J.1 AAJ MALSR FY 21 Inspection and Repair SOW.doc

AAJ MALSR Inspection & Repairs

Binghamton, NY

STATEMENT OF WORK

Inspection and repairs to AAJ MALSR Structure Binghamton, NY 1.0 Scope of Work Provide all labor, tools, equipment, materials, rigging, and supervision required to perform a tower inspection, and general repairs to the AAJ MALSR. The work also includes adjusting guy tensions and re-aligning the AAL MALSR tower plumbness. This Statement of Work describes the requirements of the Federal Aviation Administration (FAA) in order to accomplish the necessary inspection and maintenance requirements.

The contractor shall provide competent technicians with previous experience of similar projects and all of the necessary hardware and other related equipment required to perform the following:

1. Perform a tower inspection in accordance with FAA and current industry, including AISC/ACI/TIA, standards; and provide FAA detailed Record of the Inspection, especially the inspection record for structure/foundation member/elements with obvious defects or material loss.

2. Measure and record existing MALSR Tower guy cable tensions and Tower plumbness; Adjust/Re-tension the guy cable tension forces to match the tensioning forces values provided in the attached AAJ MALSR Tension Force Chart with Temperature-Correction and cable length/geometry considerations; during the cable re-tensioning, re-plumb the MALSR Towers by adjusting guy cables tension forces. If the re-tensioning forces have to deviate more than 15% from the Chart values, the contractor shall request the approval of the FAA engineer for the proposed non-normal adjusting tension forces with plumb survey data of the tower in question. After the completion of all re-tensioning of cables and re-alignment of tower plumbness, the contractor shall provide the FAA a complete as-built report of the cable tension forces and tower plumbness data.

3. Perform general repairs to the AAJ MALSR as follows:

· Repair the bent mid rail between Bridge 5 and Bridge 6 where the slide pipe came out of the main pipe.

· Replace the bent diagonal found on mast 6 face C at the 50’ elevation and on Mast 10 face C at the 30’elevation.

· Enlarge the drainage holes in the base weldments on bents 1, 4 & 5 to prevent clogging. Treat with zinc rich cold galvanization compound after enlarging the holes.

· Remove the existing cotter pin installed only halfway through the hole on mast 7, east top bridge pin and mast 9, bottom bridge pin and replace with a properly sized galvanized pin.

· Replace the hinge pin at mast 9 Top east with a hot dip galvanized pin.

· Replace the unistrut used to support the control boxes at each light station with new hot dipped galvanized unistrut. Eight flasher stations are located on the structure.

· Install pal nuts on splice and stich bolts on all masts and bents to prevent loose hardware. Approximately 70% of the bolts do not have lock washers or pal nuts installed.

2.0 Site Description

This AAJ MALSR facility consists of an elevated catwalk supported by guyed steel bents and towers of various heights. These towers support walkway bridges that support the MALSR light system. The MALSR is located at the end of Runway 16 at the Greater Binghamton Airport in Binghamton, New York.

This site is a vital part of the National Airspace System (NAS) and the equipment associated with the MALSR shall remain in constant operation without interruptions, during the project. Instrument or equipment failure could have severe repercussions involving traffic in air space regulated by the FAA. The Contractor shall be required to institute practices to avoid such occurrences. The FAA Site Representative shall constantly monitor all procedures instituted by the Contractor.

3.0 Inspection and General Tower Repairs

The Contractor shall provide all materials, labor, tools, equipment, rigging, and supervision necessary to perform the following:

1. The contractor shall perform an inspection and periodic maintenance of the MALSR structures in accordance with FAA Order 6930.25A, Chapters 3, 4, & 5. A written report shall be prepared detailing the inspection. Findings shall be recorded on the tower inspection checklist attached as part of this package which shall be incorporated into a report. All three sections shall be completed – Site and Asset data, Annual Inspection, and Findings Summary. An electronic copy of the checklist is available. Two hard copies and one electronic version of the inspection report shall be submitted to the FAA Contracting Officer’s Representative (COR). The electronic format shall be in accordance with FAA-STD-002f, Engineering Drawing Preparation & Support. This report shall include a site plan, the aforementioned inspection checklist, field notes that might apply, recommendations for deficiencies with budget cost estimates and photos of the towers and deficiencies. Additionally, the contractor shall perform light maintenance such as tightening loose hardware found during the inspection. The tension meter used for the AAJ MALSR shall be calibrated for up to 25,000 lbs tension and accommodate up to 1-1/8” diameter galvanized steel bridge strand guy wires. Tension measurements, along with meteorological conditions, shall be recorded as part of the inspection report.

2. Adjust guy tensions to match the listed individual cable tension forces shown in the attached AAJ MALSR Tension Force Chart with Temperature-Correction and cable length/geometry considerations. During the re-tensioning process, measure and record the tower’s plumb. If it is discovered that the tower is out of vertical alignment, then the contractor shall align the tower as detailed in the Corrective Maintenance section of FAA Order 6930.25A and the Telecommunications Industry Association (TIA) standards (ANSI/TIA-222-G). During the tower plumb adjustment, if the cable re-tensioning force will be more than 15% more than charted re-tensioning values, the FAA Engineering approval is required.

4.0 General Requirements

The project consists of the following general requirements:

1.

Visual inspections of:

a.

Towers, including concrete foundation and all steel tower members and connection bolts/plates b.

Catwalk structure and grating, including all members and connection bolts/plates c.

Guy wires d.

Guy anchors and turnbuckles/connection part/bolts e.

Climbing devices, including all members and connection bolts 2.

Measurement of vertical alignment of towers.

3.

Measurement of existing tension and as-built re-tension forces in guy wires.

4.

Preparation of report documenting findings and recommended corrective actions.

5.

Contractor shall refer to FAA order 6930.25A for specific guidance on test procedures.

5.0 Inspection Requirements

A. Visual Inspection

1.

Perform visual inspection of all components to determine physical condition a.

Identification of damaged, deformed and corroded members (ie, beams, columns, braces, rails, and foundations) b.

Identification of faulty, failing and corroded structural connections 1) Bolted connection (missing or loose bolts, and bolt with section material loss due to corrosion) 2) Welded connections (cracked welds or weld with section material loss due to corrosion) c.

Identification of loose or displaced grating – not secure to structure with proper bolting or welding d.

Identification of loose or displaced grating – broken welds in grating e.

Identification of corroded grating f.

Identification of faulty or failing climbing/fall protection systems g.

Identification of frayed, faulty, failing or corroded guy wire.

h.

Identification of faulty, failing and corroded guy connections.

1) At/to tower structure and foundation 2) At guy anchor and foundation a) All components at anchors (thimble, turnbuckles, clamps, shackles, safety wire, insulators) b) Foundation conditions if visible.

3) Identification of faulty, failing or corroded anchor components a) Eye bolts and concrete conditions if visible b) If anchor foundation is invisible, check if guy anchor is displaced or moveable by hand power.

B. Measurement of Vertical Alignment

1. Measure the vertical alignment of each tower and bent by utilization of precision land surveying equipment.

C. Measurement of Guy Tension 1.

Measure and record the tension in each guy wire, noting the wire size, number of strands and grade of steel (if possible).

2.

Method of testing shall be shunt –type where the test can be conducted without breaking in on the guy to be tested.

3.

The tension meter or dynamometer used shall hold calibrations specifically for the size and strand configuration being tested and shall have a capability of measuring tensions up to 25kips.

4.

Measure tension a minimum of three times in each wire and average the results with in-situ field temperature recorded.

5.

Measurements shall be corrected for temperature from a basis of 60 degrees Fahrenheit.

6.

Operation of the testing device shall be in strict accordance with the manufacturers operating instructions.

D. Final Report

1.

The report shall document all of the results of visual inspections and measurements.

2.

Create a section in the report for each catwalk/bridge section and each tower mast.

a.

Each AAJ CATWALK/Bridge section of the report shall document the results of the visual inspections as described in section 5.0.A.1. The first catwalk/bridge closest to runway shall be identified as “Catwalk/Bridge Span #1” and the catwalk/bridge farthest from runway shall be identified as “Catwalk/Bridge Span #10”. Subparts of the CATWALK/Bridge section shall include:

1) Condition a) Damaged or severely corroded members b) Structural Connections/bolts c) Grating d) Climbing Devices e) Guy Connections (if applicable) 2) Corrective action required and estimated cost.

b.

Each TOWER MAST section of the report shall document the results of visual inspections, vertical alignment measurements and guy wire existing tension and as-built re-tensions as described in sections 5.0.A.1, 5.0.B and 5.0.C. The first tower bent closest to runway shall be identified as “Tower Bent #1” Or Tower T1, with referenced original Mast sequence number, and the tower mast farthest from runway shall be identified as “Tower Mast #10” or Tower T10, with referenced original Mast sequence number. Subparts of TOWER SECTION shall include:

1) Condition a) Damaged and severely corroded members b) Structural Connections/bolts c) Climbing Devices (if applicable) d) Guy Wires e) Guy Connections f) Guy Anchors g) Concrete foundations 2) Vertical Alignment (Plumb) of each Tower/Mast 3) Guy Wire Tension a) Guy wires shall be identified with tower mast # and as right/left, front/back and follow the guy nomenclature in the UIS Tower Inspection Report Data.

b) Measurements shall be compared to Re-Tensioning Forces with Temperature-Correction listed in the attachment.

4) Corrective action required and estimated cost.

6.0 Rights

The FAA shall have UNLIMITED RIGHTS under this contract to all information and materials developed under this contract and furnished to the FAA and documentation thereof, reports and listings, and all other items pertaining to the work and services pursuant to this agreement including any copyright. Unlimited rights under this contract are rights to use, duplicate, or disclose data and information, in whole or part in any manner and for any purpose whatsoever without compensation to or approval from Contractor. The FAA will at all reasonable times have the right to inspect the work and will have access to and the rights to make copies of the above-mentioned items. All digital files and data, and other products generated under this contract shall become the property of the FAA.

7.0 Requirements of the Contractor

Personnel Any personnel assigned to this project shall meet the following requirements:

Shall be trained in elevated work construction in accordance with the fall protection standards of the Occupational Safety and Health Administration (OSHA).

The Contractor shall provide all required personal protective equipment (PPE) needed to successfully complete the project.

The Contractor shall provide the following information in an organized manner to the FAA Safety & Environmental Compliance Manager (SECM):

1. The name and contact information of a readily accessible company representative(s) for emergencies.

2. A list of personnel who will be used to complete the needed work, including:

· Applicable Safety Training Certificates Certifications

· Applicable Experience Lists

3. Proposed subcontractors (if applicable) including:

· Applicable Safety Training Certificates Certifications

· Applicable Experience Lists

4. Written Fall Protection and Personal Protective Equipment Programs including a rescue plan.

5.

Material Safety Data Sheets (MSDSs) for all chemicals to be used in the execution and completion of this project.

Restrictions and Security Concerns:

The Contractor is advised that the towers are part of a secured facility and all personnel, possessions, equipment, materials, vehicles, etc. are subject to inspection at the discretion of security personnel while on the premises. All Contractor personnel shall maintain on their person, at all times while on the grounds, current photo identification. Contractor personnel shall be prepared to relinquish their identification for review by security at any time while on the grounds.

The FAA Site Representative shall supply appropriate keys to the Contractor's on-site supervisor, when applicable. All facility keys will be returned to the FAA Site Representative at the completion of each day's activities. The Contractor supervisor is solely responsible for facility key while in his/her possession. In the event of a loss of facility keys, the Contractor supervisor will be responsible for the cost of installation of new key capacity. The Contractor shall provide the FAA Site Representative with a list of the personnel requiring access to the site. This list shall include the employee's full name, social security number, and the date of birth. It will be necessary to coordinate all activities with the FAA Site Representative to minimize interference with site operations.

Special Contractor Requirements:

The following is a list of special requirements the Contractor will need to be aware of:

Pre-Construction Meeting - The Contracting Officer will arrange a conference at a location mutually agreeable to the FAA Representative and Contractor after the contract has been awarded. It will be mandatory that key Contractor personnel or their representatives attend.

Site Visit - It is strongly recommended that the Contractor make a site visit prior to submitting a quote. Arrangements for a site visit shall be made through the facility point of contact. All site visits shall be arranged through the Elmira SSC Manager, Jeff Reimel, at 607-207-7797 or at Jeffrey.M.Reimel@faa.gov.

Work Schedule - Normal work hours will be from 8 am to 4:30 pm, Monday through Friday. All work outside of the normal time frame will be coordinated with the COR. The contractor shall give a minimum of 48 hours notice prior to commencing with work outside of normal work hours.

Final Inspection:

After completion of all contracted work, a final inspection will be held with the SSC Manager and the FAA Site Representative. The inspection shall be conducted in such a manner as to provide a detailed review of all work performed, to ascertain that all contracted work is completed in accordance with the Scope of Work, disturbed areas restored, and installation areas cleared and left in satisfactory condition.

Regulatory Compliance:

All work shall be performed in accordance with Federal, state, and local regulatory requirements. In cases where regulations and/or contract documents are conflicting or discrepancies occur, the more stringent requirement shall be followed and enforced. Applicable regulations include, but are not limited to:

Occupational Safety and Health Administration (OSHA)

· 29 CFR 1910.23 Guarding Floor and Wall Openings and Holes

· 29 CFR 1910.27 Fixed Ladders

· 29 CFR 1910.268 Telecommunications

· 29 CFR 1926 Subpart M Fall Protection

· 29 CFR 1926.62 LEAD

United States Department of Transportation, Federal Aviation Administration (FAA)

· FAA Order 3900.19B Occupational Safety and Health

· FAA Order 6930.25A Maintenance of Structures and Buildings

· FAA Order 3900.63A Air Traffic Organization Fall Protection Program

· FAA-STD-019e Lightning and surge Protection, Grounding, Bonding and Shielding Requirements for Facilities and Electronic Equipment Federal Specification RR-S-0011301 (FAA) Safety Equipment, Climbing American National Standards Institute (ANSI)

· A14.3-1984 or newer American National Standard for Ladders – Fixed

· TIA-222-G or newer Structural Standard for Antenna Supporting Structures and Antennas.

Additional requirements may be incorporated by reference in the above-mentioned documents.

Responsibility for Damages:

The FAA seeks to avoid any activities by the Contractor that may lead to damage of government property. The Contractor is therefore advised to take all necessary precautions to avoid potentially damaging activities. The Contractor is advised to place special emphasis on avoiding unnecessary contact including jarring, touching, placing tools on, etc. any equipment. In addition, all devices, electrical plugs, equipment, etc. must be safely maintained as damage could reduce the effectiveness of existing air traffic control activities. Any such damage resulting from neglect or unreasonable actions by the Contractor's personnel shall be repaired or replaced by the Contractor at no additional cost to the government. If the Contractor fails or refuses to make such repairs or replacements, the Contractor shall be liable for the cost, which may be deducted from the contract price. A comparison of the initial inspection and final inspection reports and acceptance of each area by the FAA Site Representative shall be the basis for assessment of any damages, if any.

Disposal of Debris:

Items or debris that are not designated, as salvage by the Government shall become the property of the Contractor. The disposal of materials off the site in a legal manner and payment of any fees required is the responsibility of the Contractor. When hazardous materials are encountered during demolition or excavation operations, comply with applicable federal, state, and local regulations, laws, and ordinances concerning removal, handling, and protection against exposure or environmental pollution. Burning of removed materials is not permitted on the work site.

Appendix A

Reference Drawings/Charts AEA-D-31999 Shts 1, 2, & 3

AEA-D-33798 Shts 5, 6, 15, & 20

AAJ MALSR Guy Cable Re-Tensioning Forces Chart with Temperature-Correction

FAA Orders/Checklist/Report

FAA Tower Inspection Checklist

FAA Order 6930.25A

Penn-Tech International Tower Inspection Report Sep 2020

AAJ MALSR

10R Guy Anchors

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AAJ MALSR FY 21 Inspection and Repair SOW