Phasing_Plan_Final_-_Approved_4_Feb_19.pdf

PREPARED FOR DEPARTMENT OF THE

AIR FORCE

BY

AERTEC SOLUTIONS S.L.

MORÓN AIR BASE

CONSTRUCTION PHASING PLAN FOR:

PROJECT QUUG 08-1006

ADD APPROACH LIGHT SYST, RWY 20

A 2019/01 Cristina Collazos

Rev No. Date Revision(s) Prepared by Reviewed by Approved by

CONSTRUCTION PHASING PLAN

CONTRACT: FA5575-17-F-0017

PROJECT: QUUG 08-1006

TABLE OF CONTENTS

1. CONTENT

2. CONTRACT SCOPE

2.1. Site Data

2.2. Organizational Chart

2.3. Offices Location

3. CONTRACTOR INFORMATION

3.1. Estimated number of workers

3.2. Type and number of vehicles available

3.3. Workers with escort permit and workers with CMA access permit

3.4. Subcontractors

4. WORKS LOCATION AND CMA ACCESS CONDITIONS

4.1. Working area

4.2. Access routes to working area

4.3. Access and withdrawal procedures

4.4. Working in adverse weather conditions

4.5. Evacuation of the working areas in the case of an extreme emergency

4.6. Working restrictions near operational areas

4.6.1. Restrictions applicable to the runway approach area

4.6.2. Restrictions on excavation works

4.6.3. Restrictions on the use of heavy machinery

4.6.4. Restrictions on radio power easement

4.6.5. Signalling of working areas

5. WORKS DESCRIPTION

5.1. Description

5.1.1. Earthworks

5.1.2. Pavement works

5.1.3. Cable pulling

5.1.4. New manholes and covers

5.1.5. New lighting fixtures

5.1.6. New perimeter fence

6. TRAINING

7. COMMUNICATIONS WITH ATCT

8. SUBCONTRACTOR AND SUPPLIERS MONITORING

9. SAFETY SURVEILLANCE

9.1. FOD Control

10. FOLLOW-UP MEETINGS

11. ANNEXES

LIST OF FIGURES

Figure 1. Longitudinal profile. Obstacle limitation surfaces Figure 2. Authorized Vehicles Only Sign Figure 3. Obstacle limitation surfaces. Work area Figure 4. Cable spools

LIST OF TABLES

Table 1. Organizational Chart Table 2. Type and number of vehicles available

ADD APPROACH LIGHT SYST, RWY 20 CONSTRUCTION PHASING PLAN

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1. CONTENT

This Construction Phasing Plan is developed to fulfil the requirements established UFC 3-260- 01, Appendix B, Section 14. The purpose of this document is to establish the requirements, guidelines and constraints the contractor must follow during construction and maintenance works to be carried out in the controlled area and its surroundings in order to guarantee the safety of air operations during the construction works.

2. CONTRACT SCOPE

2.1. Site Data

The scope of this project is to add approach light system for runway 20 at Morón Air Base, in order to comply with length requirements, set for in applicable regulations from NATO and

ICAO.

The scope of the work of this project is the extension of the airfield approach and sequence flashing lights to the standard length required for a Precision Approach Runway, Category I in the North end of the runway at Morón Air Base (runway 20).

The main activities on site will be the following:

a. Construction of a one-way road, running along the extension of the airfield approach and sequence flashing lights and ending at T- shape turning. Including the construction of culverts with headwall and wingwalls for the new perimeter road, and the construction of ditches along the new perimeter road edges.

b. Installation of a galvanized chain link fence around the West, North and East perimeter of the project area.

c. Installation of additional LED Approach Lights and LED Sequence Flashing Lights (SFL) including the extension of the existing approach airfield lighting circuit, extension of the existing SFL circuit, and the extension of the existing duct banks.

2.2. Organizational Chart

Hereby are the key personnel data:

NAME POSITION PHONE EMAIL

Cristina Collazos Designer of Record

95 10 10 200 ccollazos@aertecsolutions.com

Blank for future updates with

Contractor key personnel / subs

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NAME POSITION PHONE EMAIL

Table 1. Organizational Chart

2.3. Offices Location

The Annex 1 shows the office location drawing. Additional contractor vehicles will be parked at the office location or at the equipment storage area.

3. CONTRACTOR INFORMATION

3.1. Estimated number of workers

The estimated number of workers who will access to the surrounding area to carry out the construction activities are 15.

3.2. Type and number of vehicles available

The type and number of vehicles available to carry out the different activities will be:

No. Type of vehicle Max. Height

1 Dozer 4 m

1 Loader 4 m

4 Truck 4 m

2 Compactor 3 m

1 Paver 4 m

1 Pneumatic Roller 3 m

2 Van 2 m

1 Crane truck 8 m

1 Backhoe 10 m

1 Concrete mixer 5 m

1 Manlift 8-10 m

Table 2. Type and number of vehicles available

3.3. Workers with escort permit and workers with CMA access permit

Estimated number of workers with escort permit are ten (8).

Due to the location of the works, workers with CMA Access permit are not required.

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3.4. Subcontractors

The contractor will have a subcontractor to carry out the construction civil works. The name of the subcontractor is still not known.

The contractor shall report regarding health and safety aspects to its subcontractors and suppliers.

The new employees in the project will be given training in this regard before starting the activities and during the development of it.

4. WORKS LOCATION AND CMA ACCESS CONDITIONS

4.1. Working area

Working area is depicted in Annex 1.

The work area shall be a non-operational aircraft area and no closed pavement markings or displaced thresholds will be required. Approach and take-off surfaces will not be violated. The contractor will ensure the maximum height of equipment in each area remains below the take-off climb surface provided below:

Figure 1. Longitudinal profile. Obstacle limitation surfaces

4.2. Access routes to working area

Concerning the location of the works, no access to the CMA (Control Movement Area) will be authorized. The CMA at Morón AB consists of the runway, Parallel Taxiway, all ladder taxiways (Alpha – Delta), 100 feet/30 meters from the west side of the runway edge, 100 feet/30 meters beyond each overrun, and 100 feet/30 meters from the eastern edge of the Parallel Taxiway. In the rare case that a vehicle or individual requires access to the CMA, a roll-over FOD check will be conducted on all vehicles prior to entrance to the CMA by a qualified

QUUG 08-1006 Page 7 of 17 operator. There are no FOD checkpoints in the traditional route to the worksite, only when entering the CMA.

All vehicles and staff entering the CMA must have the permit to access the airfield (AF Form 483), bi-directional radio and obtain direct approval of ATCT via such radio or be escorted by a vehicle and personnel having it. Airfield Management will be advised prior to such requests to validate compliance with Morón AB Instruction 13-213. Active entrances to the CMA are denoted by mandatory hold signs, VFR hold markings, or the signs below.

Figure 2. Authorized Vehicles Only Sign

Furthermore, every worker must wear high visibility clothes in all the working areas.

Haul routes to the work area and construction vehicle access roads are shown in Annex 1.

Firefighting and rescue vehicles shall access the area in the event of a mishap in the same way than during normal operations, by using the same fence gate habilitated for the construction vehicles.

4.3. Access and withdrawal procedures

Weekly work plans will be made reporting the work areas.

Before entering the working area, the works to be carried out will have been previously coordinated with the Electric shop. The disconnection of the circuits to be worked will be requested, by means of the corresponding power outage request (Work Clearance Request, AF 103).

The contractor will check in with Airfield Management, located in building 1411 room 163A, each day to acquire radios prior to entering the worksite. After completion of each day’s work, the contractor will check out with Airfield Management to return the radios and validate all works are complete for the day. The contractor will brief Airfield Management about works to be carried out each day in order for proper notifications, Notices to Airman, restrictions and coordination to be relayed to other airfield stakeholders.

Although the work area is outside the CMA, the Spanish Air Force has directed that communication will be established with the ATCT (Air Traffic Control Tower) when reporting to the work area at the beginning of each day and upon completion of each day’s work. This

QUUG 08-1006 Page 8 of 17 serves as an advisory to the ATCT that personnel are working in proximity to the runway but remaining off the runway and out of the clear zone. Under no circumstances will the area be accessed without the prior approval of the ATCT.

Once the work is completed, the area will be cleaned, the machinery used to perform the work will be removed each day, as well as the possible FOD will be collected. In addition, the proper condition of the zone will be checked.

Afterwards, the electrical shop will be reported in order to restore the power again, if needed.

To leave the area the ATCT will be contacted requesting permission to do so.

4.4. Working in adverse weather conditions

In case of heavy rain, strong wind, heavy fog, etc., work will be interrupted, and in any other circumstance if it is requested by Airfield Management.

Under these circumstances, once communicated via radio, the area will be cleared, and machinery, tools and personnel will be collected, the work area will be abandoned, and a visual inspection will be carried out in order not to leave FOD.

Any debris and construction material shall be collected and affixed in such a way as to prevent the projection of parts and particles outside the working area.

4.5. Evacuation of the working areas in the case of an extreme emergency

Under an extreme emergency communicated by ATCT, the fence gate of the Air Base shall be immediately closed, and without picking up any tool or material, the Contractor will evacuate the working areas by using the existing dirty roads outside the airbase in 5 minutes. In such case they would leave all the equipment and material, evacuating only the personnel and vehicles of the area.

4.6. Working restrictions near operational areas

There are restrictions on the performance of works near operational areas of the runway 20 approach area. All projects to be executed in the CMA in the Base must comply with the restrictions indicated in the project specifications.

In order to delimit the area where the works will be carried out a mesh and/or a new jersey barrier solution will be used by the contractor for this purpose. In addition, and to allow a better visual works area identification, a red steady lighting will be installed on the top of these elements (keeping a maximum distance of 3 m between each light).

If the delimitation is done with a mesh, the lights will be mounted using a cone and a PVC pipe.

On the contrary, if new jersey barriers are used to delimit the area, the lights will be mounted on the top of this element. Please, refer to Annex 1.

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4.6.1. Restrictions applicable to the runway approach area

The works are developed in the North end of runway 20. The works in this area shall be performed without a temporary displacement of the threshold since most of the works are developed outside Morón Air Base boundary fence, more than 450 meters from runway threshold. Due to this, it is not justified such displacement; therefore, maximum coordination with Airfield Management is required and in order to avoid the incursion into the approach surface and the take – off surface a restriction in terms of maximum height achievable by the vehicles is required.

Figure 3. Obstacle limitation surfaces. Work area.

It is important to remark that the Contractor has to know and respect the limitation in terms of maximum height achievable during the works in order to avoid the incursion to the approach and or take-off surfaces.

It has been considered that all the works will be performed in one (1) phase. The Contractor shall perform excavation, placement of conduits, concrete pouring and backfilling activities in the affected area, previously coordinated with the Airfield Management and ATCT. Maximum height and location of excavated material shall be as indicated in the Temporary Construction Waiver for this project.

Concerning the works developed inside Morón Air Base, personnel will be in contact with

ATCT.

4.6.2. Restrictions on excavation works

Excavation works required for the installation of new manholes and duct banks (in the non-operational areas mainly) shall be conveniently signaled and marked with lighting (flashing red or yellow light units during hours of restricted visibility) in the case that excavations must remain open during periods of reduced visibility.

The excavated material can be placed in piles maximum one-meter height. Measures shall be taken in order to prevent the stockpiled material from excavations could constitute a FOD hazard, such as dampening the stockpiles or collecting immediately objects that can be

Phase I

QUUG 08-1006 Page 10 of 17 ingested by jets or dispersed by them (jet blast) or by the wind. Excess waste will be disposed of offsite.

4.6.3. Restrictions on the use of heavy machinery

Machinery access routes thru the airbase shall observe the prescriptions of the Health and Safety Plan. The airfield management will coordinate requirements for machine operations with the contractor and ATCT.

Contractor employees must park and service all construction machinery in an area designated by the air base management outside the CMA and never in the safety area of the runway or taxiway. Inactive equipment must never be parked on a closed taxiway or runway overnight, on weekends, or during other periods when construction is not active, nor on an extension of them. Furthermore, the equipment must be well lighted. Parking areas must not obstruct the clear line of sight by the ATCT to any taxiways or runways under air traffic control nor obstruct any runway visual aids, signs, or navigation aids.

4.6.4. Restrictions on radio power easement

Although none of the actions considered in this project affect the ILS (Instrument Landing Systems), there are works that shall be performed close to this element. Due to this, special care is required in order to avoid any possible anomalies. Concerning the works developed close to this unit, will be in contact with ATCT.

4.6.5. Signalling of working areas

The working areas will be signalized according to the Health and Safety Plan. On other hand, if it were necessary to leave an excavation or any open holes until the following day, they will be signalized with low profile “new jersey” barriers (height 60 cm) and red lighting beacons. For the work area, low-profile barriers shall be installed in the paved area, while the rest of the area shall be surrounded with orange warning mesh with small size holes as shown in Annex 1.

5. WORKS DESCRIPTION

5.1. Description

These are the different kind of works that will be done within the scope of the project:

5.1.1. Earthworks

For the earthworks the following equipment and procedures will be used:

Vehicles (all equipment and vehicles in airfield clearance areas will be marked and/or lighted for daytime visibility):

1ea: Dozer (maximum height 4 meters)

1ea: Loader (maximum height 4 meters)

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2ea: Truck (maximum height 4 meters)

1ea: Compactor (maximum height 3 meters)

Staff:

One (1) site supervisor.

Two (2) workers

Work description:

The material shall be constructed in lifts as established in the control strip, but not less than 6 inches (150 mm) nor more than 12 inches (300 mm) of compacted thickness.

Time to evacuate/ leave in an emergency:

Does not apply, since these works are to be carried out in the work area, not being an aircraft operational area.

Working areas:

The whole project

5.1.2. Pavement works

For the pavement works the following equipment and procedures will be used:

Vehicles (all equipment and vehicles in airfield clearance areas will be marked and/or lighted for daytime visibility):

2ea: Truck (maximum height 4 meters)

1ea: Paver (maximum height 4 meters)

1ea: Compactor (maximum height 3 meters)

1ea: Pneumatic Roller (maximum height 3 meters)

Staff:

One (1) site supervisor.

Five (5) workers

Work description:

The asphalt mixture shall be thoroughly and uniformly compacted by self-propelled rollers.

The sequence of rolling operations and the type of rollers used shall be at the discretion of the Contractor. The speed of the roller shall, at all times, be sufficiently slow to avoid displacement of the hot mixture and be effective in compaction.

Time to evacuate/ leave in an emergency:

Does not apply, since these works are to be carried out in the work area, not being an aircraft operational area.

QUUG 08-1006 Page 12 of 17

Working areas:

The whole project

5.1.3. Cable pulling

For the cable pulling the following equipment and procedures will be used:

Vehicles (all equipment and vehicles in airfield clearance areas will be marked and/or lighted for daytime visibility):

2ea: Van (maximum height 2 meters)

1ea: Crane truck (maximum height 8 meters)

Material to be used:

Cable spools: (maximum height 2 meters)

Figure 4. Cable spools

Tools to be used:

Manual means only.

Staff:

One (1) site supervisor.

Five (5) workers

Work description:

The cable spools will be positioned near to the initial manhole of the cable span. Firstly, it will be pulled a steel cable through the conduit where the cables will be run, and one end of this cable will be grabbed by personnel in this end of the duct bank in order to proceed with the cable pulling. Once cable pulling is finished, the cable spools will be removed.

Time to evacuate/ leave in an emergency:

Does not apply, since these works are to be carried out in the work area, not being an aircraft operational area.

Working areas:

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The whole project

5.1.4. New manholes and covers

For the installation of new manholes and covers the following equipment and procedures will be used:

Vehicles (all equipment and vehicles in airfield clearance areas will be marked and/or lighted for daytime visibility):

2ea: Van (maximum height 2 meters)

1ea: Crane (maximum height 9 meters)

1ea: Backhoe (maximum height 10 meters)

1ea: Concrete mixer (maximum height 5 meters)

Material to be used:

Prefabricated Manholes: (maximum height 2 meters)

Manhole covers

Tools to be used:

Hand tools

Staff:

One (1) site supervisor.

Ten (10) workers.

Works description:

For the installation of the new manholes and duct banks an excavation will be carried out, once it is done, the prefabricated manhole will be transported with the crane and it will be installed with the help of a crane.

Time to evacuate/ leave in an emergency:

Does not apply, since these works are to be carried out in the work area, after the temporal threshold displacement, not being an aircraft operational area.

Working areas:

The whole project

5.1.5. New lighting fixtures

For the installation of new approach lighting fixtures, the following equipment and procedures will be used:

Vehicles (all equipment and vehicles in airfield clearance areas will be marked and/or lighted for daytime visibility):

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2ea: Van (maximum height 2 meters)

1ea: Crane truck (maximum height 8 meters)

1ea: Manlift (maximum height 8-10 meters), only for installation of wiring in the higher masts. (the last three barrettes).

Material to be used:

Equipment (transformers, light fixtures and frangible poles and masts): maximum height 5 meters.

Tools to be used:

Hand tool

Staff:

One (1) site supervisor.

Five (5) workers.

Works description:

New lighting fixtures installation: In the non-paved areas, the light fixtures shall be mounted in frangible poles as indicated in the project.

Time to evacuate/ leave in an emergency:

Does not apply, since these works are to be carried out in the work area, after the temporal threshold displacement, not being an aircraft operational area.

Working areas:

The whole project

5.1.6. New perimeter fence

For the installation of the new perimeter fence, the following equipment and procedures will be used:

Vehicles (all equipment and vehicles in airfield clearance areas will be marked and/or lighted for daytime visibility):

2ea: Van (maximum height 2 meters)

1ea: Crane truck (maximum height 8 meters)

1ea: Backhoe (maximum height 10 meters)

1ea: Concrete mixer (maximum height 5 meters)

Material to be used:

Equipment (The fabric width of the chain link fence shall be 2 m and the height of the fence, including the 3 strands of barbed wire shall be 2.30 m. Posts will be installed each 3 meters): maximum height 3 meters.

QUUG 08-1006 Page 15 of 17

Tools to be used:

Hand tool

Staff:

One (1) site supervisor.

Five (5) workers.

Works description:

A galvanized chain link fence around the West, North and East perimeter of the project shall be installed

Time to evacuate/ leave in an emergency:

Does not apply, since these works are to be carried out in the work area, , not being an aircraft operational area.

Working areas:

The whole project

6. TRAINING

The Contractor undertakes that the staff will be trained in aspects related to Safety at Morón Air Base and in their own activity and to be able to document it by keeping a record of signatures of all the employees who have received the required training.

7. COMMUNICATIONS WITH ATCT

As discussed in section 4.3, the site supervisor located within the working area must be in contact with the ATCT, by means of a radio using the Tower Net frequency, in order to react to possible requirements provided by the Tower.

If an incident is detected, it must be firstly notified that incident to the ATCT via radio communication, and then follow the ATCT instructions.

Under the request to stop the works for safety affections, the ongoing task will be stopped, and the working area will be left in the way and time previewed in each situation.

In these circumstances, once the stoppage of the works is notified via radio, the working area will be left as it is explained in point number 4 of this construction phasing plan, the area will be evacuated and the site supervisor will make a visual inspection in order to collect or fix any debris, waste or construction material to avoid the projection of these out of the working area.

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8. SUBCONTRACTOR AND SUPPLIERS MONITORING

The Contractor must fully comply and enforce the requirements in safety regulations that are required by Morón Air Base.

For this fulfillment, The Contractor will train and inform each subcontractor and staff involved in the works, regarding the requirements to fulfill in every working area, and regarding safety measures.

Risks will be daily evaluated depending on the works to do, as well as on the weather conditions or any other requirement from the Air Base.

9. SAFETY SURVEILLANCE

9.1. FOD Control

FOD because of being ejected or absorbed by the jet blast can damage vehicles and aircrafts or injure airfield staff by an impact.

Between the possible FOD that could be generated in this project would be:

Small stones and sand.

Nuts and screws from the machinery and equipment used.

Waste and garbage.

Remains of cable after working in an electric circuit.

Tools forgotten at the end of the day in the working area.

Plastic and sheet not collected after the end of the working day.

This is a general description of the good practice procedures that are applicable for FOD control.

Checking of the underbody and tires prior to entering active aircraft movement areas.

Proper storage of the construction material protected from aircraft jet blast.

Checking that the construction waste is stored in the designated areas, that they are not being moved accidentally to the operational area and that they are collected according to the established plan.

Checking that the vehicles and work equipment is parked/stored in the designated areas for them.

Use of containers to deposit waste that can become FOD (plastic wrappers, cardboard, Keep personal objects, equipment and tools controlled and do no leave them in inappropriate places.

Inspection of the working area and surrounding.

Establishment of cleaning daily programs of the working area and surrounding.

QUUG 08-1006 Page 17 of 17

All those objects that could make damage to the aircraft will be cleaned and deposited in containers where they will be transported to authorized dumps.

In the most critical areas, the number of vehicles accessing to the site will be as minimum as possible, in order to minimize the hazard of FOD on the runway and taxiways. At the end of the day, or before if it is necessary, the affected area and machinery will be cleaned with pressurized water or a sweeping machine.

10. FOLLOW-UP MEETINGS

Previously to start the works there will be a meeting with all staff involved in order to define the limits and conditions to work on site.

In addition, there will be weekly follow-up meetings with the different staff involved where the progress and planning of the project will be discussed, plus the items considered of interest that will be notified in an agenda in advance of the meeting.

11. ANNEXES

Annex 1: Offices Location, Access routes & Work area.