Tab A - Planning Charette Report.pdf

FACILITY SUSTAINMENT, RESTORATION, AND MODERNIZATION (FSRM)

PLANNING CHARRETTE REPORT (PCR)

BUILDING 1007, AIRCRAFT FUEL SYSTEMS MAINTENANCE HANGAR

AT

FAIRCHILD AFB, WA

Opportunity Number: 1054998

October 8, 2018

Point of Contact:

Erik Broderson 92 CONS 509 247 4871 erik.broderson@us.af.mil

Lt. Dana Sanelli 92 CES/CENP 509 247 3067 Dana.Sanelli.1@us.af.mil

Merle Gilliland Bernardo/Wills Architects 509 838 4511 mgilliland@bwarch.com

CAP1027134 TAB A

Table of Contents

Planning Charrette Report

1.0 Introduction 1

2.0 Project Description 1

2.1 General description

2.2 Current situation

2.3 Impact if improvements are not provided

2.5 Concept

3.0 Scope Analysis 5

3.1 Cost and Scope Thresholds

3.2 User and Facility Requirements

3.3 User Equipment

3.4 Hazardous Substances

3.5 Approvals/Exemptions/Waivers

Simplified Analysis of Alternatives (SAoA) 21

Appendices 22

Floor Plan Option 3A A

Site Plan – Option 3A B

Elevation Model C

Existing Utility Plan D

Existing Hangar Photographs E

F

As-Is Submittal G

Options Considered

Option 1 H

Option 2 I

Option 3 J

List of Participants K

CAP 1027134_B1007 FUEL CELL HANGAR

TAB A

1. Introduction

This document provides the Facility Sustainment, Restoration, and Modernization (FSRM) Planning

Charrette Report (PCR) for Building 1007, Aircraft fuel Systems Maintenance Hangar at Fairchild AFB, WA.

The primary purpose of the PCR is to validate the project scope, site, and costs and to refine the programming documentation in preparation for possible submission for project approval; DD 1391. It also provides the designer a basis for understanding the project requirements and establishes a framework for project execution.

The PCR development was accomplished by Bernardo/Wills Architects, Coffman Engineers, Inc., and

David Evans Associates. Key users included in the development of this document includes Erik

Broderson, 92 CONS/PKB, Jonathan Wald, 92 CES/CENM, Capt. Brian Hudson, 92 CES/CENP, Lt.

Dana Sanelli, 92 CES/CENP, John Dupler, 92 MX6/MXOP, Bryant Benitez, 92 CES/CEF and Ken

Walters, 92 CES/CENP.

The project scope and costs are described below and in the appendix.

The following is a summary of the basic project information:

Project Name: Planning and Programming Documents for Building 1007, Aircraft Fuel

Systems Maintenance Hangar

Project Number: Opportunity Number: 1054998

Installation: Fairchild AFB, WA

Requiring Command:

Host Command:

Fiscal Year (FY) Planned: 2020

Category Code(s):

Proposed Acquisition Method: (DB or DBB)

Status of Design: Program Level

Design Agent: Bernardo/wills Architects

Construction Agent: N/A

2.0 Project Description

2.1 General Description

U.S. Air Force plans are to locate additional KC135 Tankers at Fairchild AFB. Adding these aircraft requires adding support facilities such as this planned Fuel Cell Maintenance Hangar. B1007, one of the existing aircraft weather shelter hangars has been chosen to be converted into a fuel cell maintenance hangar.

This existing hangar is a simple structure with reinforced concrete floor designed to withstand the weight of a KC135 aircraft and the floor is sloped to drain. The exterior skin consists of a low Concrete Masonry

(CMU) wall around the perimeter of the building with metal siding walls to the eave line. Aircraft enter the hangar through ten rolling hangar doors at dimensions of 20’X20’ that are manually operated with a roll-up door for the tail clearance height of 50 feet. A tug roll-up door is located opposite the hangar doors.

There exist three common personnel entry doors plus two personnel doors within the rolling doors. The roof structure is supported by steel clear-span frames spanning 208 feet. The roofing material is metal paneling. The building has no water supply and minimal electrical power. The lighting, inside, was recently changed to LED lighting.

The project is to convert this hangar into a fuel cell maintenance hangar. This conversion requires all the elements necessary for a functioning fuel cell maintenance operation including an epoxy floor, a CMU wall separating the support space from the hangar, an automatic fire sprinkler system and a foam suppression system with an adequate water supply, a ventilation system, overhead rails for supporting a fall protection system, multiple locations for emergency eye-wash stations and emergency showers convenient to the aircraft, heating system, and a conversion of the hangar doors from a manual operating system into an electric powered operating system. Deicing of the hangar doors will be by adding suspended infrared tube heaters inside the hangar, along and parallel to the hangar doors. This method of deicing hangar rolling doors has been successful at other installations at Fairchild AFB. The supporting areas include a cell room, tool room, computer room, offices and training room, a break room and toilet rooms. The emphasis here is to provide a safe working environment while maintaining fuel cell maintenance system.

Fairchild AFB building improvements are within a Controlled Perimeter. Therefore, the analysis of antiterrorism standards to be incorporated into the renovation will be guided by UFC 4-010-1, Figure B-3

Parking and Roadway Control for Existing Buildings – Controlled Perimeter. Hangar B 1007 is within a bank of hangars on the easterly end of the flight line. The fuel cell maintenance operation, with the normal number of personnel within the building being in the 10 - 12 range, is in the category of an “Inhabited

Building” rather than a “Primary Gathering” building or “Billeting”. However, these are enclosed with reinforced CMU bearing walls, which will resist the blast forces. Using the “Metal Panels” as the Wall

Type listed in Appendix B, Figure B-1 indicates that a 39-foot unobstructed space is required. This will place parking areas and trash containers outside the 39-foot standoff line. However, to reduce blast design loads at windows and doors, the standoff distance should be extended as far from the building as is practical, and access control implemented if roads, parking, or trash is required closer to the building. Future blast analysis may help determine the most practical and economical approach to balance standoff distances and impacts to the building.

2.2 Current Situation

Fairchild AFB was selected to receive additional Air Force tankers as other bases were chosen for the KC-

46 tankers. As the KC-46 tanker is delivered to chosen bases, the KC135s must be moved out. Maintenance facilities at Fairchild AFB must be upgraded to handle the maintenance needs of the additional aircraft.

Selecting an aircraft weather shelter hangar for conversion to a fuel cell maintenance hangar will provide the needed maintenance facility at a lower cost than construction of a new building and the timing of delivery will be greatly improved.

2.3 Impact if Improvements are Not Provided

Fairchild AFB has recently received several KC-135 aircraft and is expected to receive additional aircraft as other refueling operations receive the KC46 aircraft. The added aircraft places a greater demand on the fuel cell maintenance facilities. If this project does not proceed, there will be a major back-up in repairing fuel cells resulting in major delays.

2.4 Cost Estimate

2.5 Concept

Three options, for converting Hangar B1007 into a fuel cell maintenance hangar, were developed into sketch form through the planning effort and . Hangar B1007 is rectangular and measures 208’-7” x 135’-0” with a pop-out at the nose of the aircraft of 75’-0” x 41’-5”.

The KC135 has a wing span of 130’-10’ and the minimum horizontal clearance around the aircraft is 15’-

0”. The existing door height for the tail clearance is 52’-2” and exceeds the minimum clearance required of

7’-0”. The aircraft parks in the center of the hangar. This leaves support space on either side of the aircraft of 23’-4” beyond the 15’ clearance zone for support space and facilities. At the corners of the building, forward of the wings, additional space is created by the rectangular shape of the hangar. The aircraft, including the clearance space, requires approximately 19,500 square feet; that leaves approximately 11, 484 square feet for support space. With the space symmetrical in nature and 250 square feet dedicated to the tug access path, there is approximately 5,600 square feet on each side of the aircraft for support.

The Statement of Work defines 3,383 square feet of specific support space needs. The work space is to be separated from the hangar with a CMU wall a minimum of 10 feet high. For simplicity of construction, placing all the support space on one side of the aircraft is a practical layout. One option was developed that placed all the support space on one side, with the concrete masonry wall separating the support space from the hangar. A second option was developed incorporating an interior corridor for circulation between the support spaces without having to enter the hangar area. A third option was developed that took advantage of the expanded areas in the corners forward of the wings on each side of the aircraft. Although this concept separated the support space into two somewhat equally sized spaces, the arrangement places all the support space more central to the work activity on the aircraft. The user selected this concept as the most efficient layout in meeting the needs of the maintenance personnel.

The improvements necessary for this conversion include adding thermal insulation to the roof and exterior walls (including the hangar doors), motorizing the hangar doors, adding an automatic fire sprinkler system, adding a foam suppression system, adding a ventilation system, adding cell purging systems, adding heating and air-conditioning, adding supporting rails for the fall protection system personnel use when on top of the wings and fuselage, adding an epoxy finish to the concrete floor and adding emergency eye wash/shower stations. Support spaces incorporated into the design includes a cell room, CTK room, training room, offices, computer room, restrooms, and break room plus the electric room, communications room, fire pump and equipment room and plumbing room.

FIGURE 1: VICINITY MAP – FAIRCHILD AFB, WA

FIGURE 2: PROJECT SITE MAP - FAIRCHILD AFB, WA

HWY 2

FAIRCHILD AFB

SPOKANE AIRPORT

SPOKANE

INTERSTATE 90

ENTRY GATE

B1007

HWY 2

3.0 Scope Analysis

3.1 Cost and Scope Thresholds

Item Value Remarks

Project Program Amount

(PA)

Report PA per AFI 32-1032

Maintenance

EEIC 521xx

Repair (Sustainment)

EEIC 524xx

N/A

Repair (Restoration &

Modernization)

EEIC 522xx

N/A

Minor Construction

EEIC 529xx

N/A

Plant Replacement Value

(PRV)

Per UFC 3-701-01, paragraph 3-2.2; refer to details in AFI

32-1032 paragraph 3.5.1

PA / PRV ratio Coordinate with AT/FP requirements below in Section 2.5.

Estimated Replacement

Cost (ERC)

Report ERC as stipulated by AFI 32-1032 paragraph 3.5.1;

applies a factor to PRV to account for additional costs of a construction project such as supporting structures and demolition.

PA / ERC ratio

Existing Building Area, Gross

31,884 SF

Size of Addition, Gross --------- N/A

Addition/Existing Ratio N/A

3.2 User and Facility Requirements

With Fairchild AFB receiving additional tankers, additional facilities are needed for maintaining fuel cells.

Hangar 1007, a weather shelter hangar, was selected for conversion into a fuel cell maintenance hangar.

The existing building is composed of simply a concrete floor, designed for the heavy aircraft, that is sloped to the exterior, a low CMU wall around the perimeter with metal paneling above the CMU extending up to the eave line. The roof is metal decking. Other than the building having been converted to LED lighting, the building remains a shell without improvements.

The fuel cell maintenance operation requires all the normal utilities of an occupied building as well as specialized utility to provide the safeguards important in a fuel cell maintenance operation.

The support space includes a CTK (tool room), Cell Room, Computer Room, Offices, Training Room, Restrooms, and Break Room. These spaces are separated from the hangar by a CMU wall. Safety features includes emergency eye wash and shower areas, automatic fire sprinkler system, foam suppression system, rails for providing fall protection as personnel work on top of the aircraft wings and fuselage, major ventilation systems. The existing sloping concrete floor will have an epoxy coating applied for improved fuel spill clean-up. The installation of required electrical power will be placed at such heights to reduce the risk of a spark igniting gas vapors and as required by code.

Requirements Remarks

GENERAL

As-Built Drawings

The existing building, selected for the fuel cell conversion, was designed and constructed in the 1956 period. Minimal

As-Built information was found on this building.

Bernardo/Wills Architects retained 2D As-Built to measure the interior of the hangar including providing interior elevations.

Site Accessibility Concerns The building is located along the flight line and does have convenient access from both sides of the security fence.

Construction Security The building, being on the flight line, will have security measures in place to prevent the contractors from accessing the flight line.

Temporary user space The building is unoccupied. Once construction begins, the base will not have the hangar available to park aircraft.

Facility Addition The project does not include adding any additional space to the footprint.

Allied Support

Requirements N/A

SITE, CIVIL, AND

GEOTECHNICAL

Civil scope of work consists of providing utilities to the building as well as minimal site work around the building to meet standoff distances requirements. Utilities are within proximity of the building.

Existing Site Conditions The site is an existing hangar. Project improvements are primarily within the existing hangar building. The south side of the hangar is the aircraft apron. The two sides of the building are service areas and are paved with asphaltic concrete paving and the north side has minimal landscaping, sidewalks and asphalt paving in vehicle parking areas.

Facility Siting The fuel cell maintenance facility will be located within an existing building. The existing building is of adequate size to accommodate the user needs without adding to the building footprint.

Removals/Demolition A minor amount of demolition will occur. A recently completed environmental analysis indicated the presence of

LBP.

Geotechnical Report Required NA

Special soil conditions NA

Roads and Drives This project has minimal effect on the adjacent roadways and parking. No changes in the roadways are proposed. Minor changes are proposed in the service area between buildings to comply with standoff distances.

Vehicle Parking The personnel assigned to this operation will be in the range of

10-12 persons. Adequate parking is within the vicinity of the hangar. Some revisions may be recommended per specific blast analysis

Site Work Site work includes flat work in conjunction with adding exterior doors to the hangar, moving parking spaces outside the standoff distances, and paving for the tug to have improved access the flight line.

Grading & Storm Water Minimal grading may be necessary to maintain the existing surface flow in conjunction with the modifications to the site.

UTILITIES Required utilities are near the hangar. A preliminary hydraulics analysis determined that adequate water is available for the automatic fire sprinkler system and foam suppression system.

Water Distribution The availability of an adequate water supply for the automatic fire protection system and the foam suppression system was investigated.

The conclusion of a Preliminary Hydraulic Analysis prepared by Mr. David G. Luders, P.E., WA 29878, Civil Engineer, 92

CES/CEOER, Fairchild AFB states that the required Fire Flow

Demand (3,000 gpm) for Building B1007 is less than the available fire flows (typically ~3,300 gpm).

Water Distribution - Continued The A/E FPE has estimated the maximum required fire flow for the building is 2,743 gpm which is less than the available flow of ~3,300 gpm.

Sanitary Sewer A new 6- inch sanitary service will be required to serve the new restrooms within the hanger. Sewer service is available along the south and east sides of B1007.

Natural Gas The existing natural gas main is expected to be sufficient for the scope of the project.

Exterior Electrical The existing electrical distribution transformers are expected to be sufficient for the scope of this project.

Exterior Communications A communications room is provided.

Cathodic Protection N/A

ARCHITECTURAL

REQUIREMENTS

This project is a conversion of an aircraft weather shelter to a fuel cell maintenance hangar. The building shell is to be converted from a shelter to an inhabited building. This requires the shell to meet the requirements of an inhabited building. The shell is to be made weather tight with thermal insulation added to the exterior walls, hangar doors and to the roof. The hangar doors are to be weather-striped. All the safety features of a fuel cell maintenance hangar are to be incorporated into the design. Aircraft clearances are to be maintained.

Air Force Corporate Facility

Standards (AFCFS)

Air Force requirements in the design and construction includes: UFC 4-211-01, Aircraft Maintenance Hangars, UFC 1-

200-01, UFC 4-010-01 DoD Minimum

Antiterrorism Standards for Buildings, UFC 3-600-01, NFPA 101, NFPA 409, IBC, and Base Design Standards

Air Force Standard Designs New facility to meet Fairchild AFB Base Design Standards

Installation Facilities Standards

(IFS)

Standard designs for fuel cell maintenance hangars include stringent safety features. The support space must be separated from the hangar by a CMU wall a minimum of ten feet high.

Epoxy covering to be applied to the hangar floor. Ventilation systems designed to bring in outside air and exhaust contaminated air. Electrical systems protected against explosions caused by fumes. Emergency eye wash/showers

Installation Facilities Standards

(IFS) - Continued installed. Fall protection rails are included for workers positioned on the wings and on the fuselage. Cell purge systems are located at three convenient positions.

Space Requirement Analysis The space requirements are included in a table on the sketch drawing of the fuel cell maintenance hangar. The spaces are consistent with AFMAN 32-1084.

Finishes (exterior walls, interior walls, ceilings)

Existing exterior walls are CMU low walls with metal panels above the CMU extending up to the eave line. The mission of the program is to convert this hangar into habitable space.

The many holes in the metal panels as well as open joints between panels are to be repaired. Damaged panels are to be replaced and painted. In the interior, where improvements are not covering-up the inside face of the wall, the walls will receive thermal insulation with a serviceable finished surface. The wall separating the hangar from the support spaces shall be a painted CMU wall. The hangar is to receive an epoxy coating over the floor. Support spaces shall be finished in accordance with the Base Design Standards.

Interior partitions, where the CMU walls are not required, will be metal studs with gypsum wall board painted. In wet areas, ceramic tile floors and walls are proposed. Acoustic tile ceilings in offices, training room, computer room and break room.

SCIF/VAULT N/A

Sound Attenuation N/A

Elevators N/A

Correction of Architectural Barriers

Act (ABA) Deficiencies Improvements to the hangar shall be designed to be

ADA compliant.

State Historical Preservation Office

Review N/A

STRUCTURAL REQUIREMENTS

Foundation Hanger structure foundations are assumed to be adequate for the minor overall load increase. Existing hanger slab is adequate to support CMU wall loads as it is designed for aircraft wheel loads.

Roof The existing roofing material (metal roofing panels) is to remain in place. Numerous holes occur in the metal panels and these are to be patched. A few joints, between panels, have opened-up and these are to be repaired. Panels damaged beyond repair shall be replaced and painted.

Structure See below

Modification/increase in loads Loads added to the structure because of adding roof thermal insulation, automatic fire sprinkler system, foam suppression system, fall protection rails and heaters exceeds the original structural design loads. Therefore, the steel frames are to be reinforced and new steel purlins will be added to transfer the loads to the steel frames

Structural Repairs Although site visits revealed numerous holes and gaps in the metal skin requiring repair, no structural damage was observed.

Seismic Evaluation Required Per UFC 3-310-04 and RP 8, because the project exceeds

50% of the replacement value of the building, a Tier 3 seismic evaluation is triggered per ASCE/SEI 41-13. The evaluation and retrofit performance objects are Life Safety in

BSE-1E. A Tier 1 Analysis was performed as part of this programming phase, and no deficiencies were found. The more rigorous Tier 3 Analysis may find areas requiring improvement, however, they are likely to be minor structural upgrades.

State Historical Preservation Office

Review

N/A

MECHANICAL & PLUMBING

SYSTEMS

Mechanical work is the addition of heating, ventilation and cooling to all spaces within the building. There are currently no existing mechanical or plumbing systems in the building.

HVAC system or component modifications Complete HVAC system to include ventilation and radiant heating for the maintenance bay area and conditioned air for the support spaces.

- Unusual ventilation The maintenance bay requires emergency exhaust in addition to the required minimum ventilation supply and exhaust, as well as 3 purge ventilation systems for the aircraft’s fuel tanks. The fuel cell repair room requires its own dedicated purge ventilation system

Special heating/cooling loads Heat provided by radiant heat must be low-intensity enclosed radiant tubes with ducted outside air and exhaust to outside the hangar.

Temp/humidity control Support spaces require standard temperature control. No cooling required for the maintenance bay area, but the purge ventilation systems must supply conditioned air. The maintenance bay area must be maintained above 40 degrees while occupied.

Plumbing system or component modifications

No existing system is in place. Complete plumbing system is required for maintenance operations, emergency showers, bathrooms, and break area to include sewage, domestic water, and domestic hot water.

FIRE PROTECTION

REQUIREMENTS

The hangar building will require a new fire suppression and alarm system throughout in accordance with the UFC 4-211-

01 criteria. These system requirements would include a fire pump, automatic fire sprinkler system, high expansion foam system, fire alarm and mass notification system and detection/releasing system. The building will also need to meet the specific fire separation and egress requirements of

UFC 4-211-01.

Two new fire hydrants are required with one at the southeast corner and one at the southwest corner of the hangar to meet the coverage requirement.

Category of Work The category of work for this existing building is Vacant

Buildings as indicated in UFC 3-600-01 section 34-1.9. The project must comply with the requirements for new construction in accordance with the UFC 3-600-01 and

NFPA 101. This would then require the compliance with

UFC 4-211-01 for Aircraft Hangars by reference.

Fire Safety Deficiencies (FSDs)

And Corrective Action Plans (CAPs)

N/A

Changes to facility egress Exit requirements of a fuel cell maintenance hangar exceeds the current number of exits; therefore, the scope of work includes adding exits. Exiting the support spaces must occur without passing through the hangar and the maximum distance one must travel while exiting the hangar sets the minimum number of exits.

Changes to occupant density The existing hangar has no occupants other than when bringing an aircraft into or taking an aircraft out of the hangar. The fuel cell maintenance program will have 10 –

12 personnel in the hangar on a 24/7 shift basis. Therefore, there is a major change in use of the building. Support space for the personnel incudes: offices, training room, computer room, restrooms and a break room, large tool room and cell room where fuel cells are repaired. None of these spaces currently exists in the hangar.

Facility houses Mission- Support or

Mission- Essential Equipment

The nature of the fuel cell maintenance work requires an automatic fire sprinkler system, a foam suppression system, emergency eye wash and shower stations and alarm systems. Installation of electrical equipment must be done in a manner to reduce the risk of sparking and prevent an explosion from the ignition of gas fumes.

Hangar The building currently does not have a fire suppression system. The fuel cell building requires an automatic fire sprinkler system and a foam suppression system with all the necessary alarms as well as an elaborate exhaust system.

ELECTRICAL SYSTEMS

Primary Power Services Primary power service will include both 480V and 208V 3-phase power.

Interior Electrical Existing panelboards will be removed. The distribution will be designed to fit the use of the spaces. New receptacles will be placed in rooms and corridors. Power will be provided to mechanical equipment.

Lighting Existing lighting is expected to be sufficient in the hangar bay.

New lighting will be provided in new rooms.

Lightning Protection Lightning protection does not exist in the current hangar.

A lightning system protection should be installed according to UFC 4-211-01. System include roof air terminals and down conductors to ground grid.

RPIE Generators Generators are not included in this project’s scope.

Special user requirements To provide protection for the working personnel, within the building and the government’s assets, safety features are included in the building’s design and construction. The user must provide the necessary tools used in the fuel cell maintenance. The building’s Plumbing, HVAC and Electrical systems are to be designed to accommodate any user hook-ups.

ANTITERRORISM / FORCE

PROTECTION

Current number of occupants: 0

Current occupancy level: Very low Planned number of occupants: 10 – 12 w/each of 3 shifts

Planned occupancy level: Low

UFC 4-010-01

Antiterrorism Minimum Standards;

project scope requires full mandatory compliance

Project scope does trigger compliance requirement (PA > 50%

PRV). Creating required standoff distances around building.

Building is within a Controlled Perimeter. The Building

Category is Inhabited Building.

- Unique Occupancy Factors Occupancy is a very low occupancy and is to be considered an

Existing Inhabited Building.

- Standoff Distances Building is within Controlled Perimeter. UFC 4-010-01, Table

B-1 places the Standoff Distance as 13 ft. Building exterior skin is primarily non-load bearing metal panels. Table B-2 places the minimum standoff distance as 39 ft. for a Metal

Panel Wall Type in an applicable Explosive Weight II

Category. Plans are to comply with the 39-foot standoff distance requirements. This includes adding concrete curbs as barriers to prevent vehicles from entering the 39-foot clear zone. A blast consultant should be hired to verify the existing hanger structure is acceptable at this standoff distance and will not collapse. If larger standoff distances are practical, they should be incorporated to reduce blast forces at new doors and windows.

- Window or Glazed Door Replacement The existing building has no windows. Three personnel doors are metal clad. The roll-up tug door is to be replaced with a new roll-up door. The tail clearance door will be replaced with a new roll-up door. New doors and added windows will meet

AT/FP regulations.

- HVAC replacement or upgrade The building’s HVAC system will be new and meet minimum

AT Standards.

- Mass Notification System (MNS) Does require the mass notification system for an inhabited building.

Antiterrorism or Force Protection

Requirements beyond Minimum AT

Standards

The scope of work for this project does not include going beyond the AT Minimum Standard.

SUSTAINABILTY REQUIREMENTS

UFC 1-200-02, HPSB

Requirements

This document provides the minimum unified requirement, and guidance for planning, designing, renovating and maintaining, high performance and sustainable buildings enhancing DOD mission capability. The nature of the tasks performed within the fuel cell maintenance hangar requires specialized building improvements and equipment.

Personnel safety and protection of the Air Force’s assets is top priority in the design of an efficiently operating fuel cell maintenance hangar. These requirements must be met while incorporating High Performance Sustainable Building

Requirements - Continued

Requirements into the design of the conversion of a weather shelter hangar into a fuel cell maintenance hangar

UFC 1-200-02, HPSB

Requirements

The weather shelter hangar was designed and built in the mid

1950’s and has remained substantially as originally constructed.

Recently, the general lighting, within the hangar, was converted to low energy LED fixtures. Certain structural elements, supporting the added weight of the automatic fire sprinkler system, foam suppression system, ventilation system, heaters, and fall protection rails and thermal insulation, require upgrading. Efforts will be made to preserve as much of the existing building’s structural system and skin as possible while incorporating modifications necessary for a safe, efficient working environment in accomplishing the Air Force’s mission.

Requirements

The planned automatic fire sprinkler system, foam suppression system and ventilation systems as well as other building systems must meet the requirements of UFC 4-211-01, Aircraft

Maintenance Hangars, while incorporating HPSB criteria. The building systems incorporated into the design for the fuel cell maintenance operations are to include commercially available highly efficient units.

Tracking / Reporting/ Third Party Certification Required

Compliance with AF SDD Implementing

Guidance Memorandum

The goal of the Sustainable Design and Development (SDD) program is to reduce the resources our buildings consume, reduce the waste our buildings generate, and maximize the benefits our buildings provide by siting, designing, constructing, maintaining, operating, re-using, and demolishing Air Force facilities in a sustainable manner. For new construction and renovation activities this requires an integrated approach through all phases of the project delivery process. The Federal sustainability mandates which are commonly referred to as High

Performance and Sustainable Buildings Guiding Principles

(HPSB GP) or Guiding Principles for Sustainable Federal

Buildings are detailed in UFC 1-200-02, High Performance and

Sustainable Building Requirements.

Third-Party Certification To determine whether third-party certification is required, review the thresholds in Table 1-1 of UFC 1-200-02. Projects requiring third-party certification will use the DoD version of either the USGBC/GBCI Guiding Principles Assessment or the GBI Guiding Principles Compliance system. These documents provide general guidance and information on beginning the certification process

ENVIRONMENTAL

REQUIREMENTS AND

HAZARDOUS SUBSTANCES

Environmental Permitting Required N/A

TAB A

http://wbdg.org/ffc/dod/unified-facilities-criteria-ufc/ufc-1-200-02 http://wbdg.org/ffc/dod/unified-facilities-criteria-ufc/ufc-1-200-02 http://wbdg.org/ffc/dod/unified-facilities-criteria-ufc/ufc-1-200-02

Hazardous Materials Remediation A Hazardous Materials Inspection report was conducted by

Fulcrum Environmental Consulting, Spokane, WA dated

April 26, 2018. The Scope of work was limited to Asbestos

Containing Materials and Lead Containing Materials.

Asbestos was not found on the site, but LBP was found.

Remediation will follow adopted procedures.

Environmental Impact Analysis

Process (EIAP)

N/A

DESIGN AND ACQUISITION OF

UNFUNDED REQUIREMENTS

This PCR includes all building improvements necessary for a functioning fuel cell maintenance hangar. The PCR does not include user provided equipment and tools.

Furniture Fixtures and Equipment

(FF&E) Acquisition

This PCR does not include any scope or budget for FF&E.

Existing FF&E Reuse N/A

Non-RPIE

Communications Acquisition

N/A

Non-RPIE

Generators/UPS/other backup power storage or capability

N/A

TEMPEST / HEMP / RF

Shielding

N/A

Intrusion Detection Systems

(IDS)

N/A

Closed Circuit TV N/A

Other User Equipment, Including

Special Computer Systems or

Support

N/A

AIRFIELDS

Existing Structure Project does not include any airfield pavement repair beyond work necessary for adding fire hydrants at

Hangar 1007 per UFC 4-211-01.

Repair Alternatives Fire hydrants are required on the hangar-door side of the hangar and placement will minimally encroach into the apron area. Replacement of apron materials disturbed will match existing.

Evaluation of Excess Pavement

Facilities

Project scope does not include airfield pavement work.

Course of Action Analysis N/A

Lighting and NAVAIDS N/A

Airfield Waivers N/A

Phasing and Mission Work- Arounds N/A

Staging/Laydown N/A

Base Access N/A

Design Traffic; Structural and

Geometric

N/A

Tiedowns and Grounding N/A

Problem Soils N/A

Frost N/A

Inlets, Manholes, and Other Utility

Structures

N/A

Storm Water N/A

3.3 User Equipment – This project does not include any user equipment

3.4 Hazardous Substances

Hazardous Substances Y / N /

Unknown

Remarks (date of last survey)

Asbestos N Fulcrum Environmental Consulting Report dated

April 26, 2018

Lead Based Paint Y

PCB Unknown

Radon Unknown

IRP Sites Unknown

Known Abatement Considerations Y / N /

Remarks

Asbestos N Fulcrum Environmental Consulting Report dated

April 26, 2018

Lead Based Paint Y Fulcrum Environmental Consulting Report dated

April 26, 2018

PCB Unknown

Radon Unknown

Hazardous Waste (RCRA) Unknown

Heavy Metals Unknown

Aqueous Film-Forming Foam (AFFF) Unknown

Hazardous Substances - continued Y / N /

Remarks (date of last survey)

Toxic industrial waste Unknown

Radiological Unknown

Heavy Metals Unknown

Ozone Depleting

Substances

(refrigerants)

Unknown

Medical gases Unknown

3.5 Approvals/Exemptions/Waivers

The improvements proposed for this fuel cell maintenance facility are to be designed and constructed within an existing hangar that is void of any improvements. Therefore, the new design is expected to comply with current policies and regulations.

Simplified Analysis of Alternatives (SAoA)

FY 2020 Installation: Tririga ID:

Project Description: Converting a weather shelter hangar into a fuel cell maintenance hangar.

Impact if not funded: Fairchild AFB is receiving additional KC135 tankers. The influx of additional tankers requires additional fuel cell maintenance capability. If not funded, delays in maintenance jeopardizes the squadron’s mission.

of weather shelter hangar into a fuel cell maintenance hangar.

st n shall comply with UFC-211-01 and d regulations.

Impact if Fairchild AFB is to receive additional KC135S; not funding will limit mission’s ability to provide support.

COA 1 - Option 1

COA 2 - Option 2 r.

COA 3 - Option 3

Description: Support space located on each side of the aircraft forward of the wings.

PRO: Support space layout creates most efficient arrangement for personnel performing tasks. User favors this layout because of the efficiencies it affords.

SELECTED COA - COA 3 – Option 3 with modifications - Option 3A

Justification: COA 3, - Option 3A - with modifications: Is the most efficient layout in meeting the squadron’s mission. User’s schedule of operation is 24/7 and efficiency in very important.

Sub-AMP Manager Review and Approval

Review Date: ________________________

Approval Date: _______________________

Signature: ___________________________

AMP Manager Review and Approval

Review Date: ____________________

Approval Date: ___________________

Signature: _______________________

EXISTING HANGAR PHOTOGRAPHS

APPENDIX—E

SOUTH ELEVATION OF HANGAR B1007 SHOWING THE

HANGAR DOORS

WEST ELEVTION OF HANGAR B1007 SHOWING THE

BLANK EXTERIOR WALLS

INTERIOR OF HANGAR B1007 SHOWING STEEL FRAMES,

ROOF PURLINS AND METAL WALLS—PHOTOGRAPH PRE-

DATES THE CHANGING OF THE GENERAL LIGHTING TO LED

FIXTURES

CLOSE-UP OF STEEL FRME AT WALL LINE

CLOSE-UP OF STEEL FRAMES AT ROOF LINE HIGH WALL—AIRCRAFT NOSE END OF HANGAR

APPENDIX—E

ROLL-UP DOOR AT AIRCRAFT TAIL CLEARANCE OPENING

ROLL-UP DOOR FOR TUG

ROLLING HANGAR DOOR—ROLLERS TO BE REFURBRISHED ROOF FRAMING ALONG RIDGE LINE

APPENDIX—E

NORTHWEST WALL BASE OF STEEL FRAME, LOW CMU WALL AND “X” BRACING

OF STEEL FAMING

CLOSE-UP OF STEEL FRAME , WALL FRAMING

AND BRACING

INTERIOR OF A RECENTLY COMLETED FUEL CELL MAINTENANCE HANGAR. PHO-

TOGRAPH SHOWS THE EPOXY FLOOR, PAINTED STEEL FRAMING, VENTILATION

SYSTEM DUCTWORK, FALL PROTECTION RAILS, FIRE SPRINKLER SYSTEM AND

OTHER IMROVEMENTS

“AS-IS” Assessment B1007 Submittal

Requirements Document for

PLANNING/SCOPING OF

BUILDING B1007, AIRCRAFT FUEL

SYSTEMS MAINTENANCE HANGAR

Fairchild Air Force Base, Washington

Opportunity Number: 1054998 22 May 2018 www.bernardowills.com

Table of Contents

Executive Summary

Introduction

Purpose

Goals and Objectives

Project Description

Project Statistics

Project Narrative

Process Narrative

Area Development Plan

Aerial Views of Base

Environmental

Structural

Agreement

Attachments

1. As-Built Drawing Hangar 1007

2. Programmatic Adjacency Diagrams

3. Comparative analysis of the current conditions and Fuel Cell requirements

4. Photographs

5. Hazardous Building Materials Inspection Report

Executive Summary

The purpose of this “As-Is State of Building Report” is to explain and clarify, for the Air Force, the current conditions of the existing aircraft weather shelter hangar, B1007, and provide information necessary for further studies and options regarding the conversion of B1007 into a Fuel Cell Maintenance Hangar. The

Government provided space requirements, necessary for the various functions of the fuel cell, will be checked against the space standard guidelines per AFMAN 32-1084 and any relevant AF Design

Guidelines. The fuel cell programming, pre-design, planning, design and construction is to follow the

Government regulations, Unified Facilities Criteria (UFC), Aircraft Maintenance Hangars UFC 4-211-01

Chapters 1, 2, 3 and 5, Appendices and specifically Section 5-12. Compliance with other regulations includes the UFC 1-200-01, UFC 3-600-01, NFPA 409 and the IBC. If a conflict exists, UFC 4-211-01 supersedes UFC 3-600-01 and NFPA standards.

A. Introduction

Purpose

The purpose of the” As-Is, State of Building Report” is to provide the Air Force with the state of the existing Hangar B1007 as the first step in obtaining and analyzing the necessary information for the complete Planning and Programming Documentation for converting B1007 into a fully functioning Aircraft

Fuel Systems Maintenance Hangar. B1007 was constructed in 1958 as an aircraft weather shelter hangar and remains as a shelter with minimal improvements inside. The building size and clearances adequately supports the KC135 within. The structural framing is totally exposed inside and there are no support improvements within the building. The building has structural frames creating a clear span interior space adequately accommodating the KC135 aircraft. The bi-folding hangar doors are hand operated. As there are minimal improvements in the building the conversion will require support space such as a Cell

Room, CTK Room, Computer Room, Offices, Training Room, Restrooms, Break Room, HVAC, Plumbing, Fire Alarm and Fire Suppression Equipment Rooms, protective walls between the hangar and the support space, a fire pump system, an automatic fire sprinkler system, a foam suppression system, a fire alarm detection and releasing system, heating and an upgrade of lighting and power. A fall protection system above the wings and fuselage is to be incorporated into the building conversion. The existing concrete slab requires an epoxy coating capable of supporting the heavy aircraft and equipment loads as well as draining any fuel spills away from the aircraft. The building skin will require the addition of thermal insulation. With the potential of a fuel spill as well as fuel fumes escaping into the air, safety measures must be incorporated into the design.

Goals and Objectives

The Air Force’s goal is to convert a weather shelter hangar into a fully functional and efficiently operational fuel cell maintenance hangar with all the improvements necessary to provide a safe working and environmentally friendly environment. Achieving this goal will require the addition of a thermal enclosure to the raw corrugated metal shell. Included in this will be adding thermal insulation to the horizontal rolling hangar doors and replacing the steel rollup doors with insulated rollup doors. To cleanup any fuel spills, the concrete floor will require an epoxy coating that will withstand the heavy loading of the aircraft wheel loads and resist the effects of the aircraft fuel spills. Safety features includes the separation of the aircraft parking area from the support facilities with a CMU (concrete masonry unit) wall a minimum of ten feet high, raising the floor of the support facilities eighteen inches above the hangar floor, adding an automatic fire sprinkler system, adding a foam suppression system, adding a major ventilation system and adding a fall protection system as needed for working on wing tops and on the top of the fuselage.

Support facilities will be added, within the existing hangar space. Space requirements for this support space is provided by the Government in a document titled “Fuels 1007 requirements”. This support space is to be separated from the hangar with a CMU (cement masonry unit) wall at a minimum of ten feet high.

The floors of the support facilities spaces are to be eighteen inches above the hangar floor. The second phase of this Planning and Programming process will be to develop three options in satisfying the objectives of the project along with costs. This investigation is to include the pros and cons of each option for Government consideration. Upon the Government’s selection, BWA is to prepare the Simplified

Analysis of Alternatives (SAoA) and the Planning Charrette Report (PCR) Facility for submission.

B. Project Description

Project Statistics

Installation: Fairchild AFB, Airway Heights, WA

Fiscal Year: 2020

Project Name: Building 1007, Aircraft Fuel Systems Maintenance Hangar

PDC Number: GJKZ

Host Command:

Requiring Command:

Category Code:

Scope: Assessment of the existing building and needed improvements to convert the building into a fuel cell facility.

Programmed Amount:

Construction Cost Limitation:

Operational Need Date: 2020

Facility Need Date: 2020

Project Narrative

This building was constructed in 1958 as an aircraft weather shelter hangar and has received a

“patchwork” of repairs over the years. The hangar is sized to accommodate the KC135 with the bulk of the building having a width of 210 feet by 131 feet deep plus an extension, in the center of the building, of

42 feet deep and 75 feet wide. The ten-horizontal rolling, bi-parting hangar doors provide an opening width of more than two-hundred feet and a door height of twenty feet. To accommodate total enclosure of the aircraft a steel roll-up door, at the centerline of the hangar, provides an opening to a height of fifty feet. The center twenty-five feet of the concrete floor slab is thickened to sixteen inches to accommodate the weight of the aircraft. The balance of the concrete floor slab is eleven inches thick. The floor slab slopes to the hangar doors and to the tug door. This slope, at approximately 0.36%, allows for any fuel spills to drain away from the aircraft. The hangar is clear-spanned by steel frames spaced at approximately twenty-one feet eight inches on center. The exterior walls are concrete masonry units to approximately four feet six inches high with corrugated metal siding above to a total height of approximately twenty-eight feet at the eave line. The sloped roof reaches a height of approximately sixty feet at the ridge and is sheathed with corrugated metal panels. The exterior of the building has recently been painted.

The interior of the building is the exposed structural system and the interior of the metal siding and roofing. There are no support facilities inside the building. From inside the building one can see numerous holes in the metal panels, both wall panels and roofing panels. These holes will require patching as with the conversion the building will require thermal insulation. The lighting system is a nominal number of hanging LED fixtures. These fixtures and their corresponding controls appear to be have been installed in 2016. There are two transformers existing outside of the building providing both

208V and 480V power. It appears the 480V power is no longer fed into the hangar. The fire alarm control panel appears to be in good condition and may be able to be re-used. The electrical panelboards appear to be original to the hangar. The building is unheated and does not have an automatic fire sprinkler system.

Conversion of the aircraft weather shelter hangar to a fuel cell maintenance hangar requires the improvements necessary to create a working environment. This requires the adding of thermal insulation to the exterior walls and roof, adding thermal insulation to the bi-parting hangar doors, replacing the roll-up hangar doors with insulated roll-up doors, adding a fire pump system, an automatic fire sprinkler system, a foam suppression system, a fire alarm detection and releasing system, heating and lighting as well as support spaces. The support spaces require a 1-hour rated separation from the hangar area by a concrete masonry (CMU) wall a minimum of ten feet high as well as being raised above the floor of the hangar a minimum of eighteen inches. The floor of the hangar to receive an epoxy finish that will withstand the aircraft and equipment movements. Safety features includes an eye wash station and an emergency shower facility. The support spaces to be added include two offices, a training room, Computer/IMDS Room, CTK Room, Cell Room, restrooms, and break room.

Process Narrative

The objective of this process is to arrive at a program for the conversion of B1007 into an aircraft fuel systems maintenance hangar that will meet the needs of Fairchild AFB in maintaining the fleet of KC135 tankers consistent with the AF’s space and design standards.

Building B1007, sized to accommodate the KC135, was designed as an aircraft weather shelter in 1956.

The building has remained as a shelter during these sixty plus years. This shelter remains simply a shelter with minimal amenities and limited electrical power and lighting. There is no heat. Data will be gathered as to the “As-Built” condition of the building including the measurements of the building. This will be used to analyze the suitability of the building in supporting the functions of a fuel cell maintenance hangar.

The fuel cell maintenance operations generate a potential for a fuel spill and the resulting fire hazard.

Safety requirements includes having adequate water supply and water pressure readily available to extinguish any fires. Data provided on the available water supply indicates that adequate water flow is available but a fire pump will be necessary to meet the pressure requirement. Data will be gathered on the existing fire hydrants around B1007 and if found not meeting the standards for a fuel cell facility, additional fire hydrants will be proposed.

Following the requirements document (RD) for the fuel cell, the existing building will be analyzed for the suitability of meeting the fuel cell needs while meeting the requirements of all applicable UFC and TO requirements.

Based upon the Government’s selection, the final planning and programming documents will be developed including the Simplified Analysis of Alternatives (SAoA) and the Planning Charrette Report

(PCR).

Area Development Plan

AERIAL VICINITY MAP OF FAIRCHILD AFB, WA

AERIAL BASE MAP OF FAIRCHILD AFB, W

HANGAR B2050 W Arnold Street

US ROUTE 2

FAIRCHILD AFB, AIRWAY

HEIGHTS, WA

US INTERSTATE 90

SPOKANE INTERNATIONAL

AIRPORT

ENTRY TO

BASE

HANGAR B1007

AERIAL VIEW OF HANGAR B1007 WITH SETBACKS FROM ADJACENT BUILDINGS

B1007 B1005 B1009

B2036

37.6’ AT CLOSEST PT.

43.8’

67.3’

71.5’

Environmental

The construction elements of this building, B1007 constructed in 1958, were not under the same environmental regulations that are in place today. Fulcrum Environmental Consulting, Spokane and Yakima, Washington, was retained to provide a Hazardous Building Materials Inspection Report. Their report is dated April 26, 2018 and included in this “As-Is Assessment” as an attachment. Excerpts from the conclusion of the report indicates that Fulcrum collected 24 samples of suspect ACM during the Fairchild Airforce Base B1007 Hangar inspection. Fulcrum’s inspection did not identify any ACM within the interior or exterior of B1007 Hangar. Fulcrum’s LCM inspection consisted of paint chip sampling of painted surfaces. Of the seven (7) paint chip samples collected for analysis, four (4) were identified as lead containing and three (3) were identified as not containing any detectable concentrations of lead. The four-identified lead containing painted surfaces were the dark red and light red paints on the interior metal structure beams, and the white and yellow painted lines on the concrete floor of the hangar. Table I of the report lists results indicating paint chips having lead concentrations greater or equal to the method reporting limit of detection for total lead and potential worker protection concern.

Converting the aircraft weather shelter hangar to a maintenance hangar changes the use of the building from a weather protection building to a building where maintenance operations will be performed. The proper environment for maintenance crews working requires the building to be thermally insulated, heated and task-force level lighting added. The support spaces created require the improvements necessary for an efficient operating facility.