UHHZ_060184_-_Appendices_(Reports)_Attachment__1_of_8.pdf

G:\JOBSEVEN\12340-28\Lead Paint\REPORT-60.doc

FINAL SUBMITTAL

LEAD SURVEY REPORT

BUILDING NO. 181

UNITED STATES AIR FORCE

ROBINS PARKWAY

ROBINS AIR FORCE BASE

WARNER ROBINS, GEORGIA

G:\JOBSEVEN\12340-28\Lead Paint\REPORT-60.doc

FINAL SUBMITTAL

LEAD SURVEY REPORT

BUILDING NO. 181

UNITED STATES AIR FORCE

ROBINS PARKWAY

ROBINS AIR FORCE BASE

WARNER ROBINS, GEORGIA

MARCH 2012

DAVIS & FLOYD, INC. JOB NUMBER 12340.28

PREPARED BY

DAVIS & FLOYD, INC.

ENVIRONMENTAL DIVISION

GREENWOOD, SOUTH CAROLINA

Final Environmental Assessment

Construction and Operation of

Advanced Metal Finishing Shop

78th Civil Engineer Group, Environmental Management Division Robins Air Force Base, Georgia

January 2006

This page intentionally left blank.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

EXECUTIVE SUMMARY

The Commodities and Industrial Products Division (MAN) proposes to construct and operate an Advanced Metal Finishing Shop (AMFS) to replace the existing Plating Shop operations at Robins Air Force Base (AFB). The existing Plating Shop is antiquated and does not meet the goal of providing for increased and enhanced production capabilities and flexibility in order to meet the needs of war fighters. The proposed AMFS will meet this goal without interrupting current mission requirements to provide aircraft overhaul and repair. It will also include the use of Best Available Technology (BAT) and Best

Available Pollution Control Technology (BAPCT), and reduce environmental emissions and industrial waste generated by maintenance operations. The proposed site for the new

AMFS is currently used for Ground Support Equipment (GSE) operations; thus, new space is needed for GSE, and the 402nd Maintenance Wing (402 MXW) proposes to construct a new GSE Maintenance Facility. The new GSE Maintenance Facility will provide the needed space and meet the goal of providing a new, modernized, consolidated, and efficient GSE facility for maintenance and repair of powered and non-powered GSE, including a secure storage yard for the support equipment. It will downsize and consolidate GSE operations areas to the northwest ramp area, improve productivity of the GSE maintenance function, and support Lean manufacturing and repair functions.

The 78th Civil Engineer Group, Environmental Management Division (78th CEG/CEV) has conducted an Environmental Assessment (EA) to identify and address potential effects of construction and operation of both facilities on new sites at Robins AFB: a new

AMFS and a new GSE Maintenance Facility.

The AMFS portion of the Proposed Action consists of construction of a new AMFS on the “Building 128/148 Site,” and relocation of existing plating shop operations to the new facility. The new AMFS would consist of a new 100,000-square-foot approximate two-story building with a 40,000-square-foot containment basin. Plating and other applicable metal finishing and support operations would relocate to the new facility and the existing

Plating Shop (Building 142) floorspace would be reclaimed and then would be used for i

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop other existing MAN operations such as non-destructive inspection, structural repairs, and machining.

The GSE portion of the Proposed Action includes construction of a new GSE

Maintenance Facility near Pad 8, relocation and consolidation of GSE operations currently housed in Building 148 and at Pad 8 to the new GSE facility, demolition of the

Building 128/148 Site buildings, and demolition or relocation of the GSE-associated buildings and structures at Pad 8.

Two other feasible alternatives to construction of a new AMFS on the Building 128/148 Site are also evaluated in this EA. The two alternatives consist of two alternative sites for construction of the new AMFS, the “Building 181 Site” and the “Building 256 Site.” Like the Building 128/148

Site, the alternative sites are currently occupied by other buildings. Demolition of existing buildings would be required under either the “Construct New AMFS at Building 181 Site

Alternative” or the “Construct New AMFS at Building 256 Site Alternative.” Construction of a new GSE facility and consolidation of GSE operations as described above as part of the Proposed

Action would also occur as part of either alternative.

One other action alternative related to the metal finishing operations (modification and upgrading of current Plating Shop operations in Building 142), was considered in the alternatives analysis performed by the project proponents during prior planning phases.

However, this alternative did not meet a primary criterion for the project to continue meeting existing mission responsibilities to provide aircraft overhaul and repair while the modification and upgrading is occurring. Therefore, this alternative was eliminated from further consideration and from detailed analysis in this EA.

Two alternative actions to constructing a new GSE facility were also considered by the project proponents during the alternatives analysis. These alternative actions (renovation of existing GSE facilities and total onsite replacement of existing GSE facilities) were deemed not feasible because the existing facilities could not be renovated while operations are taking place, and no suitable temporary facility on Robins AFB is available to house the existing Building 148 GSE operations while onsite replacement is ii

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop occurring. Furthermore, these alternatives are inconsistent with Air Force Materiel

Command (AFMC) goals of downsizing and consolidation, and do not address the continuing cost of inefficient operations from dispersed facilities. These alternatives were eliminated from further consideration and from detailed analysis in this EA.

The No-Action, or “status quo” alternative evaluated herein involves no project implementation - neither the AMFS nor the GSE Maintenance Facility would be constructed, GSE operations would not be consolidated, and no structures would be demolished. Operations would continue as they do at present. The “no action” for GSE is also evaluated herein as a subset of each of the two alternatives “Construct New AMFS at Building 181 Site Alternative” and “Construct New AMFS at Building 256 Site

Alternative.”

Neither the Proposed Action, the two Alternative Actions, nor the No-Action Alternative was determined to cause significant adverse short-term or long-term impacts to the environment. Table 2-3 in Section 2.6 compares the alternatives that received detailed evaluation in the EA. In summary, constructing and operating the AMFS at any of the three proposed sites would reduce hazardous waste generation and air emissions in the long term on an equal basis. However, based on recent site investigation findings, the excavated soil and construction debris from the Building 181 Site would be characterized as listed hazardous waste and would require management and disposal as such. The excavated soil and construction debris from the other two sites (Building 128/148 Site and Building 256 Site) considered for the new AMFS will be evaluated to determine whether those materials must be managed and disposed of as solid waste or hazardous waste; the preliminary findings indicate that they would not be characterized as hazardous waste. No wetlands, floodplains, threatened and endangered species, or known cultural resources would be impacted by GSE construction and operation or by AMFS contraction and operation at any of the three proposed sites. Impacts to the other environmental elements and resources were found to be relatively similar for all three sites being considered for the new AMFS.

iii

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

Cumulative impacts were also assessed, and were determined to be insignificant, as also summarized in Table 2-3.

iv

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

CONTENTS

EXECUTIVE SUMMARY ...............................................................................................I

1.0 PURPOSE AND NEED FOR PROPOSED ACTION

1.1 PURPOSE OF PROPOSED ACTION

1.1.1 Advanced Metal Finishing

1.1.2 GSE Operations

1.2 NEED FOR PROPOSED ACTION

1.2.1 Advanced Metal Finishing

1.2.2 GSE Operations

2.0 DESCRIPTION OF PROPOSED ACTION AND ALTERNATIVES

2.1 REQUIREMENTS

2.1.1 New Advanced Metal Finishing Shop

2.1.2 New Ground Support Equipment Maintenance Facility

2.2 PROPOSED ACTION DESCRIPTION

2.2.1 Existing Plating Shop and New Advanced Metal Finishing Shop

2.2.1.1 Existing Plating Shop Building (142) and Operations

2.2.1.2 New AMFS at Building 128/148 Site

2.2.2 GSE Operations

2.3 OTHER ACTION ALTERNATIVES

2.3.1 Construct New AMFS at Building 181 Site Alternative

2.3.2 Construct New AMFS at Building 256 Site Alternative

2.4 NO-ACTION ALTERNATIVE

2.5 ALTERNATIVES CONSIDERED AND ELIMINATED FROM

FURTHER CONSIDERATION

2.5.1 Alternatives to Construction of a New AMFS

2.5.2 Alternatives to Construction of a New GSE Maintenance Facility

2.6 COMPARISON OF POTENTIAL EFFECTS

3.0 AFFECTED ENVIRONMENT

3.1 PHYSICAL ENVIRONMENT

3.1.1 Topography

3.1.2 Surface Waters

3.1.3 Floodplains and Wetlands

3.1.4 Storm Water

3.1.5 Geology and Soils

3.1.6 Groundwater

3.1.7 Water Supply and Drinking Water

3.2 AIR QUALITY

3.2.1 Regional Air Quality

3.2.2 Air Emission Sources

3.3 WASTE MANAGEMENT AND TOXIC MATERIALS

3.3.1 Wastewater

3.3.2 Solid Waste

3.3.3 Hazardous Materials and Waste

3.3.4 Toxic Materials

v

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

3.4 NOISE ENVIRONMENT

3.5 BIOLOGICAL ENVIRONMENT

3.5.1 Flora

3.5.2 Fauna

3.5.3 Endangered, Threatened, and Sensitive Species

3.6 CULTURAL RESOURCES

3.7 SOCIOECONOMIC ENVIRONMENT

3.8 TRANSPORTATION AND SAFETY

4.0 ENVIRONMENTAL EFFECTS

4.1 PHYSICAL ENVIRONMENT

4.1.1 Topography

4.1.1.1 No-Action Alternative

4.1.1.2 Proposed Action

4.1.1.3 Other Action Alternatives

4.1.2 Surface Waters

4.1.2.1 No-Action Alternative

4.1.2.2 Proposed Action

4.1.2.3 Other Action Alternatives

4.1.3 Floodplains and Wetlands

4.1.3.1 No-Action Alternative

4.1.3.2 Proposed Action

4.1.3.3 Other Action Alternatives

4.1.4 Storm Water

4.1.4.1 No-Action Alternative

4.1.4.2 Proposed Action

4.1.4.3 Other Action Alternatives

4.1.5 Geology and Soils

4.1.5.1 No-Action Alternative

4.1.5.2 Proposed Action

4.1.5.3 Other Action Alternatives

4.1.6 Groundwater

4.1.6.1 No-Action Alternative

4.1.6.2 Proposed Action

4.1.6.3 Other Action Alternatives

4.1.7 Water Supply and Drinking Water

4.1.7.1 No-Action Alternative

4.1.7.2 Proposed Action

4.1.7.3 Other Action Alternatives

4.2 AIR QUALITY

4.2.1 No-Action Alternative

4.2.2 Proposed Action

4.2.3 Other Action Alternatives

4.3 WASTE MANAGEMENT AND TOXIC MATERIALS

4.3.1 Wastewater

4.3.1.1 No-Action Alternative

4.3.1.2 Proposed Action

vi

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

4.3.1.3 Other Action Alternatives

4.3.2 Solid Waste

4.3.2.1 No-Action Alternative

4.3.2.2 Proposed Action

4.3.2.3 Other Action Alternatives

4.3.3 Hazardous Materials and Waste

4.3.3.1 No-Action Alternative

4.3.3.2 Proposed Action

4.3.3.3 Other Action Alternatives

4.3.4 Toxic Materials

4.3.4.1 No-Action Alternative

4.3.4.2 Proposed Action

4.3.4.3 Other Action Alternatives

4.4 NOISE ENVIRONMENT

4.4.1 No-Action Alternative

4.4.2 Proposed Action

4.4.3 Other Action Alternatives

4.5 BIOLOGICAL ENVIRONMENT

4.5.1 No-Action Alternative

4.5.2 Proposed Action

4.5.3 Other Action Alternatives

4.6 CULTURAL RESOURCES

4.6.1 No-Action Alternative

4.6.2 Proposed Action

4.6.3 Other Action Alternatives

4.7 SOCIOECONOMIC ENVIRONMENT

4.7.1 No-Action Alternative

4.7.2 Proposed Action

4.7.3 Other Action Alternatives

4.8 TRANSPORTATION AND SAFETY

4.8.1 No-Action Alternative

4.8.2 Proposed Action

4.8.3 Other Action Alternatives

4.9 CUMULATIVE IMPACTS

5.0 LIST OF PREPARERS

6.0 PERSONS CONTACTED

7.0 REFERENCES

vii

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

TABLES

Table 2-1. Current Plating Shop Operations… Table 2-2. Processes Considered for New AMFS................................... ……………13 Table 2-3. Comparison of Alternatives Receiving Detailed Evaluation

FIGURES

Figure 1. Vicinity Map Figure 2. Site Location Map Figure 3. Existing Plating Shop, Proposed Action AMFS Site and Alternative

AMFS Locations Figure 4. Proposed New GSE Facility Project Area Figure 5. Pad 8 GSE Structures Planned for Future Demolition

APPENDICES

A Selections from Final Programmatic Environmental Assessment for Implementation of the Updated General Plan for Robins Air Force Base, Georgia

B Supplemental and Updated Robins Air Force Base Information C Agency/Public Correspondence viii

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

ABBREVIATIONS & ACRONYMS

78th CEG/CEV 78th Civil Engineer Group/Environmental Management Division 402 MXW 402nd Maintenance Wing AASHTO American Association of State Highway and Transportation Officials ACM asbestos-containing material AFB Air Force Base AFI Air Force Instruction AFMC Air Force Materiel Command AFOSH Air Force Occupational Safety and Health AGE Aerospace Ground Equipment AICUZ Air Installation Compatible Use Zone AMFS Advanced Metal Finishing Shop BAT Best Available Technology BAPCT Best Available Pollution Control Technology bgs below ground surface BMP Best Management Practice CA-LLX Combined Anion Cation Liquid-Liquid Extraction CE Civil Engineering CEQ Council on Environmental Quality CFR Code of Federal Regulations DoD Department of Defense DOL Department of Labor DRMO Defense Reutilization and Marketing Office EA Environmental Assessment EED Emissions Elimination Device EO Executive Order EPA U.S. Environmental Protection Agency EPD Environmental Protection Division FEMA Federal Emergency Management Agency FONSI Finding of No Significant Impact FPI Fluorescent Penetrant Inspection FY fiscal year GBIA Greater Base Industrial Area GSE Ground Support Equipment HABS Historic American Building Survey HAER Historic American Engineering Record HVOF High Velocity Oxygen Fuel HWRP Hazardous Waste Reduction Plan IAP Initial Accumulation Point INRMP Integrated Natural Resources Management Plan ix

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

ABBREVIATIONS & ACRONYMS (continued)

IRP Installation Restoration Program IT Information Technology IVD Ion Vapor Deposition IWTP Industrial Wastewater Treatment Plant LBP lead-based paint LEED Leadership in Energy and Environmental Design MAN Commodities and Industrial Products Division MANPF Facility / Process Engineering MGD million gallons per day MOA Memorandum of Agreement msl mean sea level NAAQS National Ambient Air Quality Standards NDI non destructive inspection NEPA National Environmental Policy Act NESHAP National Emission Standards for Hazardous Air Pollutants NPDES National Pollutant Discharge Elimination System NRHP National Register of Historic Places OSHA Occupational Safety and Health Administration OWS oil/water separator pcb polychlorinated biphenyl PDM periodic depot maintenance PRG Preliminary Reporting Goal RCRA Resource Conservation and Recovery Act RQ Requirements Document SVOC semi-volatile organic compound SWMP Solid Waste Management Plan SWMU Solid Waste Management Unit TCLP toxicity characteristic leaching procedure USAF United States Air Force USDA United States Department of Agriculture UST underground storage tank VOC volatile organic compound WR-ALC Warner Robins – Air Logistics Center x

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

1.0 PURPOSE AND NEED FOR PROPOSED ACTION

The 78th Civil Engineer Group, Environmental Management Division (78th CEG/CEV) has conducted this Environmental Assessment (EA) pursuant to the National

Environmental Policy Act (NEPA) to identify and assess potential effects of the Proposed

Action, Alternative Actions, and the No-Action Alternatives as described in Section 2, and evaluated in Sections 3 and 4. The Proposed Action includes two projects at Robins

Air Force Base (AFB) – one to address advanced metal finishing and support operations at a site currently used for Ground Support Equipment (GSE) operations, and one to address the displaced and future GSE operations. The purpose and need for action of both projects are described in the following sections.

1.1 PURPOSE OF PROPOSED ACTION

1.1.1 Advanced Metal Finishing

The primary component of the Proposed Action addresses metal finishing/support operations and will replace the existing plating operations that are housed in Building 142 with a new Advanced Metal Finishing Shop (AMFS). The purpose of constructing the new AMFS is to enhance productivity, provide enhanced capability for metal finishing and corresponding support operations for current and future workload equipment and parts, provide modern plating techniques, and provide for Best Available Technology

(BAT) and Best Available Pollution Control Technology (BAPCT). The Proposed Action will support the Warner Robins Air Logistics Center (WR-ALC) at Robins AFB by providing a new facility to coat/plate aircraft components in a safe and efficient manner and produce fewer air emissions and less industrial wastewater. Additionally, one of the objectives of the project is to provide this facility with a certified Leadership in Energy and Environmental Design (LEED) score of 32 or better (minimum 28), and use 20 percent less energy per part compared to current Plating Shop operations in order to comply with Executive Order (EO) 13123. In order to achieve these objectives, construction and operation of a new AMFS is proposed.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

It will provide Robins AFB with state-of-the-art electroplating processes in flexible modular plating lines that are expandable to meet the dynamic aviation industry requirements. The AMFS will reduce water usage and work towards achieving a zero-discharge facility with a rate of water usage in the hundreds of gallons per day. Also, process changes will reduce or eliminate certain air emissions, and more efficient air emissions control equipment will be included in the design. Hence, the new AMFS will reduce the amount of hazardous waste and air emissions that are generated, and enhance compliance with new and ever-changing environmental regulations, although compliance is not currently a problem at the existing Plating Shop.

1.1.2 GSE Operations

The purpose of the GSE component of the Proposed Action is to construct a new, modernized, consolidated, and efficient GSE facility for maintenance and repair of powered and non-powered GSE, including a secure storage yard for the support equipment. It will downsize and consolidate GSE operations areas to the northwest ramp area, improve productivity of the GSE maintenance function, and support Lean manufacturing and repair functions.

Furthermore, constructing the new AMFS on the preferred “Building 128/148 Site” would displace GSE operations housed in Building 148, necessitating relocation of GSE operations currently housed in Building 148 to a new facility.

1.2 NEED FOR PROPOSED ACTION

1.2.1 Advanced Metal Finishing

The existing Plating Shop is not suited to meet the goals of providing increased and enhanced production capabilities and flexibility in order to meet the needs of war fighters, and reducing the environmental burden of maintenance operations; thus a new facility is needed to address the Air Force’s goals.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

The existing facilities that are used in support of the component repair of F-15, C-5, C-

130, and the C-141 aircraft at Robins AFB provide plating, chemical de-paint, abrasive blasting, and a portion of the non-destructive inspection (NDI) processes conducted at the base. The existing Plating Shop was renovated more than 16 years ago and is based on older design concepts. Some process techniques and technologies have been developed and implemented that have significantly reduced pollution, improved worker safety, and improved the metal finishing processing. However, some of the processes are still antiquated. The plating operations dispose of over 80,000 gallons of wastewater per day and some significant opportunities to reduce the amount and type of wastewater cannot be realized due to attributes of the current Plating Shop. The control devices for air emissions meet the minimum applicable aerospace National Emission Standards for

Hazardous Air Pollutants (NESHAP), but the processes could be further improved and result in fewer air emissions and less industrial wastewater than what are currently generated.

1.2.2 GSE Operations

The GSE maintenance function is integral to Robins AFB’s Aircraft Engineering and

Maintenance. Typically, each aircraft processed through a periodic depot maintenance

(PDM) cycle requires approximately 35 pieces of GSE, so this equipment must be maintained in a ready state at all times. GSE operations for maintenance and repair of powered and non-powered GSE are currently split between two maintenance areas (at

Building 148/adjacent area, and at Pads 8/9), which are located about 1.25 miles apart on either side of the existing aircraft apron. Separation of the GSE maintenance and repair function between Building 148 and Pads 8/9 results in unnecessary traffic on the apron and excessive transportation of the workforce, equipment, and materials. It results in the duplication of resources. Also, since personnel are constantly traversing between buildings, communications among personnel and supervisory controls are hampered.

Furthermore, Building 148 houses powered GSE operations, and is a World War II-vintage facility that is in poor condition. The deteriorated condition of the building and the wooden structural components are safety concerns, and the building has been

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop identified as needing demolition. Non-powered GSE operations are located outdoors at

Pad 8 and are vulnerable to inclement weather conditions.

The separation of operations and the substandard condition of some of the existing GSE buildings results in inefficiencies. Furthermore, opportunities to improve productivity of the GSE maintenance function cannot be realized with the current GSE operational setup, and manufacturing and repair functions do not support the Lean concept. Therefore, a new GSE Maintenance Facility that can consolidate GSE operations in the Pad 8 area, near the other GSE operations at adjacent Pad 9, is needed.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

2.0 DESCRIPTION OF PROPOSED ACTION AND ALTERNATIVES

This chapter presents the considerations used for selecting alternatives, describes the

Proposed Action, Alternative Actions, and No-Action Alternatives, and summarizes the environmental consequences of implementing the Proposed Action and each of the alternatives.

2.1 REQUIREMENTS

2.1.1 New Advanced Metal Finishing Shop

The Commodities and Industrial Products Division (MAN) identified several requirements that were based on fulfilling the purpose of the action for a new advanced metal finishing facility. Alternatives that merited detailed evaluation must meet the following criteria that support the purpose and need for action (provide a new facility that can increase production capabilities while reducing environmental burden of maintenance operations). In addition, alternatives were screened against:

• Air Force Handbook 32-1084, “Facility Requirements” (Category Code 211-152, “General Purpose Aircraft Maintenance Shop,” providing space for specialized maintenance activities and space for work, administration, telecommunications, tool cribs, bench stocks, lockers, storage and security of supplies and reparable parts; when possible, collocating aircraft electrical and environmental functions;

incorporating special features such as large, open, work spaces to accommodate aircraft equipment or parts being repaired and floor space and door openings that allow movement and repair of the largest item to be repaired; and providing special ventilation and floor drainage) (USAF, 1996);

• Compliance with Department of Defense (DoD) minimum force protection construction standards as outlined in DoD Minimum Antiterrorism Standards for Buildings (DoD, 2003): a building greater than 150 feet from the controlled perimeter, and a site allowing a 30-foot standoff distance from the structure;

• Ability to provide a 140,000-square-foot AMFS that can modernize plating techniques, enhance productivity, provide for BAT and BAPCT, and provide enhanced capability to electroplate current and future workloads;

• Ability to provide a new, modern building or upgraded space without interrupting current mission requirements to provide aircraft overhaul and repair; and

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

• Ability to provide a new, modern building or upgraded space that includes the following space characteristics (Robins AFB, 2001a):

o 32,292-square-foot area for a Wet Process Operational Level

6-foot minimum aisles between process lines.

Operational level at one end of room for remote/automatic handling equipment.

22 active process lines, 3 backup lines for 2 largest lines, and 1 new process evaluation line.

Sufficient height to handle hoists, ductwork, and other systems without limiting visibility/maintenance, etc.

o 16,146-square-foot area for a Wet Process Support Level

12-foot minimum height (estimated).

House the recycle/reclaim equipment associated with the vats.

o 1,076-square-foot Chemical Storage Area

Contain drums, tanks, mixing, etc. of chemicals to feed wet process lines.

Automatically feed fresh chemicals into process vats to maintain specific chemical composition.

o 32,292-square-foot Containment Area

Used solely to route piping and allow inspection/rearrangement of tanks during life of facility.

Contain no pumps or other maintainable objects. 10 feet (estimated) below grade.

o 10,764-square-foot Preparation (“Prep”) Area

Ability to prep 12 propeller assemblies and 2 design-basis parts, plus room for material storage.

o 21,528-square-foot Dry Process Area

High Velocity Oxygen Fuel (HVOF), Ion Vapor Deposition (IVD), and one additional process and space for a future process.

o 1,076-square-foot NDI Room o 1,615-square-foot Abrasive Blast Room o 11,571-square-foot space for Restrooms/Dressing Rooms (space for 15 women and 40 men), Break Area (size for 25 people), Mechanical Rooms, Electrical Rooms, Administrative Area, Laboratory, and Respirator Cleaning Area (with sinks, water, respirator washer and dryer, inspection, and clean storage area).

o Staging Area (covered path from Building 140 to the new AMFS)

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop o Initial Accumulation Point – space for up to four drums at one time

Selection of a preferred location for the new AMFS involved performance of preliminary studies (transportation assessment and site investigation) of alternative sites and, preliminarily, evaluation of other action alternatives on the current site. Based on the reasons described in Section 2.5.1, it was decided that the AMFS should be constructed at a site other than on the existing Plating Shop site because existing mission requirements could not be met by other action alternatives at the current site.

A site evaluation meeting was held among various project proponents and divisions to discuss alternative AMFS sites and identify the preferred site for the new AMFS.

Aspects of site development at the alternative sites were considered, including known site conditions (such as expected soil and debris requiring special handling and potential for disposal as hazardous waste); facility design aspects related to site topography; expected cost for site remediation, if required; greatest benefit to lifecycle Lean process; proximity to future workload; and other potential future uses of the alternative sites should they not be chosen for the new AMFS site. Based on this review, the “Building 128/148 Site” was chosen as the preferred alternative site for the new AMFS. Thus, the Proposed Action addresses construction and operation of a new AMFS at the Building 128/148 Site, and two alternative actions address construction and operation of a new AMFS at two alternative sites.

2.1.2 New Ground Support Equipment Maintenance Facility

The 402nd Maintenance Wing (402 MXW) identified several requirements that were based on fulfilling the purpose of the action for a new GSE maintenance facility.

Alternatives that merited detailed evaluation must meet the following criteria that support the purpose and need for action (construct a new, modernized, consolidated, and efficient

GSE facility for maintenance and repair of powered and non-powered GSE, including a secure storage yard for the support equipment; downsize and consolidate GSE operations areas to the northwest ramp area, improve productivity of the GSE maintenance function, Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop and support Lean manufacturing and repair functions). In addition, alternatives were screened against:

• Air Force Handbook 32-1084, “Facility Requirements” (Category Code 218-712, “Aircraft Support Equipment Shop/Storage Facility [Aerospace Ground Equipment (AGE) Facility]”) (USAF, 1996);

• Compliance with Department of Defense (DoD) minimum force protection construction standards as outlined in DoD Minimum Antiterrorism Standards for Buildings (DoD, 2003): a building greater than 150 feet from the controlled perimeter, and a site allowing a 30-foot standoff distance from the structure;

• Meet Air Force Materiel Command (AFMC) goals of downsizing and consolidation of GSE operations.

• Ability to provide a 53,000-square-foot GSE Maintenance Facility that can downsize and consolidate GSE operations areas to the northwest ramp area, improve productivity of the GSE maintenance function, and support Lean manufacturing and repair functions;

• Ability to provide a new, modern building or upgraded space without interrupting current mission requirements to provide maintenance and repair of powered and non-powered GSE; and

• Ability to provide a new, modern building or upgraded space that includes the following space characteristics (WR-ALC, undated):

o 17 to 18 544-square-foot repair work areas (9,248 – 9,792 total square feet) for powered GSE items o 12 to 13 672-square-foot repair work areas (8,064 – 8,736 total square feet) for non-powered GSE items o Outdoor semi-protected areas for two wash racks, one drum washer, and hazardous materials storage o Administrative space for eight government personnel and 15 contractor management personnel o Break/training area, including a kitchenette - large enough for 50 to 100 persons o Locker room sufficient for 110 lockers, 12-foot width, full height o Separate rooms for 3,600-square-foot welding shop, 1,000-square-foot tire shop, and 3,600-square-foot electrical shop o Dispatch area for three dispatchers and five drivers o 6,850- to 7,600 square-foot warehouse area o 60,000-square-foot, 8-inch thick concrete base secured staging area o 75,000-square-foot asphalt staging area

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

One site was identified that met the requirements above, and is herein described as

“Proposed New GSE Maintenance Facility Site.”

2.2 PROPOSED ACTION DESCRIPTION

MAN proposes to replace the existing Plating Shop by constructing and operating an

AMFS at the Building 128/148 Site, located within the Greater Base Industrial Area

(GBIA) at Robins AFB. A new GSE facility would also be constructed and operated near the Robins AFB Pad 8 area. Robins AFB is located in Houston County in central

Georgia, approximately 100 miles southeast of Atlanta, 18 miles south of Macon, and immediately east of the city of Warner Robins (Figures 1 and 2).

Components of the Proposed Action include:

• Construction of the new AMFS on the Proposed Action site;

• Relocation of Plating Shop operations and adding new metal finishing processes and pollution-control devices to the new AMFS;

• Reclamation of the existing Plating Shop (Building 142) and relocation of some existing MAN operations from Building 140 to the adjacent Building 142.

• Construction of a new GSE facility;

• Relocation of GSE operations from the Proposed Action site to the new GSE facility, and consolidation of other GSE operations at Pad 8 to the new GSE facility; and

• Demolition of buildings on the Proposed Action site, and demolition/relocation of the majority of GSE facilities at Pad 8 (if and when project funding becomes available).

A description of each of the Proposed Action components, organized by location and function (Existing Plating Shop and New AMFS, and GSE Operations), is presented in the following subsections.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

2.2.1 Existing Plating Shop and New Advanced Metal Finishing Shop

2.2.1.1 Existing Plating Shop Building (142) and Operations

The Plating Shop staff of 25 would relocate to the new AMFS. The new AMFS would replace the existing aircraft overhaul and repair mission activities currently performed in the Plating Shop (Building 142, Figure 3). The current Plating Shop operations are listed in Table 2-1.

Table 2-1. Current Plating Shop Operations

Plating Processes Acid Pickle Lubond Aluminum Etch Magnesium Coat Anodize Masking Black Oxide Nickel Plate Chrome Plate Phosphate Chemical Milling Passivate Cleaning & Corrosion Control Protective Finishes Cleaning, Alkali Selective Plate (Cad) Conversion Coat Silver Plate Copper Plate Stripping, Metex Corrosion Preventative Compound Surface Treatments Electroless Nickel Temper Etch IVD Titanium Etch / Pickling

Vapor Degrease Blasting Processes

Aluminum Oxide Blast Shot Peen Glass Bead Blast Walnut Hull Blast Glass Bead Peen Plastic Media Blast

NDI Processes NDI Processes Magneticparticle Inspections Dye Penetrant Inspections

After relocation of the Plating Shop function to the new AMFS, Building 142 would be reclaimed as useable floor space. This would include removal of all tanks, rectifiers, and piping, new flooring, etc. Henceforth, Building 142 would be used for other MAN operations associated with those currently being performed in the adjacent Building 140, including potentially NDI, structural repairs, and machining.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

2.2.1.2 New AMFS at Building 128/148 Site

The Building 128/148 Site contains Buildings 128, 138, 143, 148, and 432 and is located northwest of the existing Plating Shop (Building 142), north of Building 140, east of

Building 146, and west of Industrial Wastewater Treatment Plant (IWTP) #2. Access to the site is along an unnamed paved access road.

During construction, a contractors’ equipment lay down and staging area also would be established adjacent to the Building 128/148 construction area and along the access routes.

Building 128/148 Site Structures to be Demolished and Operations to be Relocated

Building 128 is currently being used for a variety of MAN functions and houses

Information Technology (IT) staff, the saw shop, and sheet metal storage. The staff currently working within Building 128 would be relocated to existing facilities within

Robins AFB, after which Building 128 would be demolished.

The Proposed Action at the Building 128/148 Site would also eliminate Buildings 138, 143, 148, and 432, which are currently used for GSE operations, and include offices, classroom space, shop area, material control space, material storage sheds, chemical storage area, wash rack, and equipment parking (staging). The chemical storage area for

GSE operations would be relocated to the new GSE Maintenance Facility. A second chemical storage area located near the site is used for operations in Building 140 and would be relocated to another nearby location if necessary. A propane underground storage tank (UST) located near this site, between Building 128 and Building 140, also would be removed and relocated if necessary.

The GSE operations, involving 7 government personnel and about 125 GSE staff, would be relocated to the new GSE facility that would be constructed as part of the Proposed

Action. This component of the Proposed Action is described in Section 2.2.2.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

AMFS Construction

Construction of the new AMFS would involve a 100,000-square-foot approximate medium-bay two-story building, concrete foundation, concrete walls, insulated metal roof, and basement for a 40,000-square-foot chemical containment basin, and ventilation ducting. The building would also provide offices for personnel, covered loading docks with ramps for receiving and shipping of aircraft parts and chemicals, and all supporting utilities. The facility would comply with DoD force protection requirements per unified facilities criteria, and incorporate conservation elements to meet LEED certification requirements. It would incorporate water recycling, onsite waste treatment equipment, air pollution-control devices, and consider chrome and cyanide process alternatives and the associated equipment. The final selection of processes/equipment and pollution-control equipment will be conducted during the conceptual design phase of the project.

New AMFS Operations

The existing Plating Shop workload would be transferred to the new facility, and would include the total aircraft: flaps, ailerons, stabilizers, etc., on F-15 aircraft; blades, propeller hubs, and pump housings on C-130 aircraft; pivot arms and struts on C-5 aircraft; and tubes and skins on C-17 aircraft. The new AMFS would consist of flexible modular and expandable plating lines containing state-of-the-art electroplating processes.

As previously stated, the final selection of processes/equipment and pollution-control equipment will be conducted during the conceptual design phase of the project;

wastewater reduction is a top priority of the project. The processes being considered for the new AMFS are listed in Table 2-2.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

Table 2-2. Processes Considered for New AMFS

Wet Processes Aluminum Chemical Milling Magnesium Coating Aluminum Chromate Conversion Magnesium Treating Aluminum Surface Preparation, Cleaning, and Activating for Inspection

Miscellaneous (Flex) Plating

Anodize Strip Nickel Plating Anodizing (Sulfuric, Hardcoat, and Chromic) Passivation

Black Oxide Selective Plate (Cad) Cadmium (Cyanide) Strip Silver Plating Copper Plating Temper Etching Electroless Nickel Titanium Chemical Milling Hard Chrome Plating Wax / Dewax Inorganic Coating Strip Zinc and Manganese Phosphate

Hard Chrome Stripping Dry Processes

Abrasive Blasting MPI (Hand Wipe) Fluorescent Penetrant Inspection (FPI) (wet) Shot Peen Blasting

Heat Treat (for Hydrogen Embrittlement Relief) Solvent Cleaning

HVOF

The AMFS would be capable of accepting the above-listed processes. Also, new pollution-control equipment such as air scrubbers, air emission-control equipment, and wastewater control/reuse technology equipment would be incorporated into the new

AMFS; the specific equipment will be selected during the conceptual design stage of the project and incorporated into the design. If a control device such as an “Emissions

Elimination Device” (EED) for particulate matter in chromium operations is used, the need for large fans and stacks to exhaust conditioned room air outside will be eliminated.

If Combined Anion Cation Liquid-Liquid Extraction (CA-LLX) is used, heavy metals in the metal finishing wastewater will be removed and recovered.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

2.2.2 GSE Operations

The 402nd Maintenance Wing (402 MXW) would construct a new 53,000-square-foot

GSE Maintenance Facility in the northwest ramp area, west of Building 33 and south of

Building 42 (Figure 4), near the Pad 8 area.. The new GSE building would be constructed on a concrete slab with a steel-frame, masonry walls, and a metal roof system.

GSE operations currently maintain multiple facilities on Robins AFB and a staff of 125 employees. Once the new GSE facility was constructed, GSE operations and staff working on the Building 128/148 Site and in the Pad 8 area would relocate to the new facility. This would combine numerous existing GSE maintenance facilities presently located in two separate locations on base (see Figure 2) into one location.

After construction of the new GSE facility and consolidation of GSE operations, the buildings on the Building 128/148 Site would be demolished as part of the Proposed

Action. The majority of the other existing buildings associated with GSE operations at

Pad 8 would be demolished when project funds for demolition are obtained, as noted below (Figure 5). The disposition of the GSE facilities and equipment storage area under the Proposed Action are described below.

Building 148 Area (Buildings 138, 143, 148 [43,960 square feet], and 432 [594 square feet]) – functions relocated to new GSE facility; the buildings would be demolished thereafter. The functions are:

• Contract Management Personnel

• Contract Administration

• Powered Equipment Repair

Storage Area, south end of Robins AFB (Building 657 Area) – would remain as-is under the Proposed Action. This area (see Figure 2) is used for:

• Long-Term and Seasonal Storage

Northwest Ramp Vicinity – The majority of GSE functions on Pad 8 would relocate to new GSE facility; the buildings would be demolished thereafter (see Figure 5). GSE

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop functions on Pad 9 would remain as-is under the Proposed Action. The GSE Pad 8 and Pad 9 functions include:

• Non-Powered Equipment Repair (Pad 8) – would relocate to new GSE facility

• Powered and Non-Powered Equipment Ready Lines (Pad 8) – would relocate to new GSE facility

• Powered Equipment Fuel Station (Pad 8) – would remain as-is under the Proposed

Action

• Small Item GSE Paint Function (Building 42 – Pad 9) – would remain as-is under the Proposed Action

• Sandblast and Large Item GSE Paint Function (Pad 9) - would remain as-is under the Proposed Action

The GSE-operations structures that would be demolished or removed from Pad 8 as a result of the Proposed Action, but when project funds for demolition are obtained (see Figure 5) are:

• Building 33 (189 square feet) – Restroom; constructed in 1969.

• Building 425 (432 square feet) – GSE Dispatch Office; constructed in 1985.

• Building 449 (1,632 square feet) – GSE Shop; constructed in 1974.

• Buildings 66, 67, 68 and 69 (total 900 square feet) – Portable Buildings -

Administration, Break room, other related GSE operations.

• Three outbuildings (total 373 square feet) – Administrative or storage functions.

• Pad 8 Repair/Storage Sheds. Includes: a) a three-sided steel frame, corrugated metal structure (588 square feet) used for steam cleaning. Wastewater from the steam cleaning operation flows to oil/water separator (OWS) #3 at Building 449, which is used by other facilities as well; the OWS would remain in operation. b) Two large covered metal work sheds (6,832 square feet) used to repair non-powered GSE. These provide insufficient protection from the weather elements and need to be replaced with an enclosed facility. c) Two smaller sheds (725 square feet) used for “power-up function” near the GSE powered ready line.

2.3 OTHER ACTION ALTERNATIVES

Other action alternatives considered in this EA include construction and operation of a new AMFS at one of two other sites in the GBIA at Robins AFB. These alternatives are referred to as the “Construct New AMFS at Building 181 Site Alternative,” and the

“Construct New AMFS at Building 256 Site Alternative,” and their locations are depicted on Figures 2 and 3.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

Components of each of these two alternatives include:

• Demolition of existing structures and construction of the new AMFS on the alternative site location;

• Relocation of Plating Shop operations and incorporation of new metal finishing processes and pollution-control devices at the new AMFS; and

• Reclamation of the existing Plating Shop (Building 142) and relocation of some existing MAN operations from Building 140 to Building 142.

The two alternatives also include the GSE components of the Proposed Action:

• Construction of a new GSE facility;

• Relocation of GSE operations from Building 148 to the new GSE facility, and consolidation of other GSE operations to the new GSE facility; and

• Demolition of the buildings on the Building 128/148 Site, and demolition/relocation of the majority of GSE facilities at Pad 8 (if and when project funding becomes available).

Environmental considerations and requirements of the subsequent disposition of the Building 128/148 Site (future reuse) would be evaluated by 78th CEG/CEV when the future uses were known.

As a subset of each of these two alternatives, GSE operations would either continue as at the present dispersed locations (“no action”), or a new GSE facility would be constructed and operations would be consolidated as described above. If project expenditures related to construction on the AMFS alternative sites exceeded the funds allocated for this project, the GSE would be addressed under a separate project with separate funding.

2.3.1 Construct New AMFS at Building 181 Site Alternative

Building 181 is located on the southwest corner of First Street and Robins Parkway

(Figures 2 and 3) and is currently being used for a variety of functions. It houses the

Prepaint Shop (2 workers), Life Support Shop (parachute shop, life rafts, uniforms, sales storage and operations, with 7 workers), Aileron Shop (2 workers), and generators. The building except for the generators is to be vacated independent of, and prior to, the proposed AMFS project.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

This alternative involves demolition of a portion of Building 181 and construction of a new AMFS (with all components as described in the Proposed Action) at the Building

181 Site. The portion of the building containing the generators would not be demolished and the generators would continue to operate as they do at present. The generators would continue to provide backup power to the central chilled water plant (7,000 tons serving more than 2,000 people in 15 buildings, including electronic warfare and other critical facilities).

As stated in Section 2.3, this alternative also includes the GSE components described under the Proposed Action, as well as the “no-action” as it relates to the GSE components.

2.3.2 Construct New AMFS at Building 256 Site Alternative

Building 256 is located one block east of the corner of First Street and Robins Parkway

(Figures 2 and 3) and is the furthest alternative site location from Building 142. It has been used in the past as an engine storage building and is currently vacant. Building 256 is located adjacent to a soil vapor extraction curtain, which intercepts groundwater contaminated from operations that have historically occurred in Building 181. The soil vapor extraction system is constantly operational. The groundwater extracted from the system is pumped into an aboveground tank, then pumped out and transferred to the groundwater treatment system.

This alternative consists of demolition of Building 256 and an adjacent small shed, and construction and operation of a new AMFS (with all the components as described in the

Proposed Action) at the Building 256 Site. The demolition and new building construction would be designed so that it would not require the relocation of the soil vapor extraction system.

As stated in Section 2.3, this alternative also includes the GSE components described under the Proposed Action, as well as the “no-action” as it relates to the GSE components.

Final - Environmental Assessment Construction & Operation of Advanced Metal Finishing Shop

2.4 NO-ACTION ALTERNATIVE

Under the No-Action Alternative, no construction would occur. Plating operations would continue to occur in Building 142 as they do at present. Furthermore, GSE operations would continue on the Building 128/148 Site and at Pad 8 as they do at present.

Reduced production times and improved delivery rates for aircraft components would not occur and the base would be limited in its abilities to accommodate any of the metal finishing core shortfall for cargo aircraft. The benefits of Lean manufacturing and repair would not be realized. The plating process would remain antiquated and additional BAT and BAPCT would not be available to support current and future plating workload. The increased reliability and worker safety as a result of automation would not be realized.

The No-Action Alternative would, therefore, result in operational limitations at Robins

AFB and the environmental benefits of a new facility such as reduced air emissions and waste discharge would not be realized.

Furthermore, GSE operations would continue to be inefficient and result in continued excessive vehicle transportation on the apron and excessive transportation of the workforce, equipment, and materials. Outdoor maintenance/repair of GSE would continue to be interrupted by inclement weather. Furthermore, personnel and equipment would continue to be placed at risk by performing powered GSE maintenance in a facility with wooden structural components, and buildings that have been identified as needing demolition would continue to be used.