Specifications for the LYH VOR Roof Replacement.docx

LYNCHBURG VORTAC

ROOF REPLACEMENT

DESCRIPTION / SPECIFICATIONS

TS-1 DESCRIPTION

1.1 GENERAL. This work shall consist of the removal of the existing roofing system including the sheet metal counterpoise and the installation of a new stainless steel mesh counterpoise, EPDM roof system, and related work at an FAA VORTAC equipment building along with the replacement of three steel exterior doors and frames. The area of the roof is approximately 2200 square feet. The VORTAC building contains sensitive electronic equipment and must be protected from the elements as well as possible construction damage.

1.2 LOCATION: The Lynchburg (LYH) VOR facility is located in Lynchburg, Virginia. A site visit is required and can be arranged by contacting Arnold Fouch, Supervisor Roanoke SSC, at (540) 523-8225.

TS-2 REQUIREMENTS

2.1 GENERAL: The contractor shall adhere to any restrictions placed on the conduct of work or the use of equipment, tools or vehicles identified by the Contracting Officer’s (CO) representative or his designated resident engineer. The LYH-VOR facility contains sensitive electronic equipment and must be protected from possible construction damage. Also the function of the FAA is critical to the safety of the flying public and scheduling around heavy traffic periods may be necessary.

2.2 CONTRACTING OFFICER: The term “CO” as used herein refers to the Contracting Officer, unless he has delegated his authority to someone else. The Contracting Officer may delegate, in writing, certain aspects of his authority to the Resident Engineer /Contracting Officers Technical Representative.

2.3 FAA RESIDENT ENGINEER (RE)/CONTRACTING OFFICER'S TECHNICAL REPRESENTATIVE (COTR): The RE/COTR shall receive any and all questions that may arise as to the interpretation of the specifications or plans. He will be responsible for the quality and acceptability of materials furnished, work performed, and as to the manner of performance and rate of progress of work, and the rights of the contractor and their subcontractors. The RE/COTR shall be authorized to inspect all work done and all material furnished. Such inspection may extend to all or any part of the work and to the preparation, fabrication, or manufacture of the materials to be used.

2.4 LICENSES AND PERMITS: The Contractor shall be responsible for obtaining all necessary licenses and permits and for complying with all Federal, State, and Local laws, codes, and regulations applicable to the performance of this work.

2.5 PRECONSTRUCTION MEETING: The Contractor shall attend a preconstruction meeting at the time and location specified by the (CO). The work schedule, along with local procedures related to ingress/egress, and security will be discussed during the meeting. Compliance with these procedures while on site will be mandatory.

2.6 CODE COMPLIANCE: The Contractor shall comply with local and other codes and standards; whichever requires the higher quality of material and workmanship. Where the requirements of these Specifications exceed those of the local or other codes, the Contractor shall comply with the Specifications.

2.7 PROTECTION OF FAA FACILITIES: The contractor shall take the utmost precautions to plan, organize, and carry out their work to avoid disturbance or disruption of this facility. The contractor shall bear all cost to repair or replace damaged cables, ducts, or facilities and to restore service when such damages have occurred due to their negligence or accident. The CO reserves the right to deduct such cost from any moneys due or which may become due the contractor or their surety.

2.8 SECURITY REQUIREMENTS: It is the contractor’s responsibility to provide the FAA RE/COTR with a list of the contractor’s personnel who will require access to the site. The list shall be kept current and updated as required during construction.

2.9 SITE WORK: The contractor shall accomplish the site work as specified below. All material and equipment shall be installed by the contractor in accordance with the Government furnished specifications and drawings, manufacturer installation instructions, all applicable documents, and all applicable national and local codes. The government will supply electricity for the contractors' use in completing this project.

2.10 WORK DESCRIPTION: This work shall consist of the removal of the existing roof system, inspection and replacement of wood decking as needed, and the installation of a new mesh counterpoise and installing a new EPDM roof along with related work at an FAA VOR equipment building. The LYH-VOR roof is flat and round; the radome enclosure is cone shaped fiberglass and approximately 10 feet high situated in the center of the roof. The radome enclosure will be removed and replaced by the FAA. The contractor shall install the new counterpoise and EPDM roof. The area of the roof is approximately 2200 square feet. The Contractor shall supply all materials, equipment, tools, transportation, services, and labor required to complete the work indicated in the specifications contained herein. The following work shall be part of this project:

1. The existing roofing system shall be removed and disposed of properly.

2. Survey/mark, remove and reinstall the 16 azimuth antennas. All sixteen (16) brackets and supports will be reused. Establish existing magnetic north based on north monitor bracket.

3. The existing sheet metal counterpoise shall be removed and disposed of in compliance with all local and federal environmental regulations.

4. The wood deck shall be inspected and any damaged or rotted wood shall be replaced.

5. Ice and water shield will be installed across the entire roof (approx. 2200 sq. ft.)

6. 2” Stainless steel T304 welded .105 mesh will be installed to form a continuous ground plane. The mesh will be stapled flat and welded on all seams every 6 inches with a minimum ½” tack.

7. Grounding plates shall be installed at 4 corners of the building and circular grounding plates will be welded to the mesh so that the center Antenna mount can be attached to the welded plates with screws

7. The entire roof shall be covered with 3/4 in. CDX, tongue and groove, plywood decking. The plywood shall be installed with a minimum of 2 ½” deck screws to insure the surface stays flat

8. Install a EPDM rubber roof over the entire roof directly to the surface of the CDX plywood using manufacturers suggested adhesive, seams and flashing requirements. At the center of the roof surrounding the antenna mount 1” of the welded plate will be left exposed so that the plates will be mechanically connected to the antenna mount with screws

9. Install cross grip walkway tread area around the cone and to the main access ladder supports at the roof edge. The mats shall be 4’ x 6’ by ¾” horse stall mat type.

10. Three steel exterior doors on the equipment building shall be removed and replaced with new insulated, exterior, steel doors and frames.

11. Replace Vinyl Soffit and fascia, which is showing mildew damage

2.11 CODE REQUIREMENTS: The proposed roofing system shall meet the requirement of the following recognized code approval or testing agencies. These requirements are minimum standards and no roofing work shall begin without written documentation of the system's compliance.

1. ASTM D1668 – Glass Fabrics (Woven and Treated) for Roofing and Waterproofing.

2. ASTM D4601 – Asphalt-Coated Glass Fiber Base Sheet Used in Roofing.

3. ASTM D4897/4897M - Asphalt-Coated Glass-Fiber Venting Base Sheet Used in Roofing.

4. FM – Factory Mutual Research Corporation, Current Edition Approval Guide, Roof Coatings.

5. UL – Underwriters Laboratories, Roofing Materials and Systems Directory, Fire Resistance Directory, Current Edition.

6. FAA-STD-019e - Lightning Protection, Grounding Bonding and Shielding Requirements for Facilities

2.12 PRODUCT DELIVERY AND STORAGE: All products delivered to the job site shall be in the original unopened containers or wrappings.

2.13 EQUIPMENT AND MATERIALS: Except where specifically identified as Government furnished in this contract, the Contractor shall provide all facilities, equipment, materials and services that are necessary to meet the requirements specified herein.

1. Contractor furnished equipment and material shall consist of two types, those items whose ownership remains with the Contractor and are removed from the site prior to acceptance, and those items which remain on-site and become Government property upon completion of the Contractor's on-site work.

2.14 CONSTRUCTION REQUIREMENTS. The following special requirements shall be taken into consideration by the contractor when submitting a quote.

1. The EPDM flat seam roof and stainless steel counterpoise materials may be installed under certain adverse weather conditions (temperature, moisture, humidity), but consultation with the manufacturer is advised since certain precautions may be recommended.

2. All work shall be scheduled and executed without exposing the interior building areas to the effects of inclement weather. The existing building and its contents shall be protected against all risks, and any damage shall be replaced or repaired. All exterior items such as the antenna shelter, ground check detectors, and exterior lighting shall be protected from damage.

3. Only as much of the new roofing as can be made weather tight each day, including all flashing work, shall be installed.

4. All surfaces to receive sheet metal or flashing shall be thoroughly dry. Should excessive surface moisture occur, the contractor shall provide the necessary equipment to dry the surface before application.

5. All new and temporary construction, including equipment and accessories, shall be secured against wind blow-off or damage.

6. Temporary water stops shall be installed at the end of each day's work, and shall be removed before proceeding with the next day's work. Water stops shall be compatible with all materials and shall not emit dangerous fumes.

7. The contractor shall provide all necessary protection and barriers to segregate the work area and to prevent damage to adjacent areas. Plywood protection shall be provided for all new and existing roof areas which receive traffic during construction.

8. Before and during application, all dirt, debris and dust shall be removed from surfaces by vacuuming, sweeping, blowing with compressed air and/or similar methods. All existing roofing material, flashing, etc. removed for construction shall be taken off the work site to a legal dumping site.

9. Liquid materials such as solvents and adhesives shall be stored and used away from open flames, sparks and excessive heat.

2.15 CLEANUP AND RESTORATION: Site cleanup and restoration shall include the following:

1. Removal of all contractor furnished material, tools and equipment which will not become Government property upon acceptance of site work.

2. Removal from the site and disposal of all trash, litter, packing and other similar material. Other material shall also be removed and disposed of when so directed by the on site representative.

3. Repairing of any damage caused to any building of equipment including interior and exterior surfaces resulting from any Contractor performed activities.

4. Restoration of roadways, parking areas, crushed rock surfaces, or other portions of the site inadvertently damaged by the Contractor so as to be returned to the same condition as existed before beginning work at the site.

5. Upon completion of the site cleanup and restoration, the Contractor shall obtain a written release from the on-site representative attesting that the site has been restored to a satisfactory condition.

2.16 COMPLETION: Before demobilization from the site, all work shall be reviewed by the FAA resident engineer and contractor. All defects noted, non-compliance's with these specifications or recommendations of the membrane and other materials manufacturers shall be itemized in a punch list. These items must be corrected immediately by the contractor before demobilization to the satisfaction of the FAA resident engineer, the membrane manufacturer, and manufacturers, as applicable. Upon completion of the roof work and final approval, the contractor shall supply the Government with a Manufacturer's fifteen (15) year labor and materials warranty.

TS-3 SPECIFICATIONS

3.1 DECKING

1. After the existing roofing has been removed, the contractor shall replace all deteriorated or damaged wood decking, wood framing, and fascia material as directed by the COR.

2. Material:

a. Lumber - Lumber shall be southern yellow pine to match existing.

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

c. Furring strips - Furring shall be 2” x 4” (nominal)

d. Screws – Screws shall be 2 ½” deck screws minimal for CDX plywood

3. Replacement of damaged decking

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

b. All joints shall fall on nailers.

c. The CDX plywood deck is to be installed after the stainless steel mesh and applied directly on ‘ top of the mesh which will ensure that the mesh stays completely flat on the roof.

3.2 UNDERLAYMENT

1. Install Grace Ultra self-adhered architectural roof underlayment or equal. Underlayment must be compatible with a metal stainless steel counterpoise. The underlayment will be installed on top of the main deck

2. Installation - Prior to installation, remove all oil, dirt, and other debris from the roof deck.

Ensure loose or protruding nails are removed or hammered down. All surfaces shall be dry and free from frost.

3. See attached manufacturer's requirements, recommendations, and instructions for installation.

3.3 STAINLESS STEEL MESH COUNTERPOISE

1. Scope: The work covered by this section is for Stainless Steel mesh counterpoise

2. Materials:

a. Fasteners:

1. Stainless steel Staples- minimum 16ga -2” leg 304 type

2. Welding material- Shall be either solid core stainless steel for use with gas for MIG/ flux core Stainless steel for MIG or stainless steel stick for stick welding capable of type 304 stainless steel. It is suggested that the contractor use Flux core MIG techniques for this job due to the environmental factors of wind and small size of .105 mesh material. However the contractor may choose whatever method works to obtain a clean consistent weld. Most VOR buildings have 208 three phase power but for this type of weld a Flux core 120v welder is recommended.

b. Stainless Steel Sheet metal-304 type 20ga for grounding corners and center antenna array

c. 2” Mesh T304 Welded .105 48” wide – (approx. 2200 sq. ft.) NOTE: this material is available in 48” x 100’ (480 sq. ft.) rolls from www.twpinc.com at a cost of approx. 700 dollars per roll. Alternative material may be used provided it is type 304SS, min of .105 in diameter, welded not woven and 2” square openings.

d. 2” mesh shall be laid on the roof in the same direction of the decking so that it will be stapled into solid wood and gaps can be avoided. The seams of runs across the roof may be parallel for ease of welding however the horizontal runs where material butts together must be staggered.

e. 2” mesh must be welded with a minimum of a ½” tack every 6 inches on parallel and butt joints. The mesh must be rolled over the edge of the roof by 1 “. The mesh must be tacked down with a sufficient amount of 2” staples to hold it completely flat on the roof surface and flat on the roof edges.

f. Proper protection must be provided under the weld being accomplished. The deck of a VOR building is usually very dry material and easily prone to a fire hazard. The Ice and water shield is easily damaged by excessive heat, therefore it is suggested that the material be welded as it is laid down in sections. It is recommended that a ¼” x 4” x 8” copper plate attached to a piece of ¼” flat steel be dragged under the mesh at each weld to dissipate the heat and sparks created by the welding process.

g. Ground plates at 4 corners of building shall be welded with at least 6 tacks of ½ inch long. The plates should be made of 304 grade stainless steel and should be mounted under mesh with 3 inches bent under the edge of the roof so that a 2 hole ground lug can be installed. The plates should be a minimum of 4” x 8” in size

h. Center attachment plates shall be mounted under the mesh and welded to it. The plates should be a minimum of 4” in depth and completely encompass the center ring. The plates will be mechanically connected to the antenna mounting base by drilling and use of self -tapping screws

3.4 EPDM ROOF

1. General:

a. After CDX plywood is installed over stainless steel mesh. The EPDM will be installed directly over the CDX plywood and be a minimum of 60 mils in accordance with manufacturer instructions for seams and application

b. The EPDM will be rolled over the roof edges and secured by manufacturer’s instruction.

c. The EPDM will be attached to plates surrounding the antenna mounting plate with the exception of 1 “ of the edge of the plate, leaving room to attach the plate to the antenna mount.

2. Weather Limitations: Roofing materials shall not be applied until the ambient temperature is above 50 degrees F with no signs or forecast for rain. Roofing materials shall not be applied when there is excessive moisture in the air causing wet or damp surfaces.

3. Quality Assurance:

a. Approved roofing system shall have a Class I-90 wind uplift rating.

b. Applicators shall be trained and qualified for installation of the approved roofing system.

c. The roofing contractor shall be a firm with a minimum of five years’ experience with the approved roofing system.

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

5. Weather Protection: When inclement weather forces a work stoppage or when the contractor leaves the work site at night, over weekends, or any other time, the roof shall be covered with the Specified tarpaulin securely tied down and weighted with sand bags or similar means to prevent the wind from blowing the tarpaulin off. It shall be the responsibility of the contractor to insure the tarpaulin is leak-free. Roofing materials damaged from wind or rain during construction shall be replaced at the contractor’s expense.

3.5 COUNTERPOISE GROUNDING

1. Materials: #2 stranded copper ground wire IAW FAA Standard 19(x) and install a double hole lug with appropriate hardware used to ground the outside roof edge perimeter detail. IAW FAA Standard 19(x). If no appropriate grounding location is available then attach a 4 “ x 8 “ inch strip welded to the existing mesh counterpoise which will hang 4 inches on the roof extending a minimum of 3 inches below the drip edge.

3.6 DOORS & HARDWARE

1. General: This section covers the furnishing of all labor, materials, tools and accessories required to complete the door installations as shown on the project drawings.

2. Applicable Documents:

a. Federal Specifications: The following specifications of the issues in effect on the date of this solicitation form a part of this specification:

b. ASTM Specifications: The following American Society for Testing and Materials (ASTM) specification, of the issue in effect on the date of this solicitation, forms a part of this specification.

E-90 Airborne - Sound transmission loss of building partitions, laboratory measurement.

A-525 Requirements for steel sheet, zinc-coated (galvanized) by the hot-dip process.

3. Materials:

1. Hollow Metal Doors: Hollow metal doors and frames shall be the standard product of a manufacturer regularly engaged in the fabrication of hollow metal doors and frames. Profiles are to be formed true and sharp. Where label fire doors are called for in the specifications, they shall meet the requirements of the Factory Mutual Research Corporation and bear their label for the class or rating specified.

a. Steel For Doors: Door steel shall be prime grade, cold rolled sheet steel, properly annealed and process leveled, having smooth, clean surfaces in accordance with ASTM A-525, Type 1, Class D. The flush hollow metal doors shall be constructed of two face sheets of not lighter than 18 gauge, stretcher leveled, cold rolled steel with channel type vertical reinforcing members located not more than 71/2" on center. The vertical channels shall extend through the full height of the door and be spot welded to both face sheets at not more than 4" on center. Vertical welded seams shall be welded approximately 2" on center and door ends shall be closed with not lighter than 16 gauge, steel channels spot welded between the face sheets.

b. Insulated Doors: Provide insulated doors at all exterior doors and at all locations indicated on the drawings. Insulation shall provide a "U" rating of not more than 0.24. All sound rated doors and frames shall have an STC rating of 47 when tested in accordance with ASTM E-90.

c. Door Construction: Steel doors shall be of the standard type, Grade 111 seamless Model 2 or 3 size and design as shown.

2. Metal Door Frames: The door frames shall be the combination type of frame and integral trim, and be fabricated from not lighter than 16 gauge cold rolled steel to the profiles indicated on the drawings. The corners shall be mitered and welded the full length of the joints, and be ground smooth. The pressed steel frames shall be mortised, reinforced, drilled, and tapped to receive mortise hardware in accordance with the approved hardware schedule and templates furnished by the finish hardware supplier. The reinforcement for hinges, lock strikes, or other mortise hardware shall be at least 3/16" steel plate; reinforcing for surface applied items shall be not lighter than 14 gauge steel. The reinforcing for the surface hardware shall be welded in place, but drilling and tapping for the surface applied hardware shall be performed in the field. Holes shall be provided for 3 rubber door silencers in each single door frame. Frames shall have standard floor clips welded to the bottom of each jamb, and have at least three anchors per jamb and two at the head. The bottom of each 3sided frame shall have a removable steel spreader secured to the bottom of the frame to assure rigidity in handling and shipping. Reinforcement of doors and frames for hardware shall be as specified in the following table:

Gage and size of reinforcement not listed above shall be as required by the templates.

a. Finish: Prior to completion, all door and frame welds shall be ground smooth, and the door edge seams shall be filled with metallic filler and be sanded smooth. The doors and frames shall be cleaned in a continuous 3stage hot spray, cleaning and rustinhibiting, phosphatizing process. Immediately after cleaning, the doors and frames shall be finished with a standard rustinhibiting primer conforming to Federal Specification TTP636, primer coating for Alkyd, wood and ferrous metals.

3. Hardware:

a. Metal Head and Jamb Units: Shall conform to ASTM E-283 Smoke and Draft control. The gasketing shall consist of an extruded anodized aluminum with neoprene and shall be provided on all exterior doors.

b. Metal Door Bottom: Shall conform to ASTM E-283 and ASTM E90-75 (Sound tested). The gasketing shall consist of an extruded anodized aluminum with neoprene to be provided on all exterior doors.

c. Threshold: Provide the extruded anodized aluminum associated with the unit in Section 8-1.3.4.1 on all exterior doors.

d. Hinges: All hinges are to be five knuckle, flush ball bearing design with wide spaced bearings. The hinges shall be full mortise type, steel, heavy weight and high frequency hinges conforming to ANSI Standards for performance and screw hole locations. Provide three, 1-1/2 pair per door. Finish to be United States Standard (US26D) satin, chrome-plated on all exterior doors. Use 4 1/2" hinges on doors up to 36" wide and 5" hinges on doors to 48" wide. All hinges shall conform to Federal Specification FF-H-116, type T2106 (with nonremovable pin).

1) Top & Bottom Hinges: Top hinges shall be installed with the center of the hinge not more than 8 inches below the top of the door. Bottom hinges shall be installed with the center of the hinge not more than 13 inches above the finish floor.

e. Door Closer: Provide a surface mounted, reversible, adjustable door closer with delayed action on all exterior doors. The casing shall be of high strength cast iron. Finish to be U.S. Standard (US26D), satin, chrome-plated.

f. Door Stop: Provide heavy duty quality door stops for both interior and exterior doors. Door stops shall conform to Federal Specification FF-H-111, type 1330 for interior doors, type 1329 for exterior doors.

g. Locksets: Shall be compatible with the Best Lock Company, Inc., of Indianapolis, Indiana construction core. Substitutes for the core will not be considered. The locksets shall be provided with a 7pin removable core (to be replaced by the Government with a special FAA cylinder at a later date). Provide three (3) master keys for construction cores and one (1) construction core control key in all locks to the Resident Engineer.

1) Exterior Door: The locksets on hollow metal or exterior type doors located in normal weather areas shall be equipped with heavy duty cylindrical type knob locks constructed of clear finished solid brass.

h. Finishes: Finishes of Hardware shall be US26D unless otherwise specified.

4. Installation:

a. Doors and frames shall be carefully handled and protected during shipment so as to arrive undamaged at the job. They shall not be temporarily stored in direct contact with the ground. Damaged door assemblies will be rejected.

b. The frames shall be erected plumb, straight, true to plane and square with the walls. The doors shall fit accurately in their respective frames, and swing and latch freely without springing or binding. Upon completion of the work, the entire installation shall be cleaned and made ready for the finish painting.

c. Hardware for the doors shall be installed at the time of hanging the doors in order to ensure an accurate fit. The hardware shall then be removed, stored until the completion of the finish painting, and be reinstated just prior to the completion of the building.

5. Quality Assurance:

a. All items of operating hardware shall be checked for perfect operation and shall be readjusted as required. Submittals will be required for all items.

b. A hardware list shall be submitted in triplicate and shall list brand of door and complete hardware for each door.

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