CHS VOR Roofing Specifications.pdf

DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

TECHNICAL

SPECIFICATIONS

FOR

ELASTOMERIC ROOFING OVERLAY

VHF OMNIDIRECTIONAL RANGE (VOR)

CHS VOR 1400248

Charleston International Airport

Charleston, South Carolina

PREPARED BY:

Shane C. Harvey, AJW-2E15J 06/23/2020

TABLE OF CONTENTS

SECTION TITLE

DIVISION 1 – GENERAL REQUIREMENTS

1-1 SUMMARY OF WORK

1-2 SITE ACCESS, CONSTRUCTION LIMITS, USE OF

FACILITIES, AND WORK HOURS

1-3 CORDINATION, LOCAL PERMITS, AND TESTING

1-4 PLANNED CONTRACT PROGRESS SCHEDULE

1-5 MEETINGS

1-6 SUBMITTALS

1-8 MATERIALS AND EQUIPMENT

1-9 CONTRACT SLOSE OUT

DIVISION 2 SKILLS & QUALIFICATIONS

2-1 FLAT SEAM COPPER PANEL SAMPLE ROOF PANEL

CONSTRUCTION

DIVISION 5 METALS

5-1 SUMMARY

5-2 UNDERLAYMENT/ROSIN PAPER

5-3 INSTALATION

5-4 COPPER SHEET METAL ROOF

5-5 SHEET METAL ROOF INSTALLATION

5-6 WEATHER PROTECTION

5-7 FIELD QUALITY CONTROL

DIVISION 6 CARPENTRY

6A DECKING

6A1 SCOPE OF WORK

6A2 MATERIALS

6A3 REPLACEMENT OF DAMAGED DECKING

DIVISION 7 ELASTOMERIC ROOFING OVERLAY SYSTEM

7.1 SCOPE

7.2 MATERIALS

7.3 SURFACE PREPARATION

7.4 COATING APPLICATION

7.5 APPLICATION RATES

7.6 RESTRICTIONS/LIMITATIONS

7.7 METAL ROOF RESTORATION

7.8 PRODUCTS

7.9 EXECUTION

DIVISION 10 SPECIALTIES

10-A ANTENNA SHELTER (TEEPEE) REMOVAL

10-B INSTALLATION OF TEEPEE ANTENNA SHELTER

DIVISION 16 COUNTERPOISE GROUNDING

DIVISION 1 GENERAL REQUIREMENTS

1-1 SUMMARY OF WORK

1-1.1 General. – These specifications, together with the referenced specifications, standards and drawings, document the requirements of the Federal Aviation Administration, hereinafter referred to as the Government or FAA, for work associated with a liquid applied elastomeric roofing overlay to the Charleston VOR VHF Omni directional Range CHS VOR building. Work performed shall include replacement of the existing roof with a new Flat Seam Copper Panel roof substrate as described in the Scope of Work.

CHS VOR

1-1.2 Scope of Work. – The Contractor shall execute and complete the following scope of work for old roof removal and installation of the new polished Copper Sheet surface covered by liquid applied urethane based elastomeric roofing.

• Install 6 mil plastic covering over all electronic equipment inside the VOR shelter.

• Remove Teepee

• Remove 50 monitor antennas and brackets. Salvage all parts for re-use.

• Transport new GFM Teepee to site and, transport old Teepee from site.

• Completely remove and discard all roofing membrane materials down to the bare wood deck. Dispose of all materials at a facility licensed to accept construction debris.

• Install new Flat Seam Copper Panel Roof counterpoise per requirements in this specification.

• Power wash and polish entire copper surface with minimum requirements as prescribed by the manufacturer.

• Remove all dirt, chalking, debris and any other foreign matter. Provide for water to be transported to the site as needed.

• Apply seam sealer (without fabric) (Truco #7141 or equal) on all terne plate seams in order to smooth out surface.

• Apply base coat (Truco #7145 or equal). Apply flood coat and lay in fabric. Apply additional base coat (Truco #7145 or equal) while wet. Allow to dry.

• Apply two finish coats (Truco 7140 or equal). Allow to dry.

• Install new metal edge or terminal strip where required to adequately secure existing roof surface per instructions given on drawings.

• Install rubber walk pads after roof has cured (approximately 28 days). Adhere with finish coat material applied with “bulk loader” with two adhesive strips parallel to roof slope.

• Waste and excess materials are the responsibility of the contractor and shall be removed from the site.

• Install new GFM Teepee.

• Reinstall 50 mushroom antennas & covers.

• Remove damaged ceiling tiles and replace with 2’ by 4’ white, acoustical ceiling tiles.

• Remove and replace carpet in equipment room with similar material.

• Strip, clean, and buff floor tiles in the engine generator room.

1-1.3 Intent of Specifications. - This specification is intended to describe the contract work required to complete the re-roofing project. The Contractor shall provide all labor, tools, equipment, machinery and transportation necessary to execute the work. All work performed and all materials and equipment used shall be subject to the approval of the Contracting Officer's Representative (COR). This shall include, but not be limited to, testing, inspection, scheduling, reporting, and submittals.

1-1.4 Drawings & Plans. - The drawings listed below are attached and incorporated as constituting the construction drawings.

CHS-1400248-G001

CHS-1400248-G002

CHS-1400248-G003

CHS-1400248-D001

CHS-1400248-A001

CHS-1400248-A002

CHS-1400248-A003

CHS-1400248-E001

1-1.4.1 Measurements. - All dimensions shall be verified by the Contractor by actual on site measurements. Dimensions shall not be scaled from drawings or other graphical documents. Any discrepancies between the specifications and the existing conditions shall be referred to the Contracting Officer (CO) for adjustment before any work is performed.

1-1.6 Contracting Officer's Representative.- The term "Contracting Officer's Representative" (COR) as used herein denotes the authorized representative of the CO for on site coordination. The COR shall be the focal point for all coordination between the Contractor and the FAA on site. The COR represents the Government primarily in technical matters related to the plans and specifications of the project.

1-1.7 Project Coordination - The Contractor shall coordinate all on-site construction activities with the FAA by contacting the COR.

1-1.8 Layout of Work - The Contractor shall lay out his work from the drawings and limits of the existing roadway lines and shall be responsible for all measurements in connection therewith. The Contractor will be held responsible for the execution of the work to such lines as may be required or indicated in the contract documents.

1-2 SITE ACCESS, CONSTRUCTION LIMITS, USE OF FACILITIES AND

WORK HOURS

1-2.1 General.-

1-2.1.1 Site Access.- Access to the site shall be as approved by the COR in advance on a daily basis.

1-2.2 Construction Limits.- The Contractor shall confine operations, activities, materials and employees within the limits of the work area, as specified by the COR.

1-2.2.1 Damage to Site.- Damage to the FAA site or any abutting properties caused by the Contractor's activities shall be repaired. The Contractor shall pay all costs of such repairs. After notice to proceed and prior to the commencement of construction, the Contractor and the COR shall conduct joint inspections of the existing areas affected by the construction. Existing conditions shall be noted and will be used as the basis for determination of damages caused by the Contractor's operations.

1-2.2.2 Inspection of Site by Contractor.- The Contractor shall have carefully examined the work to determine the extent and conditions under which it must be done.

The Contractor is urged to make a site visit prior to submission of bid. Failure to visit the site shall not relieve the Contractor from responsibility for the work conditions and workmanship as specified herein. The FAA Contracting Officer will provide a date for one official site visit with the Engineer. If any other visits are needed, Contractor must give FAA at least five days advance notice before appearing on site. All visitors must be escorted by an FAA employee, or other authorized personnel.

1-2.3 Contractor's Use of Premises.- The site is located on the Charleston Air Force Base/International Airport property. The contractor will coordinate activities with the CHS SSC, US Air Force, and USAF Joint Base Charleston, and Charleston County Aviation Authority so as not to interfere with critical airport operations at the site.

1-2.3.1 Work Hours.- Work shall begin no earlier than 7:00 am each morning Monday through Friday and shall end no later than 4:30 pm. Any deviation from this work schedule shall be submitted to the COR for approval. All overtime shall be requested in writing to the COR a minimum of 24 hours in advance. Overtime shall be allowed at the COR's discretion.

1-2.3.1.1 Work Stoppages.- During construction, if the Contractor stops work for any reason, the Contractor shall notify the COR at least 24 hours in advance. The Contractor shall notify the COR 48 hours in advance in order to reschedule on site activity after stopping work.

1-2.3.2 Protection of Contract Materials. The Contractor shall assume full responsibility for the protection and safekeeping of any project materials and products stored on the site. Coordinate storage locations with the COR.

1-2.3.3 Housekeeping and Cleanliness. The Contractor shall maintain the job site in a neat and orderly condition including daily cleanup and removal of rubbish and securing equipment and materials.

1-2.3.4 Access to Premises. The Government reserves the right to enter the premises during the term of the contract for periodic work, inspections and to perform other tasks required for the operation and maintenance of the VOR facility. At the end of each workday the facility must be watertight.

1-2.3.5 Removal of Contractor or Subcontractor Employees. The Contractor, upon request of the COTR, shall dismiss from the premises any employee of the Contractor or Subcontractor who, in the opinion of the FAA representative, violates the terms, conditions, or specifications of the contract, or interferes with FAA operations.

Equipment operators employed under this contract shall be experienced and proficient with the equipment to be used.

1-2.4 Security Requirements.-

1-2.4.1 Personnel List.- The Contractor shall provide the COTR with a list of all contract personnel who will require access to the site. Include each individual’s name, date of birth and social security number and the company they work for. Keep the list current throughout the duration of the project work.

1-2.4.2 Security Investigation.- Contractor and Subcontractor personnel may be subject to security investigation by FAA. Upon request by the COTR, the contractor shall promptly complete all security forms provided by the COTR.

1-2.4.3 Right to Search- Current procedures at FAA facilities include the "right to search." If in the judgment of the COTR or other FAA personnel there is cause to search a vehicle or person, such search may be made.

1-3 COORDINATION, LOCAL PERMITS AND TESTING

1-3.1 General.-

1-3.1.1 Scope.- This section covers the requirements for testing and permits, inspections and approvals and coordination of construction required to complete the work.

1-3.2 Requirements.- The FAA facility operates 24 hours per day. Any work done will assure continued operation of the VOR facility.

1-3.2.1 Project Coordination.- The Contractor shall prepare a detailed schedule of work, and arrange the work so as to prevent conflicts between Subcontractors. The Contractor shall be responsible for coordination of the work by different trades and all of the work of this contract. The Contractor shall resolve all coordination conflicts that arise among Subcontractors.

1-3.2.2 Local Permits.- The Contractor shall apply, pay fees, and obtain local building permits and inspections as required. Permits shall be posted as required.

1-3.2.3 Building Codes.- Perform all work in compliance with applicable sections of the most current editions of locally adopted building, electrical, mechanical and other codes and the specifications. If contract documents exceed code requirements, the contract documents shall govern.

1-3.2.4 Test and Inspections.- Perform all testing and inspection of the work required by these specifications during the progress of work. If applicable, perform all testing required by State or local authorities having jurisdiction over the work. Testing and inspection shall be done in the presence of the COTR and other authorities requiring tests. Unless otherwise specified, the Contractor shall pay all costs, including inspection charges and fees, required for testing the work or materials.

1-3.3 Existing Utilities.- During the progress of the work, the contractor shall provide for all existing utilities and services affected.

1-4 PLANNED CONTRACT PROGRESS SCHEDULE

1-4.1 Schedule.- Submit a realistic schedule, including the salient features listed in Section 1-4.2, to the CO for approval within 10 days of the date of award of the contract, unless a different time is specified in the contract clauses.

1-4.2 Salient Features.-

a. Mobilization.

b. Remove Teepee & 50 Mushroom Monitor Antennas

c. Remove roof overlay.

d. Replace copper panel/sheet metal roof counterpoise.

e. Install elastomeric metal roof coating on Terne plate.

f. Reinstall Teepee & 50 Mushroom Monitor Antennas.

g. Demobilization.

h. Interior improvements.

1-5 MEETINGS

1-5.1 Preconstruction Conference.- The Contractor shall attend a preconstruction conference to be conducted by the FAA. Local procedures related to ingress-egress, use of premises, facility security, construction work schedule, temporary facilities, material disposal, and facility operations will be discussed. The time and location for the preconstruction conference shall be established by the CO after contract award.

1-5.2 Acceptance Inspection.- A Contractor Acceptance Inspection (CAI) shall be scheduled upon completion of the work. As a minimum, representatives from the FAA and the Contractor are required to attend.

1-6 SUBMITTALS

1-6.1 General.-

1-6.1.1 Submittal Requirements.- Provide submittals where required in the individual specification sections and as required below.

1-6.1.2 Prior to the Notice to Proceed.- Specific submittal data currently listed and required by the various sections of this specification shall be submitted to the COTR for approval. The following submittal items must be approved by the FAA prior to the Notice to Proceed:

a. Progress schedule.

b. Contractor’s pre-construction safety and health checklist.

c. Contractor’s Emergency Medical Action Plan.

d. Manufacturer to be used for elastomeric roof system.

1-6.1.3 Prior to Delivery of Elastomeric Roofing Materials.- Submit the following before any road materials are delivered.

a. Catalog Cut, Specification Sheet or Technical Data Sheet of the proposed roofing system.

b. Results of the ASTM C794 adhesion test.

c. Catalog Cuts, Specification Sheets or Technical Data sheets for any other

Contractor furnished materials that will become part of the roof overlay system.

1-6.1.4 Samples.- The Government reserves the right to request samples of any products or materials proposed for use on this project. Specific samples currently listed under various sections of this specification will be required.

1-8 MATERIALS AND EQUIPMENT

1-8.1 General.- Materials incorporated into the work shall conform to applicable specifications and standards and comply with size, type and quality specified, or as specifically approved in writing by the COTR. Products shall be suitable for the service conditions. Do not use materials or equipment for purposes other than for which they were designed or specified.

1-9 CONTRACT CLOSE OUT

1-9.1 Acceptance of Work.- The Contractor shall schedule a final inspection with the COTR. The Contractor shall correct discrepancies noted during the final inspection, clean up the premises and notify the COTR that the work is ready for acceptance.

1-9.2 Warranty – The contractor shall provide a written manufacturer’s fifteen year warranty at the close of the project. The warranty shall cover all costs associated with any failure of the elastomeric roof covering roof over the warranty period. The warranty shall identify the project, contractor, manufacturer and the system used.

DIVISION 2 SKILLS & QUALIFICATIONS

2-1 Sample Roof Panel Construction A. Sample Roof Panel. After material samples are approved and prior to starting flat seam copper panel roof work, a 4’ x 5’ portable sample panel of copper over plywood shall be constructed on site. The panel construction shall be accordance with the CDA Publication A4050-04/18: Copper in Architecture Design Handbook. At least 48 hours prior to construction the sample panel, the Contractor shall submit written notification to the Contracting Officer’s Representative. The sample panel shall not be built in, or as part of the structure, but shall be located where directed.

B. Configuration. The panel shall contain one edge with a radius and the associated wood nailer similar to the building roof edge, or otherwise configured to represent the roof edge elements. Long pan seams shall be perpendicular to edge side of panel. The edge leg of the panel shall be a 5 ft. edge. The sample panel shall demonstrate the acceptable level of workmanship for each type of soldering and metal bending represented on the project. Elastomeric roofing shall not be included on the sample panel. The Contractor shall supply legs to the sample and elevate to + 42” AFF min. for ease of inspection.

C. Composition. The panels shall show fully soldered and waterproof joints, proper attachment of cleats and, metal edge construction. Installation or application procedures for fasteners, retaining strips, edge strips, butyl underlayment and, rosin paper shall be shown in the sample panels.

D. Construction Method. The Contractor’s method for fully sweating joints, panel folding, hemming, locking, cleat placement, seaming, cleaning, tinning, wire brushing, and fluxing shall be demonstrated during the construction of the panel.

Selection of appropriate soldering copper, operating temperatures, and, proficiency in use shall be demonstrated. Each person soldering joints on the project shall demonstrate CDA method proficiencies during the sample construction. An independent CDA qualified design installer shall be onsite to verify proper techniques. Should any of the Contractor’s solderer’s not be able to demonstrate proficiency, CDA qualified training shall be required and paid for by the Contractor.

E. Usage. The completed panel shall be used as the standard of workmanship for the type of roof detail represented. Metal terne work shall not commence until the sample panel for that type of construction has been completed and approved. The panel shall be protected from physical damage and construction operations until the roof work has been completed and approved. After completion of the work, the sample panel shall be become the property of the Contractor and shall be removed from the construction site.

DIVISION 5 – METALS

FLAT SEAM COPPER ROOF COUNTERPOISE INSTALLATION

5 - 1 SUMMARY OF WORK

5-1.1 General. – This specification along with project drawings, codes and standards specifies the technical requirements of the Federal Aviation Administration (FAA) to install a Copper Sheet Metal roof on the VOR facility.

5-1.1.1 Provide new copper roofing sheet that meets ASTM standard B370 H00. New roofing sheets must be cold rolled, 99.9% plain copper. New copper roofing sheets may or may not be coated in accordance with 5-1.1.2 below. The name “terne plate” is used in this scope of work and drawings to describe both the new and the old existing roof sheets.

Furthermore, terne plate is old nomenclature that must not be used when ordering new roofing sheets.

5-1.1.2 Any coatings applied to the copper sheet must allow the soldered flat seam method of connection as prescribed by the Contract Specifications 5-4.1 below.

5-1.2 Scope of Work. – The work consists of, but is not limited to, the following:

1. Remove and replace the 16 ft. fiberglass antenna shelter.

2. Survey/mark, remove and reinstall the 50 azimuth antennas. All fifty (50) brackets and supports will be salvaged and reused to the extent possible.

Establish existing magnetic north based on north monitor bracket.

3. Reinstall the 50 azimuth positioner brackets and bracket supports per section

2A.4. Replace any damaged or missing threaded fasteners. Provide ASTM Rated, stainless steel, aluminum alloy and, hot dipped galvanized products only. No zinc coated steel items will be allowed.

4. Install a Copper Panel/Sheet Metal roof over the entire roof surface including inside the fiberglass antenna shelter. Metal roof counterpoise must be soldered and mechanically bonded to antenna mount plate.

5. Install a Copper Panel/Sheet Metal roof. Fold over roof fascia edge.

6. Install cross grip walkway tread area around the cone and to the PVC walkway treads from the main access ladder supports at the roof edge, to the antenna shelter as indicated on the contract drawings.

7. Remove one 120V ground fault interrupter A/C circuit in the antenna shelter.

8. Supply and install one tarpaulin 56 feet in diameter to cover the roof during inclement weather during construction. Diameter of roof is 52’-6”. See section 10B.

9. Provide a protective moisture barrier plastic cover over all electronic equipment, control panels, and power panels prior to start of work on roof.

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.

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 COR.

5-2 UNDERLAYMENT / ROSIN PAPER

5-2.1 Scope of Work

Install felt underlayment and rosin paper covering under sheet metal plate.

Materials

Fasteners and materials shall be approved the copper panel/sheet metal manufacturer.

1. Fasteners: As recommended by felt underlayment manufacturer.

2. Underlayment: ¾” plywood ice / water shield and 30 lb. felt rosin.

3. Rosin paper.

5-3 Installation

Prior to installation, remove all oil, dirt, and other debris from the roof deck. Ensure loose or protruding nails are removed or hammered down. All surfaces shall be dry and free from frost. Lay down one layer of felt underlayment and secure as required. Cover ice / water shield felt rosin paper as recommended by manufacturer. Do not secure rosin paper to deck, this paper serves as a slip sheet between the sheet metal and ice / water shield.

5-4 – COPPER SHEET METAL ROOF

5-4.1 Scope of Work

The work covered by this section is for a flat seam-locked and soldered copper sheet metal roof. Flat seam (also called flat locked seam) is defined as a seam between adjacent metal sheets, formed by turning up edges, folding them over, and then flattening. In a flat seam roof, all seams are soldered.

5-4.2 Materials:

A. Fasteners:

1. Nails – as specified by manufacturer of copper panel/sheet metal.

2. Screws – for batten seam roofs, use screws recommended by manufacturer, long enough to securely fasten batten to roof deck.

B. Cleats – 2” wide, length as required by type of seam being used. Consult roofing manufacturer.

C. Copper panel/sheet metal – to match gauge 20 ounce (22gam 0.027 inches) of existing roof.

D. Solder as manufacturer specifies.

E. Soldering flux per manufacturer requirement.

F. Ice / water shield.

G. Rosin paper.

H. Paint (if required) – formulated to be used on copper panel/sheet metal

Typical Physical Properties

SHEETS:

1. 20-ounce cold-rolled copper or, alloy coated copper.

2. Maximum pan size: 18” x 24”.

SEAMS:

1. ¾” flat locked and soldered.

2. Edges (to be soldered) pre-tinned.

3. Corners notched.

CLEATS:

1. 20-ounce copper.

2. Secured to wood deck or nailers with two 304 stainless steel ring shanked nails.

EDGE STRIPS

1. 20-ounce colled-rolled copper or, alloy coated copper.

2. 8’ or 10’ lengths.

3. Ends lapped at least 1”.

4. Secured with copper, copper alloy or stainless steel fasteners, spaced 4” apart.

5-4.3 Weather Limitations

Roofing materials shall not be applied until the ambient temperature is above 50 degrees 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.

5-4.4 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 five years’ experience with the approved roofing system.

5-4.5 Product Delivery and Storage

All products delivered to the site shall be in original unopened containers. Store materials lying down, fully protected from moisture. All stored materials shall be protected from damage during construction by the contractor.

5-5 Terne-coated sheet metal roof installation

A. Flat Seam Applications:

1. Copper panel/metal sheets shall be 20-ounces. Maximum pan size 18” x 24” Sheets may be fabricated from larger coil stock.

2. Form sheets on a brake as indicated by roofing manufacturer.

a. Mark folds ¾” from edge on all four edges.

3. Before beginning the first course, be governed by proper application at drip edge, end or side wall. Consult roofing manufacturer. All roof perimeters shall have appropriate copper metal drip edge.

4. All seams must be fluxed, malleted or dressed and thoroughly sweated with solder. Use solder as recommended by copper panel manufacturer.

Use rosin only as a flux. Remove excess rosin before painting. NOTE:

flux containing acid shall not be used.

5-6 Weather Protection

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. Roofing materials damaged from wind or rain during construction shall be replaced at the contractor’s expense.

5-7 Field Quality Control

Soldering should be done using soldering coppers of sufficient weight to transfer enough heat to produce a fully sweated seam. Due to difficulties of fully seating the seams, it is not recommended to use “open flame” soldering torches or electric irons for flat seam roofing. Test all soldered seams for continuity at joints after cooling, re-solder any discontinuities.

5-8 Procedure for Soldering Flat Seam Copper Roofing

The following procedure is derived from section 8.5 of Copper in Architecture Handbook and Revere Coppers Publication, Copper and Common Sense. This procedure outlines the process for obtaining a fully sweated solder joint. These procedures are industry standards and should be followed by any contractor regularly engaged in the work of installing flat seam copper roofing.

Materials used:

Dead Blow Hammer

Minimum ¾ lb. soldering irons, chisel type preferred (matched to the type of gas used)

Mapp Gas or Acetylene Gas

Johnson E127 flux (using this flux eliminates the need for pre-tinning the edges of the panel)

Johnson #497 Superflo solder

The process for properly soldering the joints shall be as follows:

-Clean edges of panels with a wire brush or scotch brite pad to remove oxides

-flux folded edges on both sides of the copper panel prior to dressing them down with a dead blow hammer

-dress down joints tightly with a dead blow hammer

-Apply flux again 1.5 inches either side of the seam (copper should be fluxed within an hour of soldering)

-solder joints fully apply soldering iron to top of seam as shown below

-wipe soldered joints clean with a damp cloth(water/vinegar solution) after soldering to remove excess flux

-inspect solder joint for any imperfections, any imperfections can be reheated and resoldered only to those that have been applied that day. Old solder joints cannot be reheated, refer to process for repairing older defective solder joints.

-keep soldering irons clean with a 50-50 mixture of ruby fluid(or equal) and water in a mason jar. Dipping the irons into this mixture will quickly clean them and allow for a quicker, better installation.

* Please note that the use of the Johnson E127 flux negates the need for pre-tinning of the edges of the copper pans.

Procedure for Repairing Older Defective Solder Joints

If the void is 3 to 4 inches long pry the joint open with a putty knife and then brush with a stiff wire brush until all the exposed solder is shiny everywhere.

Beat the brushed seam flat again and use Johnson -e127 flux liberally in and on the joint.

Using a freshly tinned iron and sufficient heat solder the 3 to 5 suspect inches and perhaps one inch on either side of the fix.

If the process outlined above is deemed not adequate by the Resident Engineer contractor shall solder a 6” x 6” 20 oz copper section over the suspect joint below using a riveted soldered lap seam

DIVISION 6 – CARPENTRY

SECTION 6A – DECKING

6A.1 SCOPE OF WORK: After the old roofing has been removed, the contractor shall replace all deteriorated tongue and groove wood decking, wood framing, and fascia material as directed by the COR. All surfaces of the VOR receiving soffit shall be furred with wolmanized furring strips of No. 2 construction grade lumber or better. This amount of material shall be included in the contract bid.

6A.2 MATERIAL:

A. Lumber. Lumber shall be southern yellow pine to match existing.

B. Decking. Decking shall be ¾” CDX tongue and groove plywood throughout.

C. Furring strips. Shall be 2” x 4” (nominal) and shall be installed as shown on project drawings.

D. Nails. Nails for decking shall be 8 penny common nails with pattern per local code for siding.

6A.3 REPLACEMENT OF DAMAGED DECKING

A. All rotted or deteriorated tongue and groove decking, sleepers, joists, and wood fascia boards shall be replaced as directed by the COR.

B. All joints shall fall on nailers.

DIVISION 7 – ELASTOMERIC ROOFING OVERLAY SYSTEM

ROOFING SPECIFICATION

7.1.0 SCOPE

The intention of this specification is to outline the procedures for the application of a synthetic, liquid applied high tensile strength and elongation urethane based elastomeric reflective roof coatings. The coating shall be monolithic, fully adhered, single layer film formed in situ on the existing metal terne plate VOR roof surface. Typical coating dry film thickness shall be approximately 40 dry mils (depending on the particular manufacturer). The coating is to become the top layer of a composite of a roof membrane and underlying existing system. These specifications describe materials, and general methods and conditions necessary for the proper application. Actual application requirements are the responsibility of the installer and should reflect the product used.

7.1.1 SEQUENCE OF OPERATION FOR VOR METAL ROOF RESTORATION

INSTALLATIONS

1. Install plastic protective shield over all electronic equipment inside the VOR shelter. Use 6 mil plastic and install per FAA on site technician requirements.

2. Remove existing Teepee antenna enclosure and outside monitor antenna supports from roof.

3. Fill in holes where Teepee was lagged into the wood decking with urethane based caulking sealant. Fill in entire hole.

4. Seal inside Terne Plate flashing area between flashing and Terne Plate below with urethane based caulking.

5. Remove existing roofing overlay system that is above the VOR Terne plate surface. Remove all overlay system flashings on perimeter.

6. Repair all rusted through Terne Plate areas with new appropriate sheet metal and fuse to Terne Plate with solder.

7. Apply rust remover/inhibiter, allow curing for 24 hours, then powering spray off rust and allow for roof to dry. Note that some seams may have to have a flashing grade material to be applied prior to power washing to prevent water from being forced down into the building. Provide portable water to be used for power spray operations.

8. Apply seam sealing material on all Terne plate seams, new sheet metal seams, and all screw holes.

9. Apply base coat with 100% embedded coverage of the polyester membrane and allow to dry. Roof coating is to be applied on the entire Terne plate area including inside the Teepee area and outside fascia.

10. Apply flashing grade elastomeric coating to fascia.

11. Apply two separate finish coats allowing each coat to dry prior to the subsequent application.

12. Re-install Teepee. Drill pilot holes for lag bolts and fill hole with urethane based caulking prior to installing lag bolts.

13. Apply urethane based caulking at exterior and interior perimeter of Teepee at its base.

14. Re-install exterior mounted antenna mounts. Install urethane based caulking in holes as was done at Teepee prior to bolting through deck.

7.2.0 MATERIALS

Materials for use on the existing metal and PVC roof structures shall be a fluid applied elastomeric roofing system. Urethane based material only is acceptable and material must be compatible with the existing substrate. Flat pitch, vertical metal panels or existing PVC membrane composition may dictate the actual chemical make up of the proposed material. It is imperative that the material is proved to be compatible by the manufacturer for the particular application. See also “Part Two – Products” below for physical performance requirements of the roof coatings.

7.2.1 Use Elastomeric Coating System, Truco or approved equal.

7.2.2 Delivery and storage:

7.2.3 Materials shall be delivered in their original, tightly sealed containers or unopened packages, all clearly labeled with the manufacturer's name, file number, and batch numbers.

7.2.4 Materials shall be stored out of the weather in their original tightly sealed containers or unopened containers as recommended by the manufacturer. Do not allow liquid coating to freeze.

7.3.0 SURFACE PREPARATION

7.3.1 Preparation shall include all requirements specified by the manufacturer to ensure proper adhesion of the products to the existing surfaces. An ASTM C794 adhesion test must be done prior to applying the system to the surface. See also “Part Three – Execution” below for further description of the preparation of the substrate on metal and Division 1-1.2 Scope of Work.

7.3.2 Preparation shall include but not limited to the following:

7.3.3 All unnecessary and non-functional equipment and debris shall be removed from the roof.

7.3.4 Substrate must be pressure-washed. A minimum working pressure of 3,000 psi shall be used to remove all dirt, dust, previous paints & coatings, which are delaminating as well as waste products (oil, oil-based roof cements, solvents, grease, animal fats, etc. Use TSP (Tri Sodium Phosphate) or a similar cleaning solution. Thoroughly rinse roof surface to make sure there is no residue left from the cleaning agent. Metal flashings that are rusted must have scale and excess rust removed per the manufacturer’s specifications before applying flashing grade materials.

7.3.5 HVAC condensate drains shall be permanently routed to roof drains or off roof so as to not adversely affect roof coating system.

7.3.6 Determine moisture content underlying the membrane. Moisture content of 15% or greater indicates a potential problem. Work shall not proceed until the cause of high moisture content is verified and the condition is corrected.

7.3.7 Inspect the condition of flashing details adjacent to protrusions, penetrations, roof mounted equipment, curbs, walls, parapets, drains and roof edge to ensure that details are acceptable and will maintain a weather-tight installation after properly reinforced and coated.

7.3.8 Ponding Water: Contractor shall mechanically eliminate all ponding water areas on the roof prior to application of roof coatings ("Ponding water" is defined as water which does not properly drain and remains for more than 48 hours).

7.3.10 Reinforce all repaired areas according to the particular manufacturer’s requirements.

7.3.11 All cracks, splits, voids or holes larger than 1/8” in width shall be filled and leveled with the particular manufacturer’s seaming requirements.

7.3.12 Reinforce all seams, parapet terminations along with roof terminations and flashing, around drains, scuppers and skylights, the base of all vents and around any other penetration.

7.4.0 COATING APPLICATION

7.4.1 Examine substrate to receive roof coating. Do not proceed with installation of coatings until unsatisfactory conditions have been corrected in a manner acceptable to the manufacturer.

7.4.2 Use a wet film gauge to determine coating thickness every 500 sq. ft. The wet film thickness should be at least twice as thick as the desired dry film thickness per coat. The wet film thickness should be as required by the particular manufacturer..

7.4.3 Entire roof shall be primed per manufacturer’s requirements and must be allowed to cure for a minimum of 24 hours.

7.4.4 Apply elastomeric coating by airless spray equipment, using a mulit-pass spray technique to ensure even application to the existing roof surface. Use a wet film gauge often to measure film thickness. Wet film thickness should be twice as thick as the desired dry film thickness.

7.4.5 First coat shall be applied perpendicular to the seams of the roofing. Dry film thickness shall be approximately 10 mils.

7.4.6 Second coat shall be applied parallel to the first coat. Dry film thickness shall be approximately 10 mils.

7.4.7 Third coat shall be applied perpendicular to the second coat. Dry film thickness shall be approximately 10 mils.

7.4.8 Apply a clear acrylic coating if recommended with the particular system used.

7.4.9 Each coat must be allowed to cure for 24 - 48 hours depending on humidity and temperature. The roof is to be inspected for defects, flaws or holidays and repaired if necessary before a subsequent coat is applied.

7.5.0 APPLICATION RATES

7.5.1 These vary per manufacturer recommendations.

7.6.0 RESTRICTIONS / LIMITATIONS

7.6.1 This system is to be used only in conjunction with commonly accepted roofing standards but not limited to the following:

7.6.2 No application of materials shall commence during inclement weather or when precipitation is imminent. No thinning of materials is permitted.

7.6.3 No materials are to be applied to wet, dirty, or frozen surfaces.

7.6.4 No materials are to be applied at temperatures below 40° F.

7.6.5 Do not apply when dew point is within 5°F of the surface temperature or if freezing temperatures (32°F or lower) are forecasted for the following 24 hours after application of coating products.

7.6.6 No materials are to be applied at ambient air temperatures above 100° F.

7.6.7 No materials are to be applied at relative humidity levels above 88%.

7.6.8 Do not spray apply if the wind velocity exceeds 15 mph without taking precautions to eliminate over spray.

7.6.9 Take all necessary precautions to protect unrelated surfaces from coating over spray or spillage

7.6.10 In conjunction with the final inspection, all debris, containers, materials and equipment are to be properly removed from the job site. Grounds are to be cleaned undamaged and acceptable to the FAA.

7.6.11 Reflectivity of coatings may be reduced if roof surface is not cleaned on a regularly scheduled basis.

7.6.12 Ponding water areas must be repaired prior to any coating application to allow water to drain off the roof.

7.7 METAL ROOF RESTORATION

This document provides sample specifications, product data and application guidelines for the installation of liquid applied elastomeric rubber coatings for the repair and restoration of metal roofs.

PART ONE – GENERAL

7.7.1.1 DESCRIPTION

A. General: Provide all labor, materials, equipment and tools as required to repair and coat existing metal roof and all vertical side wall areas with new materials as specified.

B. The installation is understood to include sealing of roof joints, including but not limited to fasteners, seams, curbs, and penetrations. All preparatory work will then be encapsulated with two coats of rubber roof coating.

7.7.1.2 QUALITY ASSURANCE

A. Qualifications of Manufacturer

1. Provide primary roof coating product from a single manufacturer which has successfully marketed and supplied the products for not less than three years. Provide secondary accessory materials only as recommended and approved by manufacturer of primary materials.

2. Primary products shall include spray, brush, and trowel grade coatings, polyester membrane, and rust conditioning materials.

3. Products primary and secondary shall be manufactured in United States of America

B. Qualifications of Contractor

1. The Contractor shall be certified in the system to be used and possess adequate numbers of qualified workers who are thoroughly trained in the crafts and techniques required to properly install the type of roof coating proposed for use and other work required to complete the work specified.

2. A single installer (roofing contractor or industrial painter) will perform the work. The installer must be trained and certified by product manufacturer, and show written evidence of his authorized status.

3. The installer will own or have access to the equipment necessary, and shall meet all safety, insurance, and technical requirements of the building owner.

C. Warranty

1. The Contractor shall coordinate all necessary inspections, corrections, re-inspections (if any), and certifications with the coating manufacturer as required.

2. Warranty requirements apply only to roof coating to be applied to metal roof areas as described in this section.

3. Warranty period is for 10 years, and shall start at date of substantial completion

7.7.1.3 Preliminary Roof Inspection

A. Upon contract award, the roofing installer and manufacturer’s representative shall tour the roof area. Manufacturer’s representative will record and submit any disputes or concerns governing the installation of the roof system. The installer will complete and submit the manufacturers “Roof Inspection Report” along with pre-application photos depicting the overall roof area and details representative of the installation.

7.7.1.4 Preliminary Project Review

Provide and review the following documentation to the FAA:

1. Specification, including product data, warranty terms, and installation guidelines.

2. Material Safety Data Sheets.

3. Product Liability Insurance.

4. Safety requirements.

5. Evaluation of the roofing material’s physical properties and performance characteristics as verified by an independent accredited testing agency.

6. Installer’s Certificate of Authorization, signed by manufacturer.

7. Roof Inspection Report, including details of special interest and any remedies proposed by manufacturer, its representative, or installer to address unusual requirements beyond the purview of this specification.

8. Review Project Contract, including installer’s logistical requirements such as water and electrical access, material storage area, designated work areas for ground to roof delivery of materials, personnel, etc. Determine work parameters required for a timely, efficient installation with minimal effect on the facilities normal operations. Note that water is not available at this site.

9. Provide a schedule estimating the project’s expected completion date. Consider the possibility of a delay due to poor weather conditions or other external factors.

Establish provisions for addressing primary waterproofing concerns in lieu of a completed installation when nearing the winter season.

10. Coordinate with the FAA for access to work site and allowable hours of work.

7.7.1.5 Factory Mutual

Provide component materials which have been evaluated by Factory Mutual for flame-spread and are rated as Class “A” materials over metal substrates. (Flame spread must be in accordance with ASTM #El0887, Uniform Building Code test method 32-7)

7.7.1.6 Installation Parameters

A. Emergency spot repairs can be made in the winter or during inclement weather.

However, extensive repairs or system installations should not be considered unless the following conditions are met:

1. Surface must be clean and dry prior to application of coatings.

2. Do not begin work if surface temperature is above 140 degrees Fahrenheit or below 40 degrees Fahrenheit, or when the dew point is less than 5 degrees Fahrenheit above the surface temperature.

3. Do not apply over silicone or PVC coatings. For questionable substrates, contact manufacturer’s technical department.

4. Do not begin spray work if wind velocity is above 15 mph.

7.7.1.7 Product Delivery, Storage, and Handling

A. Deliver only approved materials to the job site. Deliver materials in original sealed containers with seals unbroken and labels legible and intact.

B. Materials shall be delivered in sufficient quantities so as not to cause delays in work.

C. Store and handle materials in a manner which will ensure that there is no possibility of contamination. Store in a dry, well-ventilated, weather-tight place, at temperatures between 50 degrees and 80 degrees F. Do not stack pallets more than two (2) high. Do not subject existing roofing to unnecessary loading. In all cases, the storage and handling of ma&ids shall conform to the requirements of the manufacturer and all applicable safety regulatory agencies.

D. Material containers shall not be removed from the job site until final completion and/or until so authorized by the FAA. All waste materials and debris shall be cleaned up daily. Contractor is responsible to remove all trash off site.

E. Any damaged materials or materials not conforming to the specified requirements shall be rejected. Rejected materials shall be immediately re-moved from the job site and replaced at no additional cost.

7.7.1.8 Equipment

A. Roof coatings are most effectively applied using airless spray systems. Conventional air atomized spray systems can be used, but over-spray and drift are more pronounced.

Recommended Airless Spray Equipment, gasoline driven:

Graco GH 733 4050 psi and 3 gal/m capacity Grace GH 533 3000 psi and 2 gal/m capacity Magnum 4000 4000 psi and 3 gal/m capacity Hydra Pro IV or equivalent. 3000 psi and 2 gal/m capacity

B. Use only approved, high pressure, static grounded, solvent- resistant spray hose with the following minimum inside diameters:

Maximum material hose length:

1. 50 ft. - 318” ID

2. 150 ft. - l/2” ID

C. Spray tips - Reversible, self-cleaning tip with an orifice diameter of .025 to .031 with 10” fan pattern; a 0.035 tip is used when spraying the Brush Grade Seam Sealer.

D. Spray pressure - 3000 psi at pump and 1700 psi min. at spray gun.

7.8.2 PRODUCTS

7.8.2.1 Rubber Roof Coating

A. Rubber roof coating products physical specifications and minimum performance criteria shall be in accordance with the following schedules:

1. NEOPRENE FLASHING CEMENT

TEST ASTM RESULT

Elongation at 77 deg. F. ASTMD412 ASTM D412 400% Recovery from 100% Elongation 100% Tensile Strength ASTM D412 ASTM D412 600 psi Min.

ADHESIVE BOND Aluminum Q-Panels

Method A D3359-90 D3359-90 5-highest rating

Method B D3359-90 D3359-90 5-highest rating PLIABILITY @J 0 deg.F.-180 deg. bend D2823-90 D2823-90 1 inch mandrel no cracking or separation 1/4 inch mandrel no cracking or separation

WATER VAPOR PERMEABILITY

E96-80 E96-80 0.15 perms

2. BRUSH GRADE SEAM SEALER

Elongation @ 77 deg. F. ASTM D412 600%

Elongation @ 32 deg. F. ASTM D412 300 %

Recovery from 100% Elongation 100%

Tensile Strength ASTM D412 1500 psi

Viscosity ASTM D562 135-143 K.U.

3. RUBBER COATING

Dry film thickness @ 1 gal/100 sqft. 6 mils Elongation @ 77 deg. F. ASTM D412 600% Elongation @ 32 deg. F. ASTM D412 300%

Recovery from 100% Elongation 100%

Tensile Strength ASTM D412 1500 psi

Shore A Hardness ASTM D2240 70

Viscosity ASTM D562 105-l 10 K.U.

7.8.2.2 Rust Remover and Conditioner

A. Rust remover compound shall be a safe, non-toxic, non-flammable formulation which effectively conditions rust. In addition to treating rust and corrosion, product shall remove oil and dirt and prepares the surface for coating.

TYPICAL PROPERTIES

Flash Point None Specific Gravity 1.10 Weight/Gallon 9.3 Ibs.

pH, undiluted 1.8 Odor Mild, not offensive

Freeze/Thaw Stability Thaw at room-temp.

and shake or stir Spills Flush to sewer Coverage 300-400 sq.ft./gal.

7.8.2.3 Polyester Membrane

A. Reinforcing membrane shall be composed of warp knit, 100% polyester yarn fibers offering an excellent combination of high strength and elongation to accommodate unusual stress forces from thermal shock or building movement.

TYPICAL PROPERTIES

Tensile Strength ASTM D1682 90 lbs. (41 kg.)

Elongation ASTM D1682 45% Trapezoid Tear Strength ASTM D1117 22 lbs. (10 kg.)

Ball Burst Strength ASTM D3787 180 lbs. (82 kg.)

7.8.2.4 Manufacturers

A. The following roof coating manufacturers are approved for this project. Substitutions shall be approved after submission showing compliance with the required product technical properties as listed above.

Truco, Inc.

4301 Train Avenue Cleveland, OH 44113

(800) 227-4569

Western Colloid N.C., Inc.

700 71st Ave.

Oakland, CA 94621 510-430-0270

Pacific Polymers 12271 Monarch St.

Garden Grove, CA 92841 714-898-0025

Belzona 2000 N.W. 88th Court Miami, FL 33172 305-594-4994

B. Other manufacturers requesting approval must submit acceptable information certifying that they are the direct manufacturer from raw material into the specified product and meet the performance criteria required.

7.9.0 EXECUTION

7.9.3.1 Preparation of Substrate

A. Inspect Metal Deck and Metal Walls to receive coatings. Determine if any panels, skylights, stacks, or other roof accessories are beyond restoration, or pose a safety concern for traffic on the roof during or after the installation. Remove and replace as necessary.

B. Treatment of Loose Seams. Flashings & Assorted Details: All large or excessive gaps between end laps, vertical seams, curb units, etc. must be closed or made flush with self-tapping screws. (Backer rod, foam strips or urethane foam may be used to pre-till voids larger than l/4 inch)

C. Fasteners: Re-tighten existing fasteners. Remove defective fasteners and replace with over-sized fasteners. Add additional fasteners when necessary.

D. Apply rust remover & conditioner to all areas exhibiting corrosion using a hand pump/garden sprayer to the affected areas. Apply liberally to areas with severe rust.

Allow a minimum of 45 minutes to elapse before power washing the roof. Roof areas with severe or systemic rust should be provided additional time for the rust remover to react.