Attachment 5 - 220516_P-1066 CH-53K Gearbox Facility_BOD 50pct.pdf

Basis of Design

Design Development (50%) Submittal

FY 23 MCON Project P-1066

CH-53K Gearbox Facility

MCAS Cherry Point North Carolina

Contract: N40085-19-D-9041

Delivery Order: N40085-21-F-4500 eProject Work Order No: 1684760

16 May 2022

CN#9287

4525 Main Street, Suite 1400 Virginia Beach, VA 23462 https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjQ_5P26d_QAhVEyyYKHRlmDmgQjRwIBw&url=https://twitter.com/navfacmidlant&psig=AFQjCNGCerJ_DIx1zTuN2QYaU-4O0IfzOQ&ust=1481122630282245

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FY23 Project P-1066 CH-53K Gearbox Facility eProjects WON 1684760 MCAS Cherry Point, NC

TABLE OF CONTENTS

i

I. PROJECT OVERVIEW

General Design Codes and Standards (applicable to all design disciplines)

II. ARCHITECTURAL

A. Design Criteria B. General / Scope of Work C. Type of Construction D. Life Safety Code Analysis E. Gross Floor Area Calculations F. Accessibility G. Architectural Compatibility H. Roof System Selection I. Thermal Insulation J. Security Requirements K. Antiterrorism L. Architectural Acoustics M. Sustainable Design N. Doors and Windows O. Special Construction Features P. Waterproofing and Vapor Mitigation

III. INTERIOR DESIGN

A. Interior Design Overviews B. Interior Finish Materials and Specialties C. Furniture, Fixtures and Equipment (FF&E) / Collateral Equipment (CEQ)

IV. CIVIL

A. Design Codes and Standards B. General C. Existing Conditions D. Demolition E. Proposed Site Improvements F. Anti-Terrorism/Force Protection G. Water Supply H. Sanitary Sewer I. Natural Gas J. Cathodic Protection K. Stormwater Management L. Erosion and Sediment Control M. Environmental Permits

V. GEOTECHNICAL

A. Geotechnical Report

VI. LANDSCAPE

A. Design Codes and Standards A. Design Criteria

VII. ENVIRONMENTAL

A. Environmental Report

VIII. STRUCTURAL

A. Design Codes and Standards B. Design Criteria C. Foundations D. Structural Systems ii

E. Lateral Force Resisting Systems F. Anti-Terrorism and Force Protection Design (ATFP)

IX. PLUMBING

A. Design Criteria B. Plumbing Systems

X. MECHANICAL

A. Design Criteria B. Design Conditions C. Life Cycle Cost Analysis D. Heating System E. Cooling System F. Ventilation and Exhaust Systems G. Air Distribution H. Special Systems I. HVAC Control System J. Anti-terrorism and Force Protection (ATFP) K. Energy Conservation L. Testing and Balancing M. Commissioning

XI. ELECTRICAL

A. Design Criteria B. Existing Exterior Conditions C. Exterior Distribution Systems D. Interior Distribution Systems E. Interior Telecommunications and Other Related Special Systems F. Grounding Systems

XII. FIRE PROTECTION

A. Design Criteria B. Existing Conditions C. Automatic Sprinkler Systems D. Fire Detection System E. Fire Alarm/Mass Notification System F. Fire Hydrants G. Alternate Fire Suppression Systems H. Hazardous Areas I. Fire Pump/Water Supply J. Elevators

XIII. CYBERSECURITY

A. Criteria Resources and References B. Facility Related Control System Requirements for P-1066

XIV. SUSTAINABLE DESIGN

A. Sustainable Design

XV. ANTITERRORISM / FORCE PROTECTION (ATFP) – UFC 4-010-01

XVI. APPENDICES

A. DRAFT DD1391

B. BUILDING AREA CALCULATIONS

C. FF&E PRELIMINARY COST SUMMARY

D. PIASECKI FEASIBILITY STUDY

E. PERMIT RECORD OF DECISION (PROD)

F. GEOTECHNICAL REPORT

iii

G. HIGH PERFORMANCE AND SUSTAINABLE BUILDING (HPSB) CHECKLIST

H. MILCON CHECKLIST

I. ACOUSTIC STUDY

J. OWNER’S PROJECT REQUIREMENTS (OPR) DOCUMENT

K. OUTLINE SPECIFICATIONS

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BASIS OF DESIGN

I. PROJECT OVERVIEW

P-1066 CH-53K Gearbox Facility project will provide a facility that supports the heavy lift CH-53K King Stallion helicopter gearbox maintenance & testing operations for the USMC Fleet Readiness Command – East (FRCE) at the developing Hancock Village area of MCAS Cherry Point, NC. The project consists of a single-story building, site development (stormwater management, grading, parking, etc.), and associated utility work. One major priority of the design will be to manage/mitigate noise pollution from both operations inside the gearbox building, as well as from nearby airfield activity.

Along with sound concerns are the lessons learned from similar adjacent facilities, coastal environment concerns, providing cost effective solutions, and a facility that will encourage efficient operations in support of the program mission. Also considered in the design is how the project features fit into and improve the overall development of the immediate area around P-1066.

There are special design features included in the project that require increased attention and coordination. Some of these include the overhead bridge cranes, jib cranes, heavy lift support equipment, as well as the test cell apparatuses and their integrated monitoring systems / equipment.

The access to the test cell systems for their maintenance is also a point of special design effort.

General Design Codes and Standards (applicable to all design disciplines)

Unified Facilities Criteria (UFC)

• UFC 1-200-01, DoD Building Code (8 October 2019 w/ Change 1, 1 October 2020)

• UFC 1-200-02, High Performance and Sustainable Building Requirements (1 December 2020 w/

Change 1, 3 January 2022)

• UFC 4-010-01, DoD Minimum Antiterrorism Standards for Buildings (12 December 2018 w/

Change 1, 19 August 2020)

Codes Referenced by Unified Facilities Criteria (UFC)

• 2018 International Building Code (IBC)

II. ARCHITECTURAL

A. Design Criteria

Unified Facilities Criteria (UFC)

• UFC 3-101-01, Architecture (16 December 2020 w/ Change 1, 5 January 2021)

• UFC 3-110-03, Roofing (1 May 2012 w/ Change 5, 12 June 2020)

• UFC 3-600-01, Fire Protection Engineering for Facilities (8 August 2016 w/ Change 6, 6 May 2021)

• UFC 4-010-01, DoD Minimum Antiterrorism Standards for Buildings (12 December 2018 w/ Change 1, 19 August 2020)

Codes Referenced by Unified Facilities Criteria (UFC)

• 2021 NFPA 101 - Life Safety Code (LSC)

• Architectural Barriers Act (ABA) Standards, 2015

• DEPSECDEF Memorandum “Access for People with Disabilities”, October 2008

B. General / Scope of Work

The P-1066 Gearbox Facility single-story building will include spaces required to support the essential program of the FRCE CH-53K gearbox maintenance and repair mission which includes the main gearbox (MGB) test cell, nose gearbox (NGB) test cell, and tail rotor/intermediate (T/I-GB) gearbox test cell and associated support spaces. Many of these spaces require critical adjacencies which are shown in the Design Development drawings.

Building structure will be concrete masonry units (CMU) load-bearing walls and interior partitions.

Exterior envelope will be comprised of a lower wall section of cavity wall with brick veneer to 14’-0” high and metal panel rainscreen above the masonry veneer for the remainder of the wall up to roof eaves. The roof will be concrete and metal deck slab on steel bowstring joist framing. Refer to Structural section for additional information.

C. Type of Construction

P-1066 will be type IIB (non-combustible, unprotected) construction in accordance with the International Building Code (IBC).

D. Life Safety Code Analysis

Refer to general drawing sheets GI003, GI101 and GI102 for Life Safety Code Analysis detailed information. As determined by UFC 1-200-01, Means of Egress is determined by UFC 3-600-1 and ABA Standards requirements.

E. Gross Floor Area Calculations

DD1391: 31,624 GSF (program maximum)

Current Design: 31,458 GSF

Delta: -166 GSF (.5% +/-)

Refer to Appendix B herein for Building Area Calculations & Key Plan

F. Accessibility

As determined by UFC 1-200-01, the facility will provide barrier-free design in accordance with Architectural Barriers Act (ABA) Accessibility Guidelines for buildings and facilities and DoD Deputy Secretary of Defense Memorandum, Subject: Access for People with Disabilities, 31 October 2008.

The facility will be designed in accordance with all applicable Occupational Safety and Health Administration (OSHA) requirements.

G. Architectural Compatibility

The project is located within the Hancock Village area of MCAS Cherry Point and will adhere to the context of the materials, colors, and forms of the existing surrounding buildings consistent with the air station Base Exterior Architecture Plan (BEAP) dated 2007.

Exterior envelope materials will primarily consist of brick veneer to a specified height (indicated on drawings) and prefinished metal panels above the brick up to roof eaves. The brick veneer will be running bond pattern with appropriate detailing, such as soldier coursing, etc. The brick will be smooth finish, modular size and red in color. Prefinished metal panel exterior cladding above the brick veneer will be finish / color to match adjacent facilities. Roof eave soffits, fasciae and the standing seam metal roofing will be color matched in a white tone to match adjacent facilities.

The building massing and forms will be similar to the existing surrounding (& planned) buildings in the immediate area. This will include some high bay spaces resulting in high walls and lower portions in areas of the building where there is not a high bay program clearance requirement. Building forms will be thoughtful and relative to the scale of the building. The roof configuration will be curved to match the consistent theme in this portion of the base.

Fenestration in the exterior envelope will be clear anodized aluminum storefront and aluminum framed translucent wall panels. Ground floor windows, glazed doors, and clerestory translucent wall panels will be provided to maximize daylighting / views where practical. Louvers will be colored to match the adjacent wall material to blend with the field material.

H. Roof System Selection

The building various curved roof levels will be comprised of the same (2” high) standing seam metal roofing with underlayment on 1/2" cover board on rigid insulation on concrete and metal deck roof slab. The roof curves, of approximately 2:12 (+/-) equivalence, will be in accordance with the aesthetic set forth by the adjacent building roof forms. Sawtooth arrangement of the roofs over the high bay spaces will be a product of the necessary space for the overhead bridge cranes and will provide the opportunity to have clerestory translucent wall panels for daylighting. Roof eave overhangs will be minimal (2’-0” maximum) as required by the BEAP. Fascia and soffit detailing will be simple with clean lines and designed to minimize nesting for pests. Roof drainage will be provided via metal eave gutters with downspouts.

I. Thermal Insulation

Building envelope thermal properties will be designed to be in accordance with min/max values set forth in ASHRAE 90.1 dated 2019, Table 5.5-3. Exterior wall insulation will be foil-faced polyisocyanurate rigid insulation (R-6 per 1” min) with thermal performance of R-15 (min) for 2” thickness. The R-15 value includes the reflective R-value of the air space as afforded by the reflective foil-facing of the insulation board. The wall insulation will be continuous from top of foundation spread footing up to underside of roof slab. Eaves will be detail to provide continuous insulation from the wall to the roof plane. Roof insulation, completely above roof deck, will be polyisocyanurate rigid insulation (R-6 per 1” min) of built-up staggered thickness to 5” with 1/2” thick cover board for an aggregate thermal performance of R-33 (min). Exterior windows / translucent wall panels will be designed to provide U-values of 0.42 (max) and skylights to be U-values of 0.55 (max). Exterior swing doors will be designed to be U-value of 0.37 and the non-swing doors will be 0.310 for opaque doors.

J. Security Requirements

The only security requirements will be facility access control systems. Card readers and associated hardware will be provided for secure access into the building. The remainder of the door hardware will be standard type. Windows and translucent wall panels / skylights will be fixed type (non-operable). There will be no permanent roof access provided to the various roof levels, accessing the roof will be via grade level scissor, cantilever arm lifts, or similar.

K. Antiterrorism

Refer to section XV. Antiterrorism / Force Protection (ATFP) below.

L. Architectural Acoustics

Noise pollution is a concern from outside the P-1066 building primarily due to the nearby airfield, potentially by nearby similar test facilities and increased road traffic upon completion of the future DLA project. From inside the building, the noise generated by CH-53K gearbox program operations will need to be kept from becoming a nuisance to the outside environment. Both outside and inside noise sources must be mitigated to provide a safe and effective workplace.

Gearbox test stands create an acoustic hazard while they are operating. Operators will be required to wear double ear protection when entering the gearbox test stand rooms while the equipment is operating. While hearing protection is required, interior partitions within the test cell spaces will be provided with sound absorption panels to reduce the sound levels within the spaces to 84dB. Test cell rooms will be designed with partitions and doors to attenuate the extreme noise pollution generated from interfering with operations and safety in adjacent spaces. This sound attenuation includes exterior ventilation louvers to reduce the noise transfer to the outside.

Appendix H Acoustic Study included for reference.

M. Sustainable Design

Refer to section XIV. Sustainable Design herein and the Sustainability Notebook under separate cover.

N. Doors and Windows

Exterior doors will be a combination of specialty sound and ballistic rated exterior swinging doors, steel exterior personnel doors, high-speed overhead coiling doors with vehicle sensors on the interior and exterior and building main entry aluminum entrance system. The interior doors will be a combination of specialty sound and ballistic rated interior sliding doors, sound and ballistic rated interior personnel doors, steel personnel doors, and insulated overhead doors.

Exterior windows will be ATFP compliant (at Break Room only), high performance aluminum windows and aluminum curtain wall system with insulated glazing. Translucent insulated panel wall and skylight systems will be incorporated at various locations to introduce natural light. See drawings for quantities and locations.

Exterior louvers will be high performance drainable aluminum assemblies and sound attenuating storm louvers (at test cell spaces).

O. Special Construction Features

Various special design features are required for the CH-53K gearbox maintenance and repair program operations within the facility. These include:

• 5-ton overhead bridge crane, 35’ approximate hook height (MGB Test Cell)

• 4-ton overhead bridge crane, 25’ approximate hook height (Disassembly)

• 4-ton overhead bridge crane w/ (2) trucks, 25’ approximate hook height (Assembly)

• 2-ton overhead bridge crane, 20’ approximate hook height (T/I-GB Test Cell)

• 2-ton overhead bridge crane, 20’ approximate hook height (NGB Test Cell)

• ½-ton overhead monorail with branches (Small Gearbox Staging)

P. Waterproofing and Vapor Mitigation

The facility will include waterproofing and vapor retarders in the floor, wall and roof assemblies as required by UFC 3-101-01 Architecture.

III. INTERIOR DESIGN

A. Interior Design Overviews

Interior design will be handled by an NCIDQ Certified Interior Designer, who will provide a SID package in accordance with the NAVFAC Interior Design Procedures and UFC requirements. New interior finishes and details will be coordinated in accordance with user feedback during design development and review.

Light color tones will be utilized to aid with lighting and energy conservation. Specialty items such as interior identification, directional signage, and corner guards will be included and coordinated with the floor plan design and the interior finishes.

Finish selections will be made with consideration given to product durability, appearance retention, ease of maintenance, cleanability, ease of replacement if damaged, flexibility, and acoustic properties to create a functional and aesthetically pleasing professional environment. Sustainable materials will be considered and included.

B. Interior Finish Materials and Specialties

Finishes will be provided according to the UFGS, specifically the section for “Interior Design”, UFC 3-210-10. Interior signage will be provided according to UFC 3-120-01, “Design: Sign Standards”.

Products that have sustainable design characteristics will be given preferential consideration over other products. All finish materials will be selected to produce an optimally functional facility, consistent with quality commercial design.

Finish material applications for the building are as follows.

Vestibule Vestibule flooring will consist of a recessed walk off mat. Walls and ceiling will be epoxy painted.

Main Aisle, Staging and Corridor The flooring for these spaces will be poured resinous epoxy flooring with a non-slip, chemical and stain resistant finish. There will be integral flash coved six-inch-high wall base. Walls will receive epoxy paint in a satin finish and ceilings will be exposed with epoxy paint. The corridor will include an ABA double water fountain w/ bottle filler.

Break Room Break Room will have decorative flake resinous epoxy poured flooring with a non-slip, chemical and stain resistant finish with integral six-inch-high wall base, latex painted walls and suspended acoustical tile ceilings. Countertops will be solid surface with high pressure plastic laminate base cabinetry and a decorative accent wall tile full height above the countertop.

Test Cells, Control Rooms, Assembly/Disassembly, Tool Room, Production Control and Flushing spaces These areas will receive epoxy resinous poured flooring with a non-slip, chemical and stain resistant finish and an integral six-inch-high wall base. Walls will be epoxy painted, and ceilings will be exposed and epoxy painted.

Utility spaces These areas will have concrete floors with a non-slip hardener/densifier and a stain resistant protective sealer. Walls will be painted with epoxy based paint, and ceilings will be exposed and painted with epoxy based paint. The sealer for the Comm room will have antistatic properties. The Janitor’s closet will receive full height fiberglass reinforced wall panels a will include a floor mounted janitor sink with stainless steel surround.

Offices Flooring in these spaces will be decorative flake resinous epoxy poured flooring with a non-slip, chemical and stain resistant finish with integral six-inch-high wall base, latex painted walls (including accent) and suspended acoustical tile ceilings.

Restroom and Locker Rooms Flooring in these spaces will be decorative flake resinous epoxy poured flooring with a non-slip, chemical and stain resistant finish with integral six-inch-high wall base with full height porcelain tile on all walls. Shower compartments will be solid surface receptors and compartment walls will receive full height 1/2" thick solid surface material. Ceilings will be moisture resistant gypsum board with epoxy paint. Counters in the restrooms will be solid surface material and will have plastic laminate aprons.

Specialties Interior signage will be provided for all rooms. Directional and safety signage will also be provided as necessary. A building directory will be provided in the corridor, adjacent to the Vestibule. Signage components will coordinate with existing base/building nomenclature and meet all applicable code and regulation requirements.

Window Treatments Exterior windows will receive horizontal louver mini blinds.

Other Built-in equipment includes, but is not limited to, markerboards, tack boards, double tier “Z” style HDPE lockers, and shower benches.

C. Furniture, Fixtures and Equipment (FF&E) / Collateral Equipment (CEQ)

A concept level FF&E package will be developed with user input on activity requirements by an NCIDQ Certified Interior Designer in accordance with NAVFAC D/B/B Process 1. The awarded General Contractor’s Interior Designer and equipment specialists will further develop and validate the FF&E and Specialty Collateral Equipment packages to produce a functional facility, consistent with quality commercial design. A “Best Value Determination” will be completed by the awarded General Contractor’s Interior Designer utilizing GSA schedules, and other Federal contracts in compliance with priorities found in FAR Part 8.404.

Furnishings for this project will be selected based on functional requirements, ergonomic requirements, product quality and durability, flexibility, ease of maintenance and cleanability, as well as the ease of replacement if damaged. Sustainable design characteristics will also be considered.

The SID and FF&E Package submittal documentation will be provided per the SAES CID attachment requirements. The FF&E Summary cost estimate is included as an appendix.

Specialty equipment for this project includes, but is not limited to:

• Assembly:

▪ Ergo Stands - (2) larger 30002YS 20'x17', (2) smaller - 750 (Assembly). These items will be G.F.G.I.

▪ (1) Bull Gear Press (Assembly). This item will be G.F.G.I.

▪ (1) Oven 6x6 and (2) Presses 6x4 (Assembly). These items will be G.F.G.I.

• Disassembly:

▪ Ergo Stands - (1) larger 3000E 20'x17', (2) smaller - 750 (Disassembly). These items will be G.F.G.I.

▪ (1) Oven 6x6 and (2) Presses 6x4 (Disassembly). These items will be G.F.G.I.

• Small Gearbox:

▪ Ergo Stands - (6) smaller - 750 and 1/2 ton monorail (Small Gearbox). These items will be G.F.G.I.

IV. CIVIL

A. Design Codes and Standards

The civil design and analysis for this design effort uses the following codes and criteria, with the current revision date noted:

• UFC 3-201-01 Civil Engineering, with Change 5 (01 April 2021)

• UFC 3-210-10 Low Impact development, with Change 3 (01 March 2020)

• UFC 3-230-01 Water Storage and Distribution, with Change 3 (01 July 2021)

• UFC 3-230-03 Water Treatment, with Change 2 (01 May 2020)

• UFC 3-240-01 Wastewater Collection and Treatment, with Change 2 (01 January 2021)

• UFC 3-240-03 Operations and Maintenance (O&M): Wastewater Treatment (03 October

2019)

• UFC 3-250-01, Pavement Design for Roads and Parking Areas (14 November 2016)

• UFC 3-260-01 Airfield and Heliport Planning and Design, with Change 1 (05 May 2020)

• UFC 3-570-01 Cathodic Protection, with Change 1 (14 January 2019)

• UFC 3-600-01 Fire Protection Engineering for Facilities, with Change 6 (06 May 2021)

• UFC 4-022-03 Security Fences and Gates (01 October 2013)

• North Carolina Department of Environmental Quality Stormwater Design Manual (with 2020 selected updates)

• North Carolina Department of Environmental Quality Erosion and Sediment Control

Planning and Design Manual (2013 Update)

• North Carolina Department of Transportation Roadway Standard Drawings (2018 Version)

• North Carolina Department of Transportation Standard Specifications for Roads and

Structures (2018 Version)

• North Carolina Department of Transportation Roadway Design Manual (date varies by section)

B. General

The project will construct a facility to support the CH-5K3 aircraft variants with a depot-level gearbox maintenance facility. The facility will include assembly, testing, disassembly, and support space for personnel working at Fleet Readiness Center East (FRCE) Cherry Point within the Commander, Fleet Readiness Center Command within the Naval Air Systems Command. In addition to the maintenance facility, infrastructure upgrades and supporting site features will be constructed to ensure the site can support the ongoing redevelopment aboard MCAS Cherry Point.

C. Existing Conditions

The project site is located within the boundaries of the former Hancock Village housing area southeast of runway 5R/23L. The housing development was razed in the late 2000s to prepare for the redevelopment of this area as an aircraft maintenance depot due to its proximity to the runways and abundance of space within the Marine Corps Air Station Cherry Point flight line perimeter. Two facilities – building 4841 and building 4930, the Engineering Support Building and H1 Gearbox Maintenance Facility, respectively, are complete and adjacent to the proposed facility.

Access to the development is from Sheep Road, which connects via Marylou Road to Cunningham Boulevard and the core industrial area of MCAS Cherry Point.

Since the demolition of the housing complex, the former lawns and roadways are experiencing regrowth of underbrush and trees. Large, mature pine trees are located throughout the site and a dense thicket of saplings up to heights of 10-15 feet cover the site. Along the perimeter fence near Sheep Road, grassed areas are maintained for security and maintenance of the fence line.

D. Demolition

The project will selectively remove vegetation and surficial organic matter to allow construction of the facilities and supporting utility infrastructure. The mature trees will remain to the greatest extent possible. In order to connect to the existing utility systems, removal of pavement and fencing along the proposed alignment will be required.

The existing 4-inch sanitary sewer force main will be abandoned downstream of the pump station near Building 4841 to the connection to the force main to Building 93 and the pump station wet well and valve vault will be removed.

Portions of the 4-inch PVC water line that serves the area will be capped and abandoned and/or removed for the installation of the new sewer force main.

E. Proposed Site Improvements

The H-53 Gearbox Facility will be located within the current wooded area east of Building 4841 and south of Building 4930. The building will be oriented along an east-west axis to facilitate co-location with the surrounding buildings and existing roadway. Two paved access drives will be provided to connect to Sheep Road and allow for a 26-foot access drive around the rear of the building. This will support the transportation of equipment around the site. A 25-space parking lot will be provided north of the building, between the building and Sheep Road. Parking spaces will be 9-feet wide by 18.5-feet long with a 26-foot wide drive aisle. There will be one van accessible space with the required signage and pavement markings to meet ABA requirements. Mobility cart parking for 10 vehicles will be provided with heavy duty concrete pavement along the back of the site in the southeastern corner.

The access road will consist of a heavy-duty asphalt pavement section including an aggregate base course over compacted subgrade. The parking lot will consist of asphalt pavement over an aggregate base course over compacted subgrade. Concrete walkways will be provided along Sheep Road for the length of site and will connect each exterior building door to the access drive. Heavy duty concrete will be provided for access connection to the bay doors featured on the west and east sides of the building.

A dumpster pad will be provided on heavy duty concrete on the western side of the building. A Level 1 security fence will be provided on the eastern and southern sides of the site to connect to the existing base perimeter fence.

F. Anti-Terrorism/Force Protection

The facility is about 800 feet from the existing perimeter fence along Fontana Boulevard and will be approximately 100 feet from the proposed perimeter fence being relocated with this project. A clear zone of 20 feet inside the fence and 13 feet outside fence, clear of obstructions, is proposed. The fence will match the existing chain link section – 7’ high with three strands of barbed wire and will be cable reinforced with deadmen at the corners and intermittently as required. A 33-foot unobstructed space around the building will be free of vegetation and places that allow concealment. All parking areas will be located outside the unobstructed space. The refuse container and enclosure are proposed to be outside of the unobstructed space along with the mechanical equipment yard. Additional site security features are not being proposed based on the surrounding industrial area use and remoteness of the facility.

G. Water Supply

The water supply to the previously constructed facilities is through a single 4-inch PVC water line that runs from Cunningham Boulevard to near the project site. An analysis of the system indicates this line must be upgraded to provide adequate pressure to the facility. The new 12” PVC water supply will connect to the existing base water supply system at a location that has yet to be determined. The 2 ½” copper service line to the P1066 Gearbox building will connect to the proposed X-inch main. A meter will be provided near the main connection.

The existing 4-inch service line from Cunningham Boulevard will be disconnected and capped at the nearest facility that will still be served from this line along Marylou Road. The disconnected portion of 4-inch pipe will be abandoned in place.

H. Sanitary Sewer

The existing buildings in the Hancock Village redevelopment connect via a gravity pipe system to a sanitary pump station that is north of building 4841. The station was constructed with the P974 project (building 4841) and modified during construction of the P991 project (building 4930). The pump station discharges into a 4-inch PVC force main that follows the alignment of Marylou Road and continues west to connect to the 6-inch force main from Pass & ID building. The connection to the system is a manhole near Building 93.

This project will replace the pump station wet well, valve vault and 4-inch force main to increase the capacity of both features to accommodate the development of P1066, P100, P993, and the addition to Building P1100. The new pump station will be adjacent to the existing station and the force main will be increased to a 6-inch C900 PVC pipe that closely follows the alignment of the existing force main.

The new 6” force main connection will to the near the existing 4” force main connection to the force main from Pass & ID building.

The sanitary sewer lateral from the Gearbox Building will be 4-inch PVC at a minimum slope of 1 percent starting at the cleanout 5 foot from the face of the building to a new manhole in Sheep Road.

New 8-inch PVC sanitary sewer will be installed from the new manhole back to the new pump station at a minimum 0.4% slope. The invert of the new manhole has been set to accommodate flows from P995.

Upgrades such as replacing the pumps in the pump station may be required for future additional flow from P995. As more flow from future facilities is added to the Hancock Village complex a larger pump station and force main will be needed.

I. Natural Gas

The proposed natural gas service is from the Piedmont Natural Gas company’s distribution main along Fontana Boulevard, approximately 1,000 feet south of the project site. The proposed service line will be a 2-inch PE pipe and includes a below-grade meter at the property line to MCAS Cherry Point.

J. Cathodic Protection

Information on the soils is pending the geotechnical exploration. A cathodic protection system for exterior utility piping has been included in the cost estimate. Soil testing will be required during design to confirm if cathodic protection is warranted and if so, to what level/type should be incorporated into final project requirements. The preliminary schemes include the use of polyethylene wraps and zinc coatings on ductile iron pipes or the use of plastic pipe, where feasible.

K. Stormwater Management

The area encompassing Hancock Village is comprised of two large drainage areas; one that drains to the West into a culvert that flows under the airfield and one that drains to the East through multiple ditches that ultimately enter an existing offsite detention pond. The P1066 proposed building site currently sits on the drainage divide between the two areas.

The project is required to provide low impact development in accordance with UFC 3-210-10 Low Impact Development runoff reduction and compliance with the Energy Independence and Security Act (EISA) 2007 using the 95th percentile rainfall depth. One way to meet the UFC and NCDEQ requirements is to reduce the impervious area and post-development runoff. The recently designed P990 Vertical LiftFan Test Facility utilizes the impervious area associated with the former housing development as the pre-development condition since the demolition was carried out to prepare the site for the depot facilities. The post-development stormwater runoff is below the pre-development runoff as long as the total impervious area associated with redevelopment is below the impervious area associated with the housing for each of the two drainage areas. Using the Hancock Village housing as an impervious area credit bank that can be classified as redevelopment with the NCDEQ eliminates the need for stormwater BMPs and retention ponds.

A portion of the project site drains to the stormwater pond that collects and treats water from the building 4841 and 4930 projects. This pond is at capacity and considered a BASH hazard as determined during the design of the P990 Vertical LiftFan Test Facility. This project proposes to direct the majority of stormwater runoff from the site to the existing ditches and channels associated with the eastern drainage area that flows into the pond just beyond the eastern limits of Hancock Village. The total runoff to the pond from the eastern drainage area is below the pre-development runoff. The condition of the pond will need to be evaluated prior to construction and likely rehabilitated to meet current NCDEQ requirements. The small portion of area located within western drainage area will be collected in the existing swale positioned along the north side of the site. This swale will be modified to ensure that post-development runoff flows will not exceed the predevelopment flow from this area.

L. Erosion and Sediment Control

The project will include erosion and sediment control measures to prevent sedimentation of downstream areas and control erosion within the site. Measures will include temporary construction entrances, silt fencing, inlet protection, filter socks, mulching, and manufactured products. Temporary and permanent seeding is not allowed due to the proximity of flight paths and BASH criteria. The final stabilization of the site will include sod in all non-paved areas.

The land area disturbed for the project will be approximately 10 acres which includes the primary building location and water, sanitary, and gas connections to the existing infrastructure.

M. Environmental Permits

The project exceeds one acre in disturbed area and therefore will require permitting from the North Carolina Department of Environmental Quality (NCDEQ). Sediment and Erosion Control plans and stormwater management plans will be submitted to MCAS CP Environmental Affairs Department (EAD) and the NCDEQ for review and approval to obtain coverage under the North Carolina NPDES permit for Construction Activities.

NCDEQ permits will be required for water main – both domestic and fire, extensions and sewer main extensions.

V. GEOTECHNICAL

A. Geotechnical Report

A site-specific geotechnical exploration program is being performed for this effort. Results of the program are not yet available. The subsurface exploration and geotechnical engineering analysis will provide foundation design recommendations (shallow vs deep), settlement estimates, pavement design guidance, and earthwork recommendations based on the results of in-situ and laboratory testing.

Until those results are available, the 50% design submittal foundation designs are based on available information provided within the Preliminary Design Authorization (PDA) Geotechnical Engineering Report developed by Terracon dated May 14, 2021 (Terracon Project No. EC21-104G). Based on the recommendations within the aforementioned Geotechnical Engineering Report, the use of a shallow foundation system is specified.

Generally, the surficial and shallow subsurface soils encountered at the explored locations consisted of topsoil extending to depths ranging from 3 to 24 inches. As such, a cut depth ranging from about 3 to 24 inches to remove these unsuitable conditions is anticipated to be required. Deeper excavations should be expected within isolated areas to remove unsuitable Organic laden conditions.

The subsurface soils encountered at the boring locations and extending to depths generally ranging from 4 to 6 feet do not appear to meet the criteria recommended for use as structural fill. The deeper subsurface soils are anticipated to be suitable for reuse as structural fill. However, moisture manipulation in the form of stockpiling and drying is expected as these soils are located near or below the groundwater table. As such, the project’s budget should include an allowance for subgrade improvements (undercut and backfill with structural fill).

Considering the building area at this project site will be elevated with approximately 3 feet of well compacted structural fill, an underdrain system is not currently anticipated to be warranted or economical as opposed to conventional over-excavation and backfilling with open graded gravel when required.

The proposed building, gearboxes, test stands, and crane structures may be supported by means of shallow spread footings designed using an allowable bearing capacity of 2,000 pounds per square foot (psf) (minimum 24-inch embedment and minimum 24-inch width). Isolated square column footings are recommended to be a minimum of 3 feet by 3 feet in area for bearing capacity consideration.

Estimated post-construction total and differential settlements are not expected to exceed 1-inch and 1/2-inch, respectively. When full design is performed, the results of a complete geotechnical engineering program will inform the actual foundation system selection.

Floor slabs may be constructed as slab-on-grade members provided the subsurface recommendations are carried out properly. It is recommended that all ground floor slabs be “floating” and not rigidly connected to walls or foundations.

Refer to the Structural section of this document for foundation system description.

VI. LANDSCAPE

• Design is based on the following:

UFC 3-201-02 Landscape Architecture, with Change 1 (9 February 2021)

UFC 4-010-01 DoD Minimum Antiterrorism Standards for Building with Change 1 (19 August 2020)

International Green Construction Code (IgCC) (2018), Chapter 5 Site Sustainability and Chapter 6

Water Use Efficiency

Base Exterior Architecture Plan (BEAP) for Marine Corps Air Station Cherry Point, NC (30 January, 2007)

B. Design Criteria

Shade trees will be provided along the entry drive, POV parking lot and access drive around the building to provide shading. Trees will be drought tolerant. Shrubs will be provided along parking lot perimeter to form an opaque screen, and force protection compliant landscaping will be provided to screen the dumpster area and any equipment. Bermuda sodded lawn with 4” topsoil will provide a drought tolerant, low maintenance lawn. No permanent irrigation will be required. Extent of work includes a one-year landscape establishment period.

Building identification sign at the entrance drive will comply with the BEAP.

VII. ENVIRONMENTAL

A. Environmental Report

No additional environmental investigation services were performed as part of the scope. There are no known areas of environmental concern.

VIII. STRUCTURAL

Structural design is based on the following:

• UFC 1-200-01, DoD Building Code, with Change 1, 01 October 2020

• UFC 3-301-01, Structural Engineering, with Change 1, 04 February 2022

• UFC 4-010-01, DoD Minimum Antiterrorism Standards for Buildings, with Change 1, 19 August 2020

• UFC 3-320-06A, Concrete Floor Slabs On Grade Subjected To Heavy Loads, 01 March 2005

• FC 1-300-09N, Navy and Marine Corps Design Procedures, with Change 6, 09 July 2021

• 2018 International Building Code (IBC)

• ASCE 7-16, Minimum Design Loads for Buildings and Other Structures

• ACI 318-14, Building Code Requirements for Structural Concrete

• AISC 360-16, Specification for Structural Steel Buildings

• AISI S-100-16“North American Specification for the Design of Cold-Formed Steel Structural Members, 2016”

• TMS402-2016, Building Code For Masonry Structures

B. Design Criteria

Structural design criteria are based on assigning the facility to Risk Category II, in accordance with UFC 3-301-01. Design live loads are based on the anticipated use of the facility. In addition to loads specified below, the structural systems have been designed to support superimposed dead and live loads, including allowances for mechanical and electrical equipment.

Design Uniform Live Loads:

Roof 20 psf Offices 50 psf Toilets 75 psf Corridors/Break Room 100 psf

Light Storage 125 psf Tool/Mechanical/Electrical Rooms 150 psf Partition Allowance 15 psf Test Cell/Assembly/Disassembly/Shops 250 psf

Wind Loads (UFC 3-301-01 Structural Load Data Tool):

Basic Design Wind Speed, V 139 mph Allowable Stress Design Wind Speed, Vasd 108 mph Exposure Category C Gust Effect Factor, G 0.85 Internal Pressure Coefficient, GCpi +/- 0.18

Snow Loads (UFC 3-301-01 Structural Load Data Tool):

Ground Snow Load, Pg 10 psf Snow Importance Factor, Is 1.0 Snow Exposure Factor, Ce 1.0

Thermal Factor, Ct 1.0

Seismic Loads (UFC 3-301-01 Structural Load Data Tool):

Seismic Importance Factor, Ie 1.0 Spectral Response Factor, Ss 0.095g Spectral Response Factor, S1 0.048g Spectral Response Factor, SDS 0.102g Spectral Response Factor, SD1 0.077g

Site Class D (based on Geotechnical Engineering Report for Preliminary Design Authorization (PDA) dated May 14, 2021; Terracon Project Number EC21-104G)

Seismic Design Category B Basic Seismic Force Resisting System Intermediate Reinforced

Masonry Shear Walls Response Modification Factor, R 3.5

Foundation Design Criteria:

Frost Line 0 inches

Net Allowable Soil Bearing Pressure 2.0 KSF (based on Geotechnical Engineering Report for Preliminary Design Authorization (PDA) dated May 14, 2021; Terracon Project Number EC21-104G)

Materials Concrete:

Slab-on-Grade 4,000 psi, normal weight Foundations 3,000 psi, normal weight Concrete On Steel Deck 4,000 psi, normal weight

All Other Concrete 4,000 psi, normal weight Reinforcement ASTM A615, Grade 60

Structural Steel:

Wide Flange Sections ASTM A992, Grade 50

Square and Rectangular HSS ASTM A500, Grade C, Fy=50ksi Plates, Angles, and Threaded Rods ASTM A36, Fy=36 ksi Anchor Rods with Nut and Washer ASTM F1554, Grade 36

Metal Studs: Supplier Standard Shapes Based on SSMA Criteria

Cold Formed Steel framing: ASTM C955, ASTM A653, Grades 50, 33

Structural Masonry:

Concrete Masonry Units 2,000 psi, Medium Weight (115 pcf) Mortar ASTM C270 Type S Grout in CMU 2,000 psi, ASTM C476 Reinforcement ASTM A615, Grade 60

C. Foundations

A soils investigation has not yet been performed for the project. However, based on Geotechnical Engineering Report for Preliminary Design Authorization (PDA) dated May 14, 2021; Terracon Project Number EC21-104G, the foundation system for the proposed building, gear boxes, test stands, and crane structures will likely consist of a combination of spread and continuous footings founded on firm natural soil or engineered fill. The allowable net soil bearing was also specified to be 2,000 psf.

This data will be finalized with the complete geotechnical report.

The ground-supported floor levels for all of the structures will consist of a reinforced concrete slab-on-grade (with thicknesses varying between 5 and 8 inches, based on area designation) that has been designed for the identified dead and live loads designated in each area. Saw cut joints will be provided to limit slab cracking. Thicker slabs (2 feet thick) are required at the Nose and Tail Gearbox test stands.

An isolated 5-foot thick concrete inertia base is required for the Main Gearbox test stand. The extents of these equipment slabs will be coordinated with the test stand requirements, which are manufacturer-specific.

It should also be noted that a portion of the work area of will be equipped with sump pits. The pits will consist of reinforced, cast-in-place concrete and will also have removable floor grating.

D. Structural Systems

The roof structure of the facility will consist of a composite concrete slab-on-steel deck supported by sloped, open-web bowstring joists that bear on concrete masonry walls. A composite concrete slab-on-steel deck is provided at the roof level to limit sound transmission from an adjacent airfield to the interior spaces. “Removable” skylights will be provided in one location of the facility and will be supported by a combination of open-web steel joists and open-web bowstring joist girders. Framing and bolted connections within these locations will require special details to accommodate this feature.

The roof diaphragm will be designed treating these sections as openings.

The CH-53K facility will utilize a load-bearing concrete masonry wall system. Masonry walls are required in many rooms for durability, so using these as structural walls is efficient. Masonry walls within the high and intermediate roof level spaces will consist of 12-inch block, reinforced for gravity loads and lateral wind pressures. Masonry walls within the low roof level spaces will consist of 8-inch block, reinforced for gravity loads and lateral wind pressures. Interior walls will consist of 12-inch and 8-inch block reinforced for gravity loads and a nominal 5 psf interior lateral pressure.

Masonry walls surrounding the test cells must be designed for impact due to a failure within the test cell. At a minimum, the test stand manufacturers require sand-filled cores (in addition to any grouted and reinforced cells). The walls will also be evaluated for acoustic properties, to limit sound transmission from the test cells to other interior spaces.

Structural steel columns and beams will support the bridge crane systems. Steel framing will be braced to masonry walls for lateral stability. Bridge crane framing will be designed for the deflection criteria required for the crane, and for the impact loading prescribed by ASCE 7.

Roof framing will be designed to limit total load deflection to L/240. Exterior walls supporting brick will be limited to L/600 for wind in accordance with UFC 3-301-01. Overall structural lateral displacement due to wind will be limited to H/480, based on a 10 year MRI wind speed.

The outdoor canopy components of the facility will likely consist of steel roof deck supported by wide-flange steel beams or channels that will directly attach to the reinforced concrete masonry walls.

MCAS Cherry Point is classified as “C4” for environmental severity, in accordance with UFC 1-200-

01. This classification requires corrosion prevention methods for corrosion-prone exterior locations, including special coatings on steel and increased cover on exposed concrete.

E. Lateral Force Resisting Systems

The composite concrete-on-steel deck provides a semi-rigid diaphragm at the roof level, to transmit lateral loads. Chords and collectors will transfer lateral loads from the diaphragm to the intermediate reinforced masonry shear walls in proportion to the rigidity of the wall.

F. Anti-Terrorism and Force Protection Design (ATFP)

Refer to Appendix for complete ATFP Analysis.

A majority of the facility is routinely occupied by fewer than eleven DoD personnel. Therefore, the Anti-Terrorism and Force Protection provisions of UFC 4-010-01, as well as the progressive collapse avoidance measures do not apply. However, the Break Room is considered inhabited and must follow the provisions of UFC 4-010-01.

IX. PLUMBING

UFC 1-200-02 High Performance and Sustainable Building Requirements UFC 3-420-01 Plumbing Systems UFC 3-420-02FA Compressed Air UFC 3-570-01 Cathodic Protection International Building Code, 2018 International Mechanical Code, 2018 International Plumbing Code, 2018 NFPA 54-2015 National Fuel Gas Code NFPA 101 Life Safety Code ASHRAE 90.1-2013 Energy Standard for Buildings except Low-Rise Residential Buildings ASHRAE 2019 Handbook, HVAC Applications, Chapter 51: Service Water Heating Energy Policy Act of 2005 Energy Independence and Security Act of 2007 Executive Order 13693 Uniform Federal Accessibility Standards (UFAS) and Architectural Barrier Act (ABA)

B. Plumbing Systems

Backflow Prevention Domestic water will be provided from a point 5 feet outside of the building perimeter walls and enter the building’s mechanical room. Domestic water supply will be 2-1/2 inches with a shut-off valve, strainer, building water meter and reduced pressure backflow device with integral flood control system.

The domestic water line will also feed mechanical equipment requiring make-up water with an additional backflow protection device. The distribution piping for this system will be insulated Type “L” copper piping.

Domestic Water Distribution System Domestic water supply will be sized based on a fixture count of 75 supply fixture units, which converts roughly to 60gpm.

Domestic Hot Water System The domestic water heating system will be sized in accordance with ASHRAE guidelines. Domestic hot water will be provided to all fixtures requiring hot water. The water heater will be a natural gas-fired, high efficiency type (±95%) with two 75 gallons of storage and be capable of delivering 1 gallons of hot water at 90 degrees F rise per hour. The temperature at the heaters will be set to 140 degrees F. A thermostatic mixing valve at the heater will provide the distribution of 120 degrees F water to the building fixtures. The water heater system will be provided with an in-line pump for potable hot water recirculation. Potable hot water piping will be routed to provide a maximum of 20 feet between any plumbing fixture and the circulated main system to limit stagnant water biological growth.

Sanitary Sewer System Piping will extend below the floor slab to the fixture locations. Below-slab sanitary sewer piping will be cast-iron hub and spigot construction and must be supported to the structurally supported floor system above.