Attachment 1 - SOW.pdf

PROJECT SCOPE OF WORK

March 3, 2021

I. PROJECT IDENTIFICATION

A. PROJECT TITLE: Design Build Water Tower Repairs and Recertification

B. BUILDING: Department of Energy, Water Tower

C. LOCATION: 19901 Germantown Road, Germantown, MD 20874

II. PROJECT DESCRIPTION

A. This task order is to obtain Contractor Design-Build (DB) services to implement DOE recommendations in order to obtain recertification of the water tower in accordance with the American Water Works Association (AWWA). Appendix A (List of Modifications/Repairs/Upgrades) includes the list of DOE approved recommendations. It includes repair/update/replace cathodic protection, fall protection, and Non Destructive Testing (NDT) and Stress Analysis to determine the integrity of the water tower structure.

B. The design-build work shall include updating the Federal Aviation Administration (FAA) lighting system on the water tower, replacing valves in the concrete valve pit below the water tower, and providing variable speed drives for pumps in the Boiler House to maintain water pressure for the interim condition while the water tower is out of service. Training shall be provided to plant personnel on operation of the temporary variable speed drives.

C. The design phase of the project shall take 13 weeks (91 calendar days).

The construction phase shall take 180 calendar days from the Government’s acceptance of the final design submission. The total period of performance for the contract is 271 calendar days.

III. PROJECT BACKGROUND

A. The Department of Energy (DOE) Germantown, MD campus, contains a 150,000 gallon water tank constructed between 1956 and 1957 by Chicago Bridge and Iron (CBI). The tank is 125 feet tall and 40 feet in diameter. The tank is a welded steel double ellipsoid supported by five tubular legs with a center riser. GBR Architects prepared a study, dated April 30, 2018

(Attachment 1), to assess the condition of the tank’s cathodic protection system, fall protection, NDT and structural analysis and paint.

B. The tank requires periodic maintenance, repainting and replacement of the cathodic protection system. The fall protection system needs to be updated to current codes and standards. Structural integrity of the water tower has been deemed acceptable after minor repairs are made.

C. The study provided repair/replacement to be used as a guide to design for the tower repairs and recertification.

D. Making the recommended repairs and upgrades will result in the recertification of the water tower in accordance with American Water Works Association (AWWA) standards.

E. All contract personnel who plan on working or visiting the DOE Headquarters must be U.S. Citizens.

F. Project Manager is:

DOE PROJECT MANAGER

Dinis Ndubo General Engineer Department of Energy Office of Logistics and Facility Operations 1000 Independence Ave, SW Washington, D.C. 20585 Phone: (202) 450-0238 Email: dinis.ndubo@hq.doe.gov

IV. ARCHITECTURAL -ENGINEERING SERVICES (PRE-DESIGN)

A. Pre-Design Submissions as required

1. Validation of all As Built conditions including site visit.

2. Attend planning and programming meetings

3. Provide design drawings

4. Confirmation of requirements

5. Job Safety Assessment and Task Risk Assessment, if any

6. Conceptual order of magnitude construction costs

7. Conceptual construction schedule

8. Identification of utility outages, if any

9. Design Basis Document – including:

a) Assumptions,

b) Calculations,

c) Construction schedule mailto:dinis.ndubo@hq.doe.gov

V. DESIGN CONSIDERATIONS

A. The Contractor/AE shall perform all services described herein and all services incidental thereto as required under the contract to both design the project and implement that design. The contractor shall conduct adequate research, site investigation and building survey to enable preparation of accurate, updated construction contract drawings and specifications for the project description as specifically defined by the following:

B. Architectural Considerations

1. Design shall conform to all applicable codes: International Building Code (IBC), GSA Public Building Standard (PBS) P100 and State of Maryland building codes and regulations.

2. Fall protection shall be designed and installed in accordance with applicable OSHA and ANSI standards. Should there be conflict between OSHA, ANSI and GSA standards, the most stringent shall govern.

C. Civil/Structural Considerations

1. Design shall conform to all applicable codes: International Building Code (IBC), GSA Public Building Standard (PBS) P100 and State of Maryland building codes and regulations.

2. Fall protection shall be designed and installed in accordance with applicable OSHA and ANSI standards. Should there be conflict between OSHA, ANSI and GSA standards, the most stringent shall govern.

3. All work performed on the water tower shall be performed in accordance with AWWA and WSSC standards. Should there be conflict between AWWA and WSSC standards, the more stringent shall govern.

4. NDT test shall be performed in accordance with WSSC, AWWA, ASME, ASTM, ANSI and GSA standards.

5. Structural Analysis shall be performed in accordance with WSSC, AWWA ASCE, IBC, ACI, ASTM, ASME, ANSI/AISC and GSA Standards.

D. Mechanical Consideration

1. All Mechanical work shall comply with all applicable codes including GSA Public Building Standard (PBS) P100, and all applicable Federal Regulations.

2. Pre-Design shall verify all existing conditions.

3. Design shall include demolition and construction drawings required to install the variable speed drives in the Boiler House and for valve replacement in the water tower concrete valve pit.

4. The design shall specify variable speed drives that match existing models installed at the Germantown Campus.

5. The design shall include the removal of the three existing gate valves (one 10” and two 6”) in the valve pit and replacement with Government provided ball valves. The design shall include contractor provided gaskets, bolts, and flange kits. The design shall include piping as required to accommodate new valves.

6. Training shall be provided to plant operators for the new variable speed drives in the interim condition.

7. The design shall specify piping, insulation, and equipment labeling and color per DOE standards.

8. At a minimum all interior painting shall have the surface prepared by scrapping and wire brushing, then coated with an epoxy paint.

E. Electrical Consideration

1. All Electrical work shall comply with NEC, all applicable codes, GSA Public Building Standard (PBS) P100, and all applicable Federal Regulations.

2. Pre-Design shall verify all existing conditions.

3. Drawings shall include all lighting layouts.

4. Drawings shall include all information related to the new cathodic protection system.

5. Drawings shall include power plans with panel and circuit designation labels/numbers.

6. Specifications and cut sheets shall include electrical items including light fixtures, switches, cables, conduit, outlets, etc. for DOE review.

7. Lighting shall be in accordance with FAA requirements. FAA Lighting shall be in accordance with 70/7460-1L Advisory Circular Marking and Lighting.

F. Fire Protection Engineering Considerations

1. All Fire Protection work shall conform to all applicable codes and standards, including but not limited to the latest edition of the following:

• US General Services Administration, PBS P100 Facilities Standards for the Public Building Service

• NFPA 101, Life Safety Code

• NFPA 13, Standard for the Installation of Sprinkler Systems

• NFPA 72, National Fire Alarm and Signaling Code

• NFPA 241, Standard for Safeguarding Construction, Alteration, and Demolition Operations.

• International Code Council, International Building Code (IBC)

• International Code Council, International Existing Building Code

• International Code Council, International Fire Code

• Applicable 29 CFR (OSHA) Section 1910 requirements

2. Fire alarm and fire sprinkler systems shall remain active during construction at all times. If for any reason, the contractor must work on the systems, an outage request shall be submitted per DOE SOP.

If the contractor requires a fire sprinkler system shutdown of any area, an outage request and a fire watch requests shall be submitted per DOE SOPs. Provide any means necessary to keep the systems active as per GSA’s PBS-P100 and NPFA 241. At no time during the performance of this work, shall the building be left without a functioning fire alarm system.

3. Life safety devices including, but not limited to, exit signs, emergency lights, etc., shall match existing. Contractor shall coordinate or consult with DOE FPE for any deviations.

4. Contractor A/E shall review equipment location for compliance with NFPA 101 means of egress Chapter 7. Keep all means of egress clear of obstructions and open at all times during construction.

Submit life safety work phasing if means of egress are to be affected in any way by the work performed

G. Lighting Protections

1. All lightning protection system materials and components shall comply with manufacturer's standard design, in accordance with published product information.

2. Provide air terminals, conductors, connectors, conductor straps, fasteners, grounding plates, grounding rods, rod clamps, splicers, and other components required for a complete system that meets UL 96, UL 96A, or NFPA 78 standards.

3. All work shall be performed before tank exterior is painted.

If any damage to the tank results during the installation Contractor shall make the repairs.

4.

H. Safety Considerations

1. The upper and lower platforms support a variety of antennas. Work on these platforms must be coordinated with DOE to ensure these antennas are placed out of service due to RF (radio frequency) exposure concerns.

2. Confined space training must be performed prior to entering enclosed spaces. Confined space permits must be posted at these areas.

3. Working at heights hazards and fall preventions training shall be conducted for all personnel working at the site.

4. Supervisors must emphasize safety is everyone task and responsibility

VI. CONSTRUCTION CONSIDERATIONS

A. Construction shall be completed within 180 calendar days from the Government’s acceptance of the final design submission.

B. Contractor must submit a Safety Plan in accordance with 10-851 CFR and DOE HQ Work Permit for review and approval prior to the commencement of any work activities.

C. Work may be performed during normal business hours – weekdays between 6:30AM and 6:30PM.

D. The contractor shall complete all required Burn Permits and Fire Alarm System Outage Requests with adequate time to gain approval from DOE and GSA prior to any scheduled hot work or dust generating work.

E. Confined space training shall be completed prior to entering enclosed spaces including the water tower and concrete valve pit.

F. Contractor to verify all dimensions prior to construction.

G. Contractor supervisors shall enforce practice of good housekeeping before and after work.

H. All piping connections shall be installed in accordance with all applicable standards, specifications and codes.

I. The contractor shall perform Lock-out Tag-out (LOTO) for all electrical and mechanical work.

J. The contractor shall be responsible for all drain down and refill required to complete work. System isolation for drain down and system restoration after refill shall be addressed using DOE’s LOTO program, which requires a joint effort between the DOE O&M contractor and the construction contractor.

K. Perform start-up testing as required for -

1. Cathodic protection system

2. FAA lighting system

3. Piping system with replaced valves shall be flushed and leak tested

4. Interim condition for pumps in Boiler House

L. The contractor shall provide submittals for review and approval for all material and equipment to be installed under this SOW.

M. Provide the DOE with all cut-sheets, operations manuals and maintenance items, providing hard copy as well as electronic copy.

N. Welder and welder qualification shall be in accordance with AWWA and/or WSSC requirements.

O. Contractor shall perform all work in accordance with OSHA, EPA, AWWA and WSSC requirements.

P. Contractor shall provide containment as required to protect surrounding environment, structures, vehicles, personnel, etc. from damage or harm.

Q. Contractor shall coordinate surface preparation and coating application with demolition/repair/installation of structural work, fall protection, FAA lighting and cathodic protection.

R. Prior to coatings work, bring tank walls to a smooth surface and fill all voids and seams with a 100% solids, non-shrink, compound compatible with and similar in resistance, to the tank lining system. Select compound and apply in accordance with manufacturer’s recommendations.

S. Coatings shall be inspected and tested in accordance with WSSC and AWWA requirements.

VII. DRAWINGS AND DOCUMENTATION

A. All deliverables prepared under this project are the property of the Department of Energy.

B. Provide all review design drawings in half size. Half size shall be legible ANSI B (11x17) drawings. Review drawings must be marked “REVIEW

SET – NOT FOR CONSTRUCTION.”

C. Submit final design specifications in electronic format that can be directly used by Microsoft Word.

D. The contractor shall provide Final sets of design drawings by computer aided design and submit to the Department of Energy in AutoCAD and PDF format.

E. The contractor shall provide red line As-Built drawings on installations/ modifications to systems or equipment associated with this project.

F. The contractor shall provide operation and maintenance (O&M) manuals.

G. The contractor shall provide make, model, serial number, warranty, start-up documentation, and other required data for the Government’s preventive maintenance program for any new equipment installed under this project.

The contractor will fill out and complete the DOE provided forms for equipment to be entered into the preventive maintenance program. The contractor will make and provide PM asset inventory tags for all assets installed under this project per the instructions provided in Appendix A. PM asset identifier to be provided by DOE Asset Inventory Program Manager.

VIII. REQUIRED SUBMISSIONS

A. Detailed proposal and cost estimate

B. Detailed project scheduled within 1 week of Notice to Proceed

1. Schedule shall be updated and provided to DOE COR and PM when changes occur

C. Meeting minutes for project progress meetings

D. 30% Design Submission - (4 half size hard copies, 1 electronic pdf copy)

1. Conceptual design drawings

2. Conceptual specifications

3. Identification of any long lead time items

4. Conceptual construction schedule

5. On-board review meeting

6. Discussion of all Section IV.A items before proceeding to 90%

Design Submission.

E. 90% Design Submission (4 half size hard copies, 1 electronic pdf copy)

1. Design drawings incorporating all comments from the 30% Design Submission to 90% Submission.

2. Specifications incorporating all comments from the 30% Design Submission

3. Estimated construction schedule

4. On-board review meeting

F. FINAL Design Submission (1 full size, 4 half size hard copies, 1 electronic pdf copy)

1. Submission documents incorporating all comments from the 90% Submission

2. Final Original Signed and Sealed Drawing Sets

3. Final Signed and Sealed Specifications

4. Final Design Basis Document

5. Final Construction Schedule

G. Submittal Review Submission (1 hard copy, 1 electronic pdf copy)

1. Transmittal showing review and approval of all construction phase equipment and O&M submittals.

H. CM Services Submissions (1 hard copy, 1 electronic copy)

1. Provide inventory of required contractor submissions.

2. As-Built Drawing Submission (1 half size hard copy, 1 pdf electronic copy, AutoCad files)

I. Documentation as required for DOE Preventative Maintenance Program

J. O&M manuals including all balance, testing, and commissioning reports as required per the design, specifications, and SOW.

IX. DESIGN SCHEDULE BASELINE IS:

Project Kick-off This includes an onsite walkdown with AE and DOE personnel

1 week after NTP

Pre-design Engineering Services 2 weeks

30% Design Submission 4 weeks

Government Review / On Board Review meeting 1 week

90% Design Submission 4 weeks

Government Review / On Board Review meeting 1 week

Final Design Submission 2 weeks

X. ENGINEERING SERVICES (Post-Design)

A. Submittal Review

1. Certify construction contract submittals for compliance with contract requirements and provide recommendations for response and disposition of any Requests for Information and Deviation/Waivers (D/W) requiring Government attention. Provide the engineering expertise and design for corrective actions. Analyze test results and procedures.

(1) Provide the engineering expertise to evaluate and to recommend disposition of D/Ws that may be acceptable as alternative methods, techniques, or products that will meet the contract document requirements. All D/Ws recommended for approval require Government concurrence.

2. Perform a technical review of all vendor data to certify that the proposed methods and materials conform to the requirements of the contract document. Errors, misinterpretations, deficiencies, etc.

identified by the technical review shall be indicated on the submitted data in a clear and concise manner that can be readily interpreted and corrected. Based on the technical review, the A&E shall recommend approval, disapproval, or approval subject to comments of the Contracting Officer’s Representative.

3. Develop and maintain a system for the receipt, disposition, and return of all documentation. Upon completion of this contract, all documentation — including magnetic media and hardcopy — shall be turned over to the Technical Representative. The A&E shall maintain a log of vendor data and submittals that are required by the contract. This log shall contain, as a minimum, the following information:

(1) An up-to-date listing of all required documents already submitted and those still required.

(2) Transmittal number.

(3) Contract due date for Government response.

(4) A brief description of the material contained in the submittal.

(5) Action taken.

4. Support the timely resolution of RFIs that relate to the interpretation of contract documents.

B. Construction Management

1. The AE shall provide red-lined As-Built drawings post-construction.

2. Final red-lined drawings shall be provided in AutoCad and pdf formats. All structural drawings, both new and modification work (ladders, platforms, anchor points, etc.) shall be stamped by a Professional Engineer registered in the State of Maryland.

3. Final

XI. PERIOD OF PERFORMANCE

A. Phase I Design: The final submission (ie, signed and sealed drawings, and signed and sealed specifications) shall be completed 105 calendar days from issuance of the Notice to Proceed.

B. Phase II Construction: The construction shall completed 150 days after acceptance of the final submission.

C. The total period of performance is 255 calendar days after issuance of the Notice to Proceed.

XII. APPENDICIES

A. List of modifications/repairs/upgrades

XIII. ATTACHMENTS

A. GSA/DOE Water Tower Study by GBR Architects, dated April 30, 2018

B. Drawings and pictures for valve replacement

XIII Proposal and Basis of Award

END OF SCOPE OF WORK

APPENDIX A – List of Modifications/Repairs/Upgrades

1. Sanitary

a) Replace the roof suspended cathodic protection (CP) anodes with an underwater hoop type system. Access covers for the old style roof hung CP anodes have been a recurring sanitary issue on drinking water tanks. Access covers age, gaskets rot, covers move and allow contaminated roof water to enter the tank. Replacement of the current anodes will eliminate the sanitary issues related to leaking access covers and contamination of the tank. It appears that the current rectifier can be re-used as part of the upgrade.

Provide a cost to replace the rectifier.

Cathodic protection wiring shall be replaced in its entirety, in existing conduit, from end point to end point, between the Radio Building and the water tower.

b) Ensure that any openings in the roof at the corrosion protection cover plates are sealed.

c) Seal weld all existing CP covers.

d) Replace the current center roof vent with an AWWA style vacuum/pressure relief design to allow for safe use of fine mesh insect trap to meet current AWWA standards.

e) Roof hatch neck is 3.5-in high and does not meet AWWA D100 standard for 4-in minimum height. Neck height shall be increased to meet AWWA minimum.

f) Install fine mesh stainless screen into the bottom flange ring of the overflow pipe, to meet current AWWA standard.

2. Corrosion/Coatings

a) Replace interior cathodic protection anode as noted above.

b) Interior and exterior surfaces of the tank and tank appurtenances need to be NDT tested, fully blasted to bare metal and repainted. Exterior adhesion testing does not support application of an additional over coat. Contractor shall provide containment during blasting and coating as required.

c) Recommended coating systems are as follows:

(1) Interior- zinc primer on all surfaces, stripe coat of epoxy on all seams and edges, 2nd stripe coat on all seams, edges and stiffeners above water, and full application of 100% solids NSF- 61 approved coating. Apply NSF-61 approved flexible caulking to all seam gaps and skip welded areas above water after final coating is completed.

(2) Exterior- zinc primer, epoxy stripe coat all welds, full epoxy coating and then full urethane finish coat to all surfaces.

(Continued)

3. Safety Key Vulnerabilities

a) Safety climb cables on leg, shell, and roof ladders are loose and corroded.

Cables shall be replaced and kept tight per manufacturer specifications.

b) Balcony handrail does not meet OSHA Fall Protection requirements. Handrail has no mid-rail, which should be 21-in above the floor. Install a ¼-in thick by 3-inch wide steel mid-rail along the vertical posts and diagonals.

c) Leg, shell and roof ladders do not meet OSHA width requirement of 16-in between rails. Current ladder is only 13-in wide. In order to be in strict compliance with OSHA the ladders shall be replaced.

d) Remove interior ladder and replace with short section of ladder from balcony level manhole to bottom of bowl.

4. Fall Protection - In order to address fall protection concerns, the following recommended solutions have been provided:

a) Platform Access – Install a new ladder with a ladder climbing system. It is also recommended to install a cage and rest platforms. The ladder shall be designed in accordance with OSHA 1910 regulations and the ladder climbing system shall comply with ANSI Z359.

(1) The ladder shall be similar in length to the existing ladder at 106 feet, but with an increased ladder width to accommodate the ladder climbing system in the center of the rungs.

(2) The ladder climbing system shall extend to ground level to allow workers to connect prior to climbing the ladder. The system shall extend upwards to the top rung and allow the user to leave the ladder prior to disconnecting from it.

(3) A ladder cage provides some support to a climber in case they are stuck between platforms and generally makes the ladder more comfortable to climb.

(4) Similar to the existing condition, rest platforms shall be provided. For a ladder of this length, four rest platforms are be satisfactory. An additional platform shall be installed at the top of the ladder to allow the worker to exit the ladder in a side-step manner (as opposed to the step-through nature of the current ladder) to make the ladder climbing system easier to connect to and disconnect from. This provides safer access at the top of the ladder onto the upper platform.

(5) NOTE: In order to provide a fully compliant solution, both the ladder and the climbing system should be replaced.

However, if installing the solution in phases would be more practical, it is recommended to replace the ladder climbing system first. The inadequate climbing system presents a greater hazard to the worker and replacing it would offer the greater increase in safety.

b) Lower Platform – Provide drawings and cost for either option 1 or option 2.

(1) Option 1 – Install a swing gate and re-paint all exposed guardrail.

(a) The swing gate shall be self-closing and installed so that it is positioned at a height equal to the guardrail.

(b) Re-painting the steel guardrail will protect the steel from further corrosion.

(2) Option 2 – Install anchor point adjacent to the ladder in addition to the swing gate. Re-paint all exposed guardrail.

(a) If the rest platform is not addressed and modified to a compliant platform, an anchor point may be required to provide protection while a worker is transitioning from the ladder climbing system to the guardrail protection on the lower platform.

(b) The swing gate shall be self-closing and installed so that it is positioned at a height equal to the guardrail.

(c) Re-painting the steel guardrail will protect the steel from further corrosion.

c) Upper Platform – Provide drawings and costs for either Option 1 or Option 2.

(1) Option 1 – As mentioned in Option 1 for Platform Access, a platform shall be installed at the top of the ladder with a swing gate. The platform shall comply with OSHA regulations. Re-paint all exposed guardrail.

(a) The swing gate shall be self-closing and installed so that it is positioned at a height equal to the guardrail.

The gate will serve to delineate the perimeter of the upper platform from the rest platform for the ladder.

(b) An additional platform allows workers to safely disconnect from the ladder climbing system while on a protected working surface.

(c) Re-painting the steel guardrail will protect the steel from further corrosion.

(2) Option 2 – Similar to Option 2 for Platform Access, extend the ladder climbing system above the upper platform guardrail to comply with OSHA and ANSI requirements. Re- paint all exposed guardrail.

(a) Extending the ladder climbing system allows workers to safely climb over the top of the ladder and access the upper platform while continuously connected to the fall protection system.

(b) Re-painting the steel guardrail will protect the steel from further corrosion.

d) Top of Tank Access – Provide drawings and costs for either Option 1 or Option 2.

(1) Option 1 – Install new ladder and ramp combination to access the top of tank. Install a platform around the access hatch at the top of the tank. The ladder, ramp, and platforms shall comply with OSHA regulations.

(a) The ladder shall begin at the upper platform and extend vertically to near the top elevation of the tank (approximately 20 feet). At this point a ramp shall be installed to reach the tank hatch. The ladder and ramp shall be divided with a swing gate.

(b) The ladder shall either include a cage or ladder climbing system.

(i) The cage shall also include cage extensions at the beginning of the ladder to prevent a fall over the guardrail of the Upper Platform. [NOTE: A cage may only be used if the ladder height is 24 feet or less, otherwise, a ladder climbing system must be installed.]

(ii) The ladder climbing system shall only be used on vertical ladders and shall run the entire length of the ladder. The system shall be designed in accordance with both OSHA and ANSI requirements.

(c) A platform (approximately 4 feet square) provides a safe working area around the tank hatch.

(d) It may also be necessary to include a restraint anchor point to prevent a worker from falling through the hatch and into the tank.

(e) NOTE: In order to provide a fully compliant solution, the curved ladder and wire rope climbing system should be replaced. However, if installing the solution proves impractical, it is recommended to replace the ladder climbing system with a rigid rail system first, as this will provide the best increase in safety in lieu of replacing the entire ladder.

(2) Option 2 – Install new ladder and ramp combination to access the top of tank. Install a series of restraint anchor points around the access hatch at the top of the tank. The ladder, ramp, and anchors shall comply with OSHA and ANSI regulations.

(a) The ladder shall begin at the upper platform and extend vertically to near the top elevation of the tank (approximately 20 feet). At this point a ramp shall installed to reach the tank hatch. The ladder and ramp shall be divided with a swing gate. A second swing gate shall also be included at the opposite end of the ramp.

(b) The ladder shall either include a cage or ladder climbing system.

(i) The cage shall also include cage extensions at the beginning of the ladder to prevent a fall over the guardrail of the Upper Platform. [NOTE: A cage may only be used if the ladder height is 24 feet or less, otherwise, a ladder climbing system must be installed.]

(ii) The ladder climbing system shall only be used on vertical ladders and shall run the entire length of the ladder. The system shall be designed in accordance with both OSHA and ANSI requirements.

(c) The restraint points shall be installed such that a worker can neither fall off the tank nor fall through the hatch. It is also important that an anchor be installed near enough to the ramp that a worker can connect to the first anchor prior to exiting the protection of the ramp.

(d) NOTE: In order to provide a fully compliant solution, the curved ladder and wire rope climbing system should be replaced. However, if installing the solution proves impractical, it is recommended to replace the ladder climbing system with a rigid rail system first, as this will provide the best increase in safety in lieu of replacing the entire ladder.

5. Non Destructive Testing Test (NDT)

The contractor shall perform NDT test. The non-destructive test will help determine existing corrosion, the thickness of corrosion and invisible cracks on welded seams, trusses and joints.

The safety of personnel shall be of prime importance and all operations shall be conducted in full compliance with ASME B31.3, Chapter VI and inspected according to ASME B31.3 Paragraph 341.3.4.

Contractor shall perform Ultrasonic Test and/or Particle Magnet Test on the tank.

a) Ultrasonic Test: shall not be used for thicknesses less than 10mm or where the scanning surface pipe diameter is less than 4 inches NPS.

Ultrasonic examination procedures shall be sufficiently detailed to ensure 100% of the weld metal seam on the interior and exterior of the tank and non-corrosion presence and also examined on longitudinal defects per ASME V T-542.7.2.3 (1996 rev) or current standard.

b) Particle Magnetic Test: Magnetic Particle Test shall be carried out in accordance with the Contractor approved procedures based upon ASME B31.3 or ASTM E709.

c) Acceptance Criteria: For Magnetic Particle Test the dye penetrant and magnetic particle testing, the testing shall be in accordance with ASME VIII, Div. 1. For Ultrasonic Test UT, the testing indicators exceeding 20% of distance amplitude correction DAC (14 dB) shall be investigated and accepted per acceptance criteria. All defects classified as cracks on welded seams, structure joints shall be rejected and reported.

6. Lighting Protection System: Contractor shall verify the integrity of the ground ring system by making sure the parameters are still in compliance within codes of standards and the system still in good working condition. The current lightening protection uses ground ring and test must be performed beyond the ground ring to include the lightening protection rods at the top of the tower.

a) Existing Air Terminal: The existing air terminal shall be inspected to determine structure integrity.

b) Ground Connections: A minimum of two ground conductor assemblies shall be provided. Grounding conductors shall .not be formed in an included angle of less than 90 degrees, nor shall it have a radius of bend less than 8 inches (203 mi1limeters).

c) Ground rods: Ground rods shall be installed approximately 2 feet from the column footing and shall extend 10 feet (minimum) vertically into the earth.

d) Connections: Bonding plate connections shall be either welded or bolted to the tank surface. Conductor splices and connections between conductors and other components shall be approved exothermic welds. Equipment connections shall provide permanent and effective grounding and bonding.

All connections shall be in accordance with UL 96A. All bonds between elements of the lightning protection subsystem shall be made by welding, brazing, or UL-approved high compression clamping devices.

e) Soft solder shall not be used for bonding any conductor in the lightning protection subsystem. Each bond shall exhibit less than one milliohm of DC resistance.

7. Structural Analysis Recommendation: In order to ensure integrity, durability and reliability of the Water Tank tower based on the age of the water tower stress analysis shall be conducted according to ASCE-07-05 and latest AISC standards.

a) Contractor shall use structural PDMS software modeling or equivalent.

b) The model shall calculate dead, live, gravity, seismic, snow, lateral, rain and wind loads

c) The structural analysis shall provide a total report containing all loads, structural members and schematic drawings of the water tank tower.

8. Structural Recommendations - Recommendations for any required repairs for structurally deficient systems or components based on the structural inspection and assessment conducted.

a) Conduct a structural analysis on the water tank tower

b) Existing Exposed Portion of Valve Pit and Concrete Footings

(1) Repair concrete spall from freeze-thaw damage on the valve pit exposed exterior concrete, approximately 10 SF.

(2) Apply either a penetrating silane sealer such as Protectosil Chem-Trete BSM400, or a surface coating such as Miracote MPC to protect the concrete from further freeze-thaw damage, approximately 500 SF.

(3) All steel hatches and goosenecks shall have all surfaces prepared and coated in accordance with DOE approved submittals.

c) Existing Interior Portion of Valve Pit

(1) Repair corroded reinforcement on the interior of the valve pit and patch concrete, approximately 30 SF.

(2) Remove debris and standing water in the base of the valve pit.

(3) Repair the construction joint of the valve pit with urethane crack injection, approximately 15 LF x 12” thick slab.

(4) Apply either a penetrating silane sealer such as Protectosil Chem-Trete BSM400, or a surface coating such as Miracote MPC to protect the concrete from further freeze-thaw damage, approximately 500 SF.

d) Existing Steel Support Framing

(1) Clean the existing tank support steel including tank legs, steel framing, clevis pins, and turnbuckles and tension rods removing the loose paint and corrosion. Apply new protective coating system per CorrTech’s recommendation and approved DOE system.

(2) Clean the existing handrail system removing the loose paint and corrosion. Take care to remove and re-install existing attachments to the handrail. Coordinate this step with DOE.

Apply new protective coating system per CorrTech’s recommendation and approved DOE system.

Be aware of personal safety requirements associated with exposure to radio frequency radiation when working in the vicinity of the antennas attached to the handrail. Coordinate with DOE for taking antennas out of service when working in this area.

(3) Coordinate overall paint recommendations with CorrTech or another recognized provider of coatings/corrosion engineering and approved DOE system.

(4) Clean the anchor bolts at the foundations by removing debris, corrosion and paint. Apply new protective coating system per CorrTech’s recommendation and approved DOE system.

(5) CorrTech information can be found in Attachment 1.

e) In accordance with AWWA the concrete foundation pads should have adequate drainage to prevent spalling. If necessary soil shall be removed from around the pads to provide a minimum 6-in clearance between soil and top of pads.

9. Existing FAA lighting, switches and wiring in its entirety back to the electrical panel located in the Radio Building. Existing conduits may be re-used. FAA Lighting shall be in accordance with 70/7460-1L Advisory Circular Marking and Lighting.

New lighting shall be LED or as approved by DOE.

10. Contractor is responsible to install and maintain variable speed drive drives on the existing pumps in the Boiler House in order to maintain water pressure in the campus while the water tower is out of service.

11. Contractor shall provide training to plant operators during the period that the water tower is out of service.

12. Remove three (3) existing gate valves (one (1) 10” and two (2) 6”) in the valve pit.

Replace with Government provided ball valves. Contractor to provide gaskets and bolt and flange kits. Modify piping as required to accommodate new valves.

Drawings and pictures will be provided for this piping rework.

GSA/DOE Water Tower Final Study

DOE HQ Germantown, Maryland

Task # GS-P-11-17-MA-0009

April 30, 2018 water towerwater towerwater tower

Final Report

GS-P-11-17-MA-0009 DOE Water Tower Study April 30, 2018

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GSA/DOE Water Tower Inspection / Survey Study

Final Report

Task order# GS-P-11-17-MA-0009

April 30, 2018

Table of Contents

A. Executive Summary

B. Purpose of Study

C. Tank Inspection Report - CorrTech

1. Introduction

2. Executive Summary

3. Observations

a. Interior

i. Roof

ii. Ladders

iii. Shell

iv. Floor

v. Riser/Inlet/Outlet

vi. Cathodic Protection

b. Exterior

i. Roof

ii. Vent

iii. Ladders and Railings (See also Section D Fall Protection)

iv. Balcony

v. Overflow Pipe

vi. Shell

vii. Legs and Riser

viii. Riser Manhole

ix. Ultrasonic Thickness Readings

x. Paint Sample Analysis

c. Recommendations

i. Sanitary

ii. Corrosion/Coatings

iii. Structural

iv. Safety (See also Section D Fall Protection)

4. Photographs

D. Fall Protection – LJB, Inc.

1. Findings

a. Platform Access

b. Lower Platform

c. Upper Platform

d. Top of Tank Access

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2. Fall Protection Requirements

3. Fall Protection Concerns

a. Platform Access

b. Lower Platform

c. Upper Platform

d. Top of Tank Access

4. Fall Protection Recommendations

a. Platform Access

i. Option 1

b. Lower Platform

i. Option 1

ii. Option 2

c. Upper Platform

i. Option 1

ii. Option 2

d. Top of Tank Access

i. Option 1

ii. Option 2

E. Structural – McMullan and Associates

1. Existing Structure Overview

2. Structural Inspection

a. Existing concrete valve pit

b. Existing Concrete Footings

c. Existing Steel Support Framing

3. Structural Assessment

a. Existing Concrete Valve Pit

b. Existing Steel Support Framing

c. Existing Structure

d. Attachments to secondary components

4. Structural Recommendations

a. Existing Exposed Portion of Valve Pit and Concrete Footings

b. Existing Interior Portion of Valve Pit

c. Existing Steel Support Framing

Appendix

I. Photographs - CorrTech

II. Dry Film Thickness Readings – CorrTech

III. ASTM 3359 Adhesion Test Procedures - CorrTech

IV. Paint Sample Laboratory Results – CorrTech

V. Solution Sketches – LJB, Inc.

VI. Product Recommendations – McMullan and Associates

VII. Cost Estimate

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A. Executive Summary

The water tower located on the campus of the Germantown headquarters of the Department of

Energy has a 150,000 gallon elevated water tank that requires periodic maintenance, repainting, and replacement of its cathodic protection system. In addition, the fall protection system must be kept current with industry standards and codes and the structural integrity of the tower must be assessed.

This work is required to recertify the tank.

The survey team, consisting of Bob Meskill and Scott Leighton of Corrtech, Orry Zumbiel of LJB, Inc. and David Whitman-of McMullan & Associates, met at the Department of Energy Headquarters on

Saturday, September 30th to inspect and analyze the existing conditions of the elevated water tower.

The inspection had to take place on the weekend due to the fact that the water tower is a cell site and there was a concern of the radio frequency (RF) being harmful to the team.

The water tank has some corrosion on the interior roof of the tank and the interior seams as well. The interior shell coating, under the water line, has blistering but does not show signs of corrosion but the interior ladder has some metal degradation. The exterior of the tank has some delamination of the coating with some active corrosion and prior corrosion on the outside face especially at the cathodic protection cover plates on the roof. There are openings in the roof at the cathodic protection cover plates that can allow contaminated water into the tank. This presents a sanitary issue and needs to be addressed.

The tank should be scheduled for interior and exterior repainting in the next few years. The cathodic protection system will protect the submerged surfaces but the widespread corrosion on the interior roof will result in section loss on the plates and stiffeners. Coating failure on the exterior will continue to expand but does not pose a structural concern at this time. This tank should be inspected again in 2022 in accordance with AWWA standards.

The fall protection systems in place do not meet the current OSHA code requirements and it is recommended that these systems be replaced for the safety of workers utilizing the water tower. This includes installing a new ladder, with the required width and climbing system, along with a cage and rest platforms; a new swing gate at the lower platform; a new ladder and ramp combination to access the top of the tank including a swing gate; and a new platform around the access hatch. All of the new, or updated, fall system components will need to be painted accordingly.

Several structural issues were observed. Freeze-thaw damage has occurred on the exposed portion of the concrete valve pit. There is minor corrosion and section loss at the base of the steel support framing anchors. The framing and connections showed no signs of overstress or excessive deflection/deterioration. Attachments of various secondary elements such as railings, antennae and catwalks are in good condition with no signs of overstress or excessive deflection.

Recommended structural improvements include repair of concrete spall due to freeze-thaw damage, repair of corroded reinforcement and patching of concrete on the interior of the valve pit and cleaning of steel support framing and application of new protective coating systems. The rough order estimated of construction cost for the above work is $787,008

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B. Purpose of Study

The purpose of this study is to assess the water tower to determine the conditions of the cathodic protection, fall protection, structural integrity and paint to provide repair/replacement options with associated construction cost options to guide a subsequent design for the tower repairs and recertification. The water tower has a 150,000 gallon elevated water tank that requires periodic maintenance, repainting, and replacement of its cathodic protection system. The fall protection system also needs to be kept current with industry standards and codes. Since the water tower was built in

1960 the structural integrity of the tower needed to be assessed also. All of these things will result in the recertification of the tower per the American Water Works Association (AWWA) standards.

C. Tank Inspection Report - CorrTech

1. Introduction

On September 30th, 2017 CorrTech representatives, Bob Meskill and Scott Leighton performed a corrosion and structural assessment of the exterior and interior of the Department of Energy

Germantown elevated water storage tank for GBR Architects. The inspection was conducted to establish the current condition of the tank's coatings and steel substrate. The tank inspected included:

♦ DOE 150,000 Gallon Elevated Tank

This work was completed under CorrTech project #8950 dated March 27, 2017.

At the time of the inspection the following personnel were on site:

Joe Poenisch- DOE Facilities

David Whitman-McMullan & Assoc.

Orry Zumbiel- LJB, Inc.

The tank was inspected in accordance with the latest version of AWWA D101 53 (86R) standard for water tank inspections and the M42 AWWA Tank Guidance Manual.

The interior of the reservoir was inspected with the TankRover remotely operated vehicle, while full.

The TankRover is the only piece of equipment like it in the United States and was developed by

CorrTech. By using the TankRover the interior of the tank was inspected with no special preparation, no additional disinfection and no downtime.

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The TankRover is equipped with a surface-cleaning tool used to remove loose rust or debris in order to view the potential metal loss under the coating. The unit has high-powered thrusters, which are used to maneuver throughout the tank and are used to wash away bottom sediment for observations.

The exterior portions of the tank were inspected by walking the roof and shell portions that were accessible from the ground.

The objectives of the assessment were to:

1. Perform field inspections and tests to assess the structural and coating integrity of the tank.

2. Review the safety compliance of tank ladders and access.

3. Review sanitary conditions and protection

4. Provide recommendations for rehabilitation.

2. Executive Summary

The condition and recommendations for the tank are briefly summarized in this section. For detailed information regarding detailed tank conditions and the specific recommendations please refer to the designated section for the tank.

Tank should be scheduled for interior and exterior repainting in the next few years. The cathodic protection system will protect the submerged surfaces but the widespread corrosion on the interior roof will result in section loss on the plates and stiffeners. Currently there is no visible section loss or pitting on the roof plates or rafters.

Coating failure on the exterior will continue to expand but does not pose a structural concern at this time.

This tank should be inspected again in 2022 in accordance with current AWWA standards.

3. Observations

Photos provided in the report were created from a digital camera and interior pictures were captured in digital format from the interior video. The interior images are as clear as our printed technology will allow. The copies in the report provide a reference for our comments. Keep in mind that for underwater video snaps, the video provides the greatest detail and should be viewed as part of the report.

Narration on the video is done in the field and some of the comments may be different than the written report.

DOE 150,000 Gallon Elevated Tank

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Tank is a welded steel double ellipsoid supported by five tubular legs with a center riser. Tank was constructed in 1956 by Chicago Bridge & Iron. Drawing provided shows the tank to be 125-ft tall and 40-ft diameter.

The water level during the inspection was 5-ft below the overflow.

a. Interior

Inspection ROV was deployed through the perimeter roof hatch. The roof hatch is 25-in by 25-in square with a 3.5-in-in sanitary neck and a 2-in overlapping hatch cover. The hatch was not locked at the time of the inspection.

i. Roof (ceiling)

Interior coating has failed active corrosion on 95% of the surface. Edge corrosion has formed along 90% of the weld seams and along the angle iron roof stiffeners. Corrosion staining was observed along the roof plates. No significant pitting or pack rust were observed to compromise the roof structure.

ii. Ladders

Interior ladder has significant metal loss on the upper rungs which are normally above water. Section loss makes safe climbing questionable.

iii. Shell

Interior shell coating has blistering along more than 90% of the submerged surfaces. Areas where coating has delaminated due to blistering show no significant corrosion or metal loss. Mild sediment staining from water deposits was present throughout the shell.

Small pinpoint corrosion tubercles are located on horizontal weld seams. Removal of the corrosion products showed no deep pit formation.

iv. Floor

Tank bowl has a layer of sediment as well as broken anodes. Sediment depth increases from the bowl to the center with a maximum depth of 1-in measured. No significant corrosion was observed.

v. Riser/Inlet/ Outlet

Inlet pipe runs through the riser pipe grate and terminates 10-ft above the floor. Outlet pipe is located inside the riser pipe base and could not be observed due to the riser grate.

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vi. Cathodic Protection

Tank is equipped with a Corrpro impressed current cathodic protection system with roof suspended anodes. System was energized and operating at the time of the inspection with the following readouts from the bowl reference:

2.6V

0.28A

-901mV potential

System appears to be functioning properly. Majority of CP access covers on the roof are loose with a small amount of daylight seen which could present a potential sanitary issue.

b. Exterior

i. Roof

Exterior roof coating has coating delamination, active corrosion and corrosion staining on 10%. Coating has moderate chalking due to UV exposure and micro-cracking due to age. Majority of coating delamination was observed near the CP cover plates.

Dry film thickness readings were taken to determine the thickness of the coating system. The readings averaged 9.7 mils with the minimum reading being 5.5 mils and the maximum reading being 15.9 mils, see Appendix II.

An adhesion test was performed in accordance with ASTM 3359 Methods A&B. Although Method B is for thinner coatings the comparison of the test results is valuable. Method A “X” cut showed a 5A rating which is good for all layers of paint. Method B “Cross-cut” showed a poor 2-3B rating between the upper coating layers and the red primer. Overall adhesion strength is low between top coat layers and the primer.

ii. Vent

Roof vent is a mushroom style cap equipped with intact coarse mess screening and a collar diameter of

12-in and a 7-in roof to vent cap distance. Active corrosion has formed along 10% of the collar.

iii. Ladders and Railings

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Leg ladder beings 2-ft above grade and is equipped with a locked anti-climb and safety cage. Leg ladder is equipped with a cable style fall arrest system. Ladder measurements are as follows. Rung to ruing 12-in, rung to leg 7.5-in and rung width is 13.75-in. No section loss was observed.

iv. Balcony

Balcony has a width of 30-in and as active…