ATTACHMENT 1 - DESIGN ANALYSIS.pdf

ERRC HAZ-OPS BUILDING

ROOF REPLACEMENT

A&E Predesign and Design Services

FINAL SUBMITTAL

DESIGN ANALYSIS

USDA ARS

Eastern Regional Research Center (ERRC) 600 E. Mermaid Lane Wyndmoor, PA 19038

Prepared For:

U.S. Department Of Agriculture Agricultural Research Service (ARS)

A-E Contract Number: 12305B21D0013 A-E Order Number: 12305B23F0243

Prepared By:

The Johnson-McAdams Firm, P.A.

Greenwood, Mississippi

20 May 2024

EASTERN REGIONAL RESEARCH CENTER

(ERRC) ERRC HAZ-OPS Building Roof Replacement Wyndmoor, PA A&E Predesign and Design Services

FINAL SUBMITTAL DESIGN ANALYSIS

The Johnson-McAdams Firm, PA 20 May 2024

Contents

1 SCOPE OF WORK

1.1 Summary of Requirements

1.2 General Building Descriptions

1.2.1 Original HAZ-OPS Building

1.2.2 North Addition

1.2.3 South Addition

1.2.4 Environmental (Asbestos and Lead)

2 ARCHITECTURAL

2.1 Codes and Standards

2.2 Original HAZ-OPS Building

2.2.1 Demolition Work

2.2.2 Renovation Work

2.3 North Addition

2.3.1 Demolition Work

2.3.2 Renovation Work

2.4 South Addition

2.4.1 Demolition Work

2.4.2 Renovation Work

APPENDIX A – ENVIRONMENTAL ASSESSMENT

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1 SCOPE OF WORK

1.1 Summary of Requirements

The purpose of this project is to provide Architectural-Engineering (A-E) services to the United States Department of Agriculture (USDA), Agricultural Research Services (ARS), to prepare design documents to replace the existing roof assemblies at the HAZ-OPS Building at the Eastern Regional Research Center (ERRC) in Wyndmoor, PA.

1.2 General Building Descriptions

The HAZ-OPS Building can be broken into five roof areas – one for each of the primary bays of the original HAZ-OPS Building (A, B and C), one for the north addition (D), and one for the south addition (E). These areas are depicted in the photo below, and these designations will be utilized when describing the project.

Aerial of HAZ-OPS Building with roof areas labeled in red. (north is to the left)

1.2.1 Original HAZ-OPS Building

The original HAZ-OPS Building was constructed in 1950 and is a single-story structure with a footprint of approximately 1,690 square feet. The building features a cast-in-place concrete structural frame with clay masonry infill between the concrete elements. The original structure is divided into three primary bays, which correspond to Roof Areas A, B and C. Roof Areas A and C

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The Johnson-McAdams Firm, PA 20 May 2024 are approximately 16 feet above the first-floor elevation, while Roof Area C is approximately 22 feet above the first-floor elevation. A small steel ladder at the north and south walls of Roof Area B allow traversal of the three roof areas.

The existing roof deck of the original building appears to be monolithically poured with closely spaced concrete ribs. A 2.5-inch-thick concrete deck spans between the ribs, providing an effective structural depth of 12 inches. Record drawings indicate a mica entrained concrete topping slab was poured over the structural roof deck with a maximum thickness of 5.5 inches. The topping slab is sloped at 1/8-inch per linear foot toward through wall scuppers at each roof area. Core samples indicate the roof assembly to comprise of single-ply PVC membrane, one layer of 1-1/4-inch-thick polyisocyanurate insulation, plus an additional two base layers of 2-inch-thick polyisocyanurate insulation installed over the concrete deck below. Measurements taken of the existing parapet heights, ranging from 4-inches to 14-inches depending on location, indicate their heights in relation to the roof plane are roughly equal to the original design;

therefore, the heights of the parapets appear to have been increased to account for the addition of rigid roof insulation. This was likely accomplished by simply installing continuous preservative-treated wood blocking on top of the original concrete parapets. The existing parapet detail consists of the PVC membrane turning up the inside face of the parapet and extending across its top surface.

The membrane is held in place by a two-piece flashing assembly acting as both a termination bar and the building fascia. The exposed face of the fascia measures 6-inches in height and appears to be mill-finish aluminum.

Roof Area A measures approximately 465 square feet and drains to a single 4-inch by 4-inch through wall scupper at its southeast corner. Stormwater from the scupper is captured by a 12-inch-wide by 8-inch-deep by 12-inch-tall conductor head. The conductor head transitions down to its connection to a 3-inch-wide by 2.5-inch-deep downspout, which delivers captured stormwater to grade. The conductor head and downspout appear to be aluminum. The original building’s copper counterflashing is still in use along the roof’s transition to the adjacent wall plane along its south edge, though it is quite deteriorated. There are two pipe penetrations through the roof, and both are equipped with a PVC transition boot. An 18-inch-wide steel ladder ascends to Roof Area B.

Roof Area B measures approximately 758 square feet and drains to two 4-inch by 4-inch through wall scuppers – one located at both the north and south edges of the roof. Stormwater from each scupper is captured by a 12-inch-wide by 8-inch-deep by 12-inch-tall conductor head, which transitions down to its connection to a 3-inch-wide by 2.5-inch-deep downspout, similar to Roof Area A. The downspouts from Roof Area B drain into the conductor heads of the roof areas below. The conductor heads and downspouts appear to be aluminum.

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There are three pipe penetrations through the roof, and each is equipped with a PVC transition boot. A large copper ventilator original to the building is located at the west end of Roof Area B and is positioned above the fan room below. The ventilator sits atop a curb measuring 60-inches square. The ventilator at its widest point measures 76-inches square. Two 18-inch-wide steel ladders descend to the roof areas below.

Roof Area C measures approximately 465 square feet and is roughly a mirror image of Roof Area A. The roof area drains to a single 4-inch by 4-inch through wall scupper at its northeast corner. Stormwater from the scupper is captured by a 12-inch-wide by 8-inch-deep by 12-inch-tall conductor head. The conductor head transitions down to its connection to a 3-inch-wide by 2.5-inch-deep downspout, which delivers captured stormwater to grade. The conductor head and downspout appear to be aluminum. The original building’s copper counterflashing is still in use along the roof’s transition to the adjacent wall plane along its north edge, though it is quite deteriorated. There are two pipe penetrations through the roof, and both are equipped with a PVC transition boot.

An 18-inch-wide steel ladder ascends to Roof Area B.

1.2.2 North Addition

A single-story addition measuring approximately 365 square feet was constructed at an unknown date on the north end of the original HAZ-OPS Building (Roof Area D). The addition is constructed utilizing a concrete slab-on-grade, load-bearing concrete masonry walls clad with brick veneer, and steel beams supporting a steel roof deck.

Roof Area D features a built-up roof assembly with cinder-type aggregate. Core samples revealed multiple layers of roofing felt and what appears to be a soggy, wet cellulose insulation installed over the steel roof deck. The roof appears to be original to the building and displays signs of heavy deterioration at the membrane surface and parapets, along with fungal growth in many locations.

There are three pipe penetrations through the roof, each set in a pitch pocket.

There are two additional pitch pockets with anchors extending to the structure below that have been abandoned. These likely supported the flue-gas stack when the boiler was installed in the space below. The curb and transition flashing still exist where the flue penetrated the roof, but the stack has been removed and its opening capped. The surrounding parapets are roughly 30-inches tall and are capped with an aluminum coping. The exposed fascia of the coping measures 4-inches tall. The roof drains to a single internal drain with no method of emergency overflow drainage.

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1.2.3 South Addition

A second single-story addition of unknown date measuring approximately 115 square feet was constructed on the south end of the original HAZ-OPS Building (Roof Area E). Based on the brick bond coursing, this structure appears to be constructed of load-bearing masonry on a concrete foundation with a simple single slope roof, likely of wood construction.

Roof Area E measures approximately 145 square feet, which is slightly larger than the footprint of the addition due to an overhang along its south edge. The roof is a single slope structure extending from the exterior wall of the original building toward the south eave of the addition. An aluminum 6-inch K-style gutter (6-inch top width, 4-inch bottom width and 4.5-inch depth) lines the low eave with a single 4-inch by 3-inch downspout delivering water to a concrete splash block at grade. The roof surface appears to be a modified bituminous membrane. The flashing at the roof’s intersection with the adjacent wall appears to be simply set in mastic against the existing brick wall. The flashing is pulled away from the brick in at least one location visible from Roof Area C above.

1.2.4 Environmental (Asbestos and Lead)

Five suspect building material samples were taken and sent to an analytical laboratory for asbestos and lead content analysis. The steel access ladders located on the roof of the original HAZ-OPS Building have been identified as being coated with a very-high lead content paint (19% by weight) that is in poor condition. One mastic sample taken from the west parapet of the north addition (roof area D) tested positive for asbestos. Samples taken from the north addition pitch pockets, roofing felts and cellulose insulation tested negative for asbestos containing materials. See Appendix A for a copy of the environmental assessment.

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2 ARCHITECTURAL

2.1 Codes and Standards

USDA ARS Facilities Design Standard 242.1 2021 International Existing Building Code (IBC) 2021 International Building Code (IEBC) 2021 International Energy Conservation Code (IECC)

2.2 Original HAZ-OPS Building

2.2.1 Demolition Work

The existing roof assemblies across Roof Areas A, B and C of the original HAZ- OPS Building are to be removed in their entirety, including but not limited to roofing membranes, insulation, fasciae, downspouts, flashing, etc., down to the existing concrete roof decking. The existing steel access ladders extending up to Roof Area B are coated in heavily deteriorating lead-based paint. Due to the deterioration of the hazardous finish and the shortcomings of their design, the ladders will be removed and new ladders installed. The existing copper ventilator on Roof Area B will be carefully removed and stored for reinstallation as it is a contributing element to the architectural character of the original building. No asbestos containing materials were identified in the roof assemblies of the original structure.

2.2.2 Renovation Work

A fully adhered ethylene propylene diene monomer (EPDM) roof assembly will be provided at the original HAZ-OPS Building. The assembly will consist of the EPDM membrane, a 1/4-inch-thick cover board and two layers of polyisocyanurate rigid insulation board (5-1/2 inches total) installed over the existing concrete roof decking. This assembly provides an average R-value of R-30 (U-factor of U-0.032) in accordance with the provisions of the IECC. The work includes replacement of all existing aluminum fasciae, scuppers, conductor heads, downspouts and flashings.

A few specific work items associated with the roof replacement of the original HAZ-OPS building are outlined below:

The roofing configuration of Roof Areas A, B and C will remain relatively unchanged with the primary drainage provided by through-wall scuppers at each roof area. The existing concrete roof deck is sloped toward the

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The Johnson-McAdams Firm, PA 20 May 2024 scuppers, and the existing pitch will remain to maintain the exterior appearance of the building.

The existing copper counterflashing at the intersection of Roof Areas A and C to the perimeter walls of Roof Area B is heavily deteriorated and will be replaced with aluminum counterflashing to eliminate the current condition of dissimilar metals where the counterflashing intersects with the parapet flashing.

Copper flashing will be installed over the existing curb supporting the ventilator at Roof Area B.

New steel ladders will be provided at each side of Roof Area B to replace those being removed during the lead abatement process. The design of the ladders will be similar to the existing ladders to maintain their architectural character, though the ladders will be equipped with wider, slip-resistant rungs and a fall protection rail to increase personnel safety while using the ladders.

2.3 North Addition

All work associated with the roof access ladder and roof hatch at the North Addition is included as Bid Option 01.

2.3.1 Demolition Work

The existing roof assembly of Roof Area D is to be removed in its entirety, including but not limited to gravel-bitumen surfacing, roofing membranes, insulation, internal roof drain body, abandoned pipe penetrations, pitch pockets and flue curb, coping flashing, etc., down to the existing steel roof decking. The mastic utilized at the parapet flashing of Roof Area D tested positive for asbestos. Due to the limited size of the affected area, the entire roof area will be treated as asbestos containing building materials for remediation and disposal.

If Bid Option 01 is taken, the existing opening for the abandoned boiler flue will be enlarged for the installation of the ships ladder and roof hatch.

2.3.2 Renovation Work

A fully adhered EPDM roof assembly will be provided at Roof Area D. The assembly will consist of the EPDM membrane, a 1/4-inch-thick cover board, a layer of tapered polyisocyanurate rigid insulation board to provide a roof slope of 1/4 inch per linear roof, and a 3-inch-thick base layer of polyisocyanurate rigid insulation board installed over the existing metal roof decking. This assembly provides an average R-value of R-30 (U-factor of U-0.032) in accordance with

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The Johnson-McAdams Firm, PA 20 May 2024 the provisions of the IECC. The work includes replacement of all existing prefinished metal copings and flashings. The existing internal roof drain will be replaced with a combination primary and secondary drainage unit to provide Roof Area D with a means of emergency overflow drainage in case the primary drain becomes clogged. All abandoned roof penetrations will be removed to reduce points for potential leaks. All existing asbestos containing building materials will be removed.

Under the Base Bid, the existing curb and cap at the abandoned boiler flue will be removed, the steel roof deck will be patched, and the new roof assembly will fully cover the original opening. Leaving the curb and cap in place would create a condition requiring routine maintenance and would provide a point for potential water infiltration.

Under Bid Option 01, the existing curb and cap at the abandoned boiler flue will be removed, and the opening through the steel roof deck will be enlarged to accommodate the installation of a fixed means of roof access. The existing steel channels at the east and west sides of the opening will remain to support a roof hatch, while the steel channel at the south side of the opening will be removed and the steel decking cut back to the adjacent steel beam to increase the opening size. A 24-inch-wide aluminum ships ladder will extend from the existing concrete mechanical pad up to the existing steel beam on the south side of the opening. The ladder will be equipped with an extendable handrail to provide safer ingress and egress through the roof hatch above. The roof hatch will measure 30-inches-wide by 54-inches-long and will sit atop an insulated curb.

OSHA compliant safety rails will be provided at the perimeter of the roof hatch.

2.4 South Addition

2.4.1 Demolition Work

The existing roof assembly of Roof Area E is to be removed in its entirety, including but not limited to the roofing membrane, gutters, downspouts, flashing, etc., down to the existing wood roof decking.

2.4.2 Renovation Work

A fully adhered EPDM roof membrane installed over the existing wood roof decking at Roof Area E. The work includes installation of a 1/4-inch-thick cover board for adhesion of the EPDM membrane and replacement of all existing prefinished metal gutters, downspouts, drip edges and flashings. The flashing along the high side of the roof at the connection to the original HAZ-OPS

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The Johnson-McAdams Firm, PA 20 May 2024 building will be set into a continuous reglet to improve the durability and water resistance of the detail.

Wyndmoor, PA A&E Predesign and Design Services

FINAL SUBMITTAL DESIGN ANALYSIS

The Johnson-McAdams Firm, PA 20 May 2024

APPENDIX A – ENVIRONMENTAL ASSESSMENT

Environmental Assessment for Asbestos and Lead-Based Paint USDA ARS ERRC, Wyndmoor, PA

HAZ-OPS Roof Wednesday 25 October 2023

The A-E project scope for the HAZ-OPS Roof Replacement requires an Environmental Assessment for possible asbestos and lead containing building materials that may be affected by the work. Jerry Martin of The Johnson-McAdams Firm conducted the environmental survey on 11 October 2023. Mr. Martin is an EPA-Certified Asbestos Inspector, Management Planner and Project Designer.

Haz-Ops Building The Haz-Ops building was constructed around 1950 with two additions constructed at later dates. The building is primarily high-bay spaces with a central, two-store area with mechanical equipment on the second level. The building’s front entry (west elevation) is located at this central, two-story section.

Front (West) Elevation of Haz-Ops Building.

The roofs of the building are all low-sloped. The central section of the building and the roofs on each side of the central section were re-roofed at an unknown date with a PVC membrane over rigid board insulation over the concrete roof deck. The north addition (left side of the photo above) has a very old built-up roof that is in poor condition. The south addition (right side of the photo above) has a rolled roofing membrane that appears to be fairly new.

A core sample was cut from the PVC roofing membrane. The PVC roof membrane and the polyiso insulation board are not suspect asbestos containing materials. One suspect asbestos sample (A-231011-01) was taken of mastic on the west parapet of the north addition which is the only material that tested positive for asbestos (see Testing Laboratory Results). One sample of pitch pocket mastic was taken for laboratory analysis, and it tested negative for asbestos.

The built-up roofing membrane was tested for asbestos, and it also tested negative. In addition, the cellulose insulation under the built-up roofing tested negative for asbestos.

The only paint coatings that may be affected by the work are the two steel access ladders.

These ladders are original construction and extend from the lower roofs up to the central high roof of the building. The coatings on these ladders appear to be original and in very poor condition. The two ladders are rusting due to the failure of the paint coatings. One paint sample from the north ladder was sampled and tested 19% lead by weight which would suggest that the original paint was high in white lead. The coatings on the ladders would have to be abated as lead-based paint if they are maintained. The A-E suggests these ladders be removed, disposed of and replaced by new ladders in the roofing design.

End of Report (see list of Samples and laboratory analysis on the following pages)

Environmental Assessment – Samples taken of Suspect ACM

A-231011-01 = Haz-Ops Bldg., north built-up roof, mastic on parapet wall at southwest corner.

A-231011-02 = Haz-Ops Bldg., north built-up roof, mastic in pitch pocket.

A-231011-03 = Haz-Ops Bldg., north built-up roof, built-up roof membrane.

A-231011-04 = Haz-Ops Bldg., north built-up roof, cellulose insulation under built-up roofing.

Environmental Assessment – Samples taken of Suspect Lead-Based Paint

L-231011-100 = Haz-Ops Bldg., paint on roof access ladder, north side of central roof.

Sketch of Haz-Ops Roof showing sample locations.

Asbestos Bulk Analysis Report

Client:

Report Number:

Project/Test Address:

Client Number:

Reported Date:

Received Date:

Analyzed Date:

The Johnson-McAdams Firm 10/24/2023

25-3802

10/24/2023

23-10-03376

7469 Whitepine Rd

Telephone: 800.347.4010

Richmond, VA 23237

Environmental Hazards Services, L.L.C.

USDA Haz-Ops Roof; Wyndmoor, PA

Laboratory Results Fax Number:

662-455-3381

108 W. Market St Greenwood, MS 38930

10/24/2023

Layer Type AsbestosClient Sample Number

Other Materials

Lab Gross DescriptionLab Sample Number

Black to Gray/Black Pliable; Black Brittle;

Inhomogeneous

23-10-03376-001 A-231011-01 22% Cellulose 75% Non-Fibrous

3% Chrysotile

Chrysotile present in black pliable sealant/mastic-type layer located roughly central in sample.

3%Total Asbestos:

Black to Gray Pliable;

Homogeneous

23-10-03376-002 A-231011-02 35% Cellulose 65% Non-Fibrous

NAD

Black Fibrous; Black Brittle; Inhomogenous

23-10-03376-003 A-231011-03 5% Cellulose 25% Fibrous Glass 70% Non-Fibrous

NAD

Brown Fibrous; Black Brittle; Inhomogenous

23-10-03376-004 A-231011-04 80% Cellulose 20% Non-Fibrous

NAD

1 of 2Page

Environmental Hazards Services, L.L.C

Project/Test Address:

Client Number: Report Number:25-3802 23-10-03376

USDA Haz-Ops Roof; Wyndmoor, PA

Other Materials

AsbestosLab Sample Number

Layer Type Lab Gross DescriptionClient Sample Number

Melissa Kanode

1% Asbestos

Analyst:

Reporting Limit:

Method:

QC Blank:

QC Sample:

Mark Case

EPA Method 600/R-93/116, EPA Method 600/M4-82-020

QA/QC Clerk

Reviewed By Authorized Signatory:

58-M12017-1

SRM 1866 Fiberglass

NAD = no asbestos detectedLEGEND:

These results are based on a comparative visual estimate. The condition of the samples analyzed was acceptable upon receipt per laboratory protocol unless otherwise noted on this report. Each distinct component in an inhomogeneous sample was analyzed separately and reported as a composite.

Results represent the analysis of samples submitted by the client. Sample location, description, area, volume, etc., was provided by the client. This report cannot be used by the client to claim product endorsement by NVLAP or any agency of the U.S. Government. This report shall not be reproduced except in full, without the written consent of the Environmental Hazards Service, L.L.C. California Certification #2319 NY ELAP #11714 NVLAP #101882-0 VELAP 460172. All information concerning sampling location, date, and time can be found on Chain-of-Custody. Environmental Hazards Services, L.L.C. does not perform any sample collection.

Environmental Hazards Services, L.L.C. recommends reanalysis by point count (for more accurate quantification) or Transmission Electron Microscopy (TEM), (for enhanced detection capabilities) for materials regulated by EPA NESHAP (National Emission Standards for Hazardous Air Pollutants) and found to contain less than ten percent (<10%) asbestos by polarized light microscopy (PLM). Both services are available for an additional fee.

400 Point Count Analysis, where noted, performed per EPA Method 600/R-93/116 with a Reporting Limit of 0.25%.

* All California samples analyzed by Polarized Light Microscopy, EPA Method 600/M4-82-020, Dec. 1982.

2 of 2Page

Analysis Report

Client:

Project/Test Address:

The Johnson-McAdams Firm

7469 Whitepine Rd

Telephone: 800.347.4010 Richmond, VA 23237

Environmental Hazards Services, L.L.C.

USDA Haz-Ops Roof; Wyndmoor, PA

Client Number:

25-3802

Fax Number:

662-455-3381Laboratory Results

Analyzed Date:

Client Sample Number

Lab Sample Number

Pb (ug/g) ppm

Lead Paint Chip

10/24/2023

10/24/2023

23-10-03380

Reported Date:

Received Date:

Report Number:

108 W. Market St Greenwood, MS 38930

Narrative

ID

10/24/2023

Collection Location % Pb by Wt.

10/11/2023Collection Date:

L-231011-10023-10-03380-001 190000 19

Melissa Kanode QA/QC Clerk

Analysis Method: EPA SW846 7000B

The Reporting Limit (RL) for samples prepared by ASTM E-1979-17 is 10.0 ug Total Pb. The RL for samples prepared by EPA SW846 3050B is 25.0 ug Total Pb. Paint chip area and results are calculated based on area measurements determined by the client. All internal quality control requirements associated with this batch were met, unless otherwise noted.

LEGEND Pb= lead ug = microgram ppm = parts per million ug/g = micrograms per gram Wt. = weight

Reviewed By Authorized Signatory:

Preparation Method: ASTM E-1979-17

The condition of the samples analyzed was acceptable upon receipt per laboratory protocol unless otherwise noted on this report. Results represent the analysis of samples submitted by the client. Sample location, description, area, etc., was provided by the client. Results reported above in mg/cm3 are calculated based on area supplied by client. This report shall not be reproduced except in full, without the written consent of Environmental Hazards Services, L.L.C.

ELLAP Accredtitation through AIHA LAP, LLC (100420), NY ELAP #11714.

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