 449: The 11FC is one-component polyurethane construction adhesive. The primer is clear, solvent base primer.

5) Fasteners:

Any screws, nails or miscellaneous hardware for attaching flashing, ladder deck supports, etc., shall be 302, 304, or 18-8 stainless steel alloy. Any screws, fasteners, etc., to attach the treated wood nailers to the existing counterpoise deck shall be stainless steel or similar corrosion resistant fasteners designed to be used in treated wood as shown on the drawings.

7C.3 Caulking for PVC Membrane Caulking to be used on the flashing 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, shall be chemically compatible with the PVC membrane. The following caulking/sealants are accepted, based on chemical compatibility with PVC membranes:

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

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

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

7C.4 Weather Limitations Roofing or insulation materials shall not be applied until the ambient temperature is above 50 deg F with no signs or forecast for rain. Roofing materials shall not be applied when there is excessive moisture in the air causing wet or damp surfaces.

7C.5 Quality Assurance

1) Approved roofing system shall have a Class I-90 wind uplift rating.

2) Applicators shall be trained and qualified for installation of the approved roofing system.

3) The roofing contractor shall be a firm with a minimum of two years experience with the approved roofing system.

4) The Contractor shall be required that the manufacturer’s tech rep visit the site one days at the beginning, one days at the end of the project.

5) The tech rep advice the contractor and COTR concerning the effectiveness and acceptability of the contractor has proposed and implemented method of welds.

6) The tech rep, contractor and COTR shall test all the welds. All welds shall be tested for continuity by running a rounding edge screwdriver along the membrane joints after cooling. Any discontinuities shall be re-welded. Positive evidence of good welding is characterized by an uninterrupted extrusion of melted black material from the joint.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

7) The Resident Engineer (COTR), shall require the contractor to sample the welded seams by cutting two-inch wide cross-section samples of the welded seams. Correct welds will display failure from shearing of the membrane prior to separation of the weld. The Contractor at no additional charge to the FAA shall patch each test cut.

Expect to test at least twice each seams done at that day.

8) The tech rep shall confirm that the finished product will receive the specified manufacturer’s warranty; and send a copy of their site visit report to the COR.

9) The tech rep inspects the roof just before installation of the walkway to assure the roof is watertight. All welds shall be tested and sample for continuity weld.

10) Seam Probing - The Applicator is responsible for probing of all seams.

11) After the membrane has cooled from hot-air welding, check the seams for continuity using a rounded flat head screwdriver or other acceptable tool (seam probe). Firmly press the edge of the screwdriver firmly into the seam area while moving it along the seam. Mark areas where the probe can penetrate the seam for repair.

Quality Assurance Procedures

Seam Samples — A minimum of 3 seam test samples, each approximately 1 inch wide, must be taken on a daily basis by the Roofing contractor. Samples should be taken at the start of each days welding, when they stop for brake, and when starting back up after lunch breaks.

1. Allow the membrane to cool off after hot-air welding. The sample is taken by cutting out a cross-section of the seam approximately one-inch wide by eight inches long with the seam in the center.

2. Using Vice-Grips or pliers, pull the seam apart. The seam is considered acceptable when the top membrane separates within itself.

3. Repair the sample area by hot-air welding a patch that is at least 3 inches larger than the opening in all directions.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

Samples must be dated, and welded over the patch area for the tech rep.

This was a hand weld pass the peel test

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

Machine fail peel test

View of Good peel test cut fiberglass reinforced and polyester reinforced membranes.

7C.6 Product Delivery and Storage All products delivered to the site shall be in original unopened containers. Store membrane rolls lying down, fully protected from moisture. All stored materials shall be protected from damage during construction by the contractor.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

7C.7 Membrane Installation

View of the vor roof and the base for the cone

1) Inspection: The roofing contractor shall examine the surface scheduled to receive the membrane for defects that will adversely affect the execution and quality of work.

2) Preparation: The surface of the insulation and other surfaces to receive membrane shall be dry and free from dust or loose particles which would interfere in obtaining proper adequate bond.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

View of the roof drip edge area

3) Application:

a) Lap Seams Shingle Fashion: The VOR-DME or TACAN counterpoise roof slopes from the fiberglass antenna shelter to the outer edge in all directions. The contractor shall begin at the south edge of the counterpoise roof and lay the PVC membrane east-west towards the center of the roof and stop when reaching the center. Then the contractor shall begin at the north edge of the counterpoise roof and lay the PVC membrane east-west working towards the center of the roof and finish up with a closure strip across the center. This will allow the roof to drain over the laps in a shingle fashion. All references to north-south and east-west are based on the azimuth positioner brackets, which are set on magnetic bearings. A layer of plywood or equal, shall be applied over the fiberglass cone interior floor, prior to installing the PVC membrane. After the antenna shelter is reinstalled, the VOR antennas shall be replaced by the FAA and then the five pedestal antenna supports shall be flashed with PVC membrane. See the project drawings for details.

b) Fully Adhered Membrane: Carefully follow the PVC membrane manufacturer's instructions for using adhesive to install a fully adhered membrane system. The membrane shall be smooth and free from wrinkles, air bubbles, puckers, and similar irregularities which leave an unsightly appearance. Membrane laid that is not in

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562 accordance with this contract , shall be replaced or repaired, at the Contractor’s cost, in a manner that is acceptable to the manufacturer, in order to pass the required inspection for the required manufacturer’s extended warranty. The membrane shall be installed in strips as long as possible in order to minimize the number of end laps and short pieces.

c) Additional Wind Uplift Protection: The first seam from the north and south edge of the starting strip shall have a row of deck screws with plastic plates set on 12 inch centers prior to hot air welding the seams. The first four feet from the roof edge shall have deck screws with plastic plates set on 12 inch centers. See the project drawings for additional wind uplift fastener locations.

d) Joining Overlapped Roof Membrane: All joints shall be made by hot air welding with electric hot-air welding equipment meeting the membrane manufacturer’s approval. Lap areas shall be a minimum of 6 inches wide. No adhesive shall be present within the lap area. Machine welding shall be used on all seams where possible. Hand welding shall only be used where seams are not accessible for machine welding.

e) Machine Welding: Machine welding shall be achieved by the use of an automatic welding machine approved by the membrane manufacturer. When using this equipment, the manufacturer's instructions shall be followed and local code for the electric supply, grounding, and overcurrent protection observed. The automatic welding machine requires 218 to 230 volts at 30 amps. (The use of a contractor-furnished portable generator is recommended.)

f) Hand Welding: The equipment shall be allowed to warm up for at least one minute prior to the start of welding. The lap shall be welded every three feet to hold the material in place. The back edge of the lap shall be welded with a thin, continuous weld to prevent loss of hot air during the final welding. The hot-air nozzle shall be inserted into the lap, keeping the welding equipment at a 45 degree angle to the side lap. Once the proper welding temperature has been reached and the material starts to flow the hand roller shall be applied at a right angle to the welding bun and pressed lightly. For straight laps, the 1 1/2 inch wide nozzle shall be used. For corners and compound connections, the 3/4 inch wide nozzle shall be used.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

Inside cone flashing or Liquid roof detail (can use the liquid or membrane set in sealant). Note new stainless-steel lag bolts and base brackets

g) Roof Edge Flashing: The roof edge fascia flashing and bottom retaining strip shall be fabricated from pvc metal clad metal or approved equal. Flashing details are shown on the project drawings. The roof edge fascia flashing shall be attached to the solid wood nailers with two rows of #10 x 1 1/4 inch long annular ring stainless steel nails set 3 inches on center in a staggered pattern as shown on the drawing details.

The bottom retaining strip shall be attached with #10 x 1 inch stainless steel hex head sheet metal screws set 6 inches on centers.

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

7C.8 Weather Protection

Replacement of the existing roof with a new, single-ply membrane on the HLI VORTAC roof Spec. No. FAA-HLI-1505562

When inclement weather forces a work stoppage or when the contractor leaves the work site at night, over weekends 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.