Bldg 22 and 31 Cheyenne Roof Report 2019.pdf

ROOFING SYSTEMS

CONDITION REPORT

WYOMING AIR NATIONAL GUARD

CHEYENNE ANGB

CHEYENNE REGIONAL AIRPORT, WYOMING

NATIONAL GUARD BUREAU

CIVIL ENGINEERING TECHNICAL SERVICES CENTER

MINOT, NORTH DAKOTA

AUGUST 2019

TABLE OF CONTENTS

EXECUTIVE SUMMARY

ROOF INSPECTION SUMMARY

METHODOLOGY

ROOF SYSTEMS MANAGEMENT

ROOF CONDITIONS

Building 1, Gate House Building 9, POL Operations Building 10, POL Building 11, POL Pump House Building 14, Weapons Storage Building 15, 30th Airlift Support Squadron Building 16, Admin/Training/Ops Building 18, AES\SFS\Storage Building 20, Temp Trailer Building 21, Storage\Vehicle Maintenance Building 22, Fuels Systems Maintenance Building 23, Vehicle Maintenance Building 24, AGE Building 26, Hazmat Storage Building 27, Disaster Preparedness Building 30, Dining Facility Building 31, BCE Building Building 32, Starbase Building 33, Fire Station Building 34, Avionics Building 35, Corrosion Control Building 36, Squadron Operations Building 37, Airlift Support Complex Building 40, ATC\Rapcon Building 41, Flight Simulator Building 20340, LOX Shelter Building 20902, POL Storage Building 21101, Tool Storage Building Building 21103, POL Control Building Building 21104, Mogas Control Room Building 21105, Engine Test Stand Building 21107, POL Maintenance

ROOF DISTRESS LEGEND

ROOF SYMBOLS LEGEND

DISTRESSES: SINGLE-PLY ROOFS

DISTRESSES: BUILT-UP ROOFS

DISTRESSES: MODIFIED BITUMEN ROOFS

DISTRESSES: SHINGLED ROOFS

DISTRESSES: METAL ROOFS

REFERENCES

DISTRIBUTION

EXECUTIVE SUMMARY

The NGB/A4OC Pavement Maintenance Management Team performed a visual eval-uation of the roofing systems maintained by the Wyoming Air National Guard at the 153rd Airlift Wing, Cheyenne Air National Guard Base, WY. The team acquired and entered data into ROOFER, a Sustainment Management System (SMS) database for analysis. The results are incorporated into this report, which contains quantified information about existing and predicted roof conditions, along with recommended corrective actions. The report is intended to provide a roof condition index (RCI) sum-mary and to assist the Base Civil Engineer in making decisions regarding roofing maintenance, repair or replacement. Air Force Instruction (AFI) 32-1051 identifies the requirement and provides guidance for establishing and maintaining a Roof Man-agement Program.

The 153rd CES is doing a good job sustaining the roofs at Cheyenne ANGB. In order to improve the current roofing program, the National Roofing Contractors Association (NRCA) recommends craftsmen inspect the roof system twice a year, (spring and fall).

Thirty two buildings were inspected at Cheyenne ANGB. Of these, twenty four build-ings have recommended repairs and buildings 9, 22 and 26 are recommended for im-mediate replacement.

The most common distress on metal panel roof systems is surface deterioration, and in some cases localized corrosion due to exposure. Other metal panel distresses rec-orded are backed out, missing, or corroded panel fasteners, missing/broken flexible flashing boots, improperly mounted equipment, loose flashing, and debris.

The most common distress on single ply roof are; holes in the membrane, unattached membrane on the base flashing, holes\splits in the membrane reinforcement along the edge metal, and debris.

To prevent the possibility of structural or interior damage from water intrusion, a roof-repair project should be initiated as soon as possible. To develop a repair project, the Corrective Action section of this report should be checked for distresses that were rated as medium or high severity. Those distresses have the most potential for water intrusion and damage to the building’s structure or contents.

ROOFER SMS estimated repair costs, formulates the basis for the corrective action recommendations included in the Roof Inspection Summary, along with the addi-tional service life that can be expected if the recommended repairs are accomplished.

The listed repair costs cover only the quantities of distresses that were recorded dur-ing the evaluation. The cost of replacing wet insulation is not included, but repairs should include replacing wet insulation whenever it is encountered. Repair costs do not include mobilization, overhead and profit. An estimated value of 20%, to cover these costs, has been incorporated into total repair cost identified on the Roof Inspec-tion Summary beginning on page 3. The estimated total cost for all required roof repairs at Cheyenne ANGB is $394K. Of which, $64K may be covered by warranties.

Buildings 9, 22, and 26 are recommended for replacement at a projected cost of $582K. It should be noted that all three of these roofs should only be replaced if the WYANG will continue to utilize these buildings long term. Otherwise demolition is a better option.

Based on our visual inspection two other roofs in addition to those identified in the previous paragraph may require replacement within the next 5-7 years. In our judge-ment buildings 34, and 35, sections A, B, and C will likely require replacement within the next 5-7 years if proper repairs are not completed. Note: Estimates are based on replacing the existing roofing systems with a similar system. Also, these costs are not included on the Roof Inspection Summary beginning on page 3.

Building Section Cost Replacement Year

Comments

34 A $385K 2025 35 A, B, & C $480K 2025

Finally, upon completion of this inspection and report generation, direct rating of roof conditions for each facility have been incorporated into the ANG’s BUILDER data-base. Condition changes noted during future annual roof inspection should also be incorporated into the BUILDER database.

B ui ld in g N um be r

Se ct io n

B ui ld in g N am e

R oo f T yp e

Su rf ac e

C ol or

Se ct io n

A re a (S

F)

R C

I

A R

/R R at io

R oo f A ge

W ar ra nt y

R ep ai r

C os t $

W ar ra nt ie d

R oo fs ep ai r C os t $

R ec om m en de d ai r

Ye ar

A dd it io na l S er vi ce

Li fe w it h R ep ai rs

R ep la ce m en t Y ea r w it h

R ep ai rs

R ep la ce m en t Y ea r w it ho ut R ep ai rs

R ep la ce m en t C os t $

* R ec om m en da ti on

20 A Temp Trailer SP Black 7,840 96 0.16 6 Yes 267 2020 3 2037 2034 172,108 Repair

21 A Vehicle Maint / Storage CM Silver 4,200 84 0.28 54 No 4,068 2020 8 2032 2024 92,201 Repair

22 A Fuels Systems Maint MB Gray 9,368 55 1.41 51 No 74,703 2020 6 2029 2023 205,651 Replace B MB Gray 3,574 55 1.32 51 No 29,937 2020 7 2030 2023 78,458 Replace C MB Gray 3,388 53 1.29 51 No 28,258 2020 7 2029 2022 74,375 Replace D MB Gray 3,388 53 1.29 51 No 28,457 2020 7 2029 2022 74,375 Replace E MB Gray 1,634 43 1.21 51 No 14,520 2020 8 2029 2021 35,870 Replace F SP Gray 1,552 62 0.39 27 No 2,643 2020 8 2032 2024 34,070 Replace G MB Gray 1,739 47 0.74 51 No 9,309 2020 9 2030 2021 38,175 Replace

23 A Vehicle Maintenance SP White 1,040 95 0.03 2 Yes 62 2020 11 2035 2024 22,831 Repair B SP White 3,200 91 0.03 2 Yes 20 62 2020 11 2033 2022 70,248 Repair C SP White 204 91 - 2 Yes 0 4,478 Maintain D SP White 49 100 - 2 Yes 0 1,076 Maintain

24 A AGE BUR Gray 6,877 88 0.23 28 No 893 2020 4 2035 2031 150,968 Repair

26 A Hazmat Storage SP Gray 640 54 0.71 35 No 6,399 2020 18 2040 2022 14,050 Replace

27 A Disaster Preparedness SP White 4,722 98 0.13 11 Yes 10 135 2020 4 2040 2036 103,660 Repair

30 A Dining Facility SP Black 9,320 95 0.19 13 Yes 10 533 2020 1 2035 2034 204,598 Repair B SSM Blue 3,058 98 0.20 13 Yes 376 67 2020 4 2060 2056 67,131 Repair

31 A Base Civil Engineering SP Gray 12,726 90 0.21 28 No 93 2020 1 2032 2031 279,368 Repair B SP Gray 3,329 90 - 28 No 0 0 73,080 Maintain C SP White 252 100 - 6 Yes 0 0 5,532 Maintain D SP White 3,280 89 - 6 Yes 10 2020 4 2032 2028 72,004 Repair

ROOF INSPECTION SUMMARY

CHEYENNE ANGB, WY

B ui ld in g N um be r

Se ct io n

B ui ld in g N am e

R oo f T yp e

Su rf ac e

C ol or

Se ct io n

A re a (S

F)

C

I

A R

/R R at io

R oo f A ge

W ar ra nt y

R ep ai r

C os t $

W ar ra nt ie d

R oo fs ai r C os t $

R ec om m en de d ai r

Ye ar

A dd it io na l S er vi ce

Li fe w it h R ep ai rs

R ep la ce m en t Y ea r w it h

R ep ai rs

R ep la ce m en t Y ea r w it ho ut R ep ai rs

R ep la ce m en t C os t $

* R ec om m en da ti on

53,110 63,732

$64,000

581,369 $582,000

100 - 85 84 - 60 59 - 0

* Does not include Mobilization, Overhead or Profit

ROOF INSPECTION SUMMARY

CHEYENNE ANGB, WY

Total repair cost for roofs not under warranty to be repaired: 274,840 Total Cost (with 20% Mobilization, Overhead and Profit): 329,808

Total cost rounded: $330,000

Total repair cost for roofs to be repaired under warranty:

Total Cost (with 20% Mobilization, Overhead and Profit):

Total cost rounded:

SP = Single-ply Roofing SSM = Standing-seam Metal CM = Corrugated Metal

Total repair cost for roofs to be replaced:

Total cost rounded:

RCI

Roof is in satisfactory condition Roof is in degraded condition

Roof is in unsatisfactory condition

Roofing Types: BUR = Built Up Roof MB = Modified Bitumen SH = Asphalt Shingles

METHODOLOGY

In order to obtain maximum value for the ANG’s roofing investment, the National Guard Bureau’s Civil Engineering Technical Services Center provides roof condition assessment services to the ANG organizations. The NGB/A4OC Pavement Mainte-nance Management Team inspects roofing systems to collect distress and condition data, which is entered into the web-based ROOFER Sustainment Management Sys-tem (SMS) database. This process provides a systematic procedure for determining priorities and strategies for repair or replacement of roofing systems.

The roof survey is a visual inspection, only. Roofing system material samples were not taken during this survey. NGB/A4OC’s repair or replacement costs and recom-mendations are based on reports generated by ROOFER, modified by the assessor’s engineering judgment. Water infiltration should be investigated to determine the extent of the infiltration. Wet insulation can be verified by core samples. Water infiltration can cause a variety of problems: stains on ceiling and walls, structural damage due to corrosion of structural metal, wet insulation can affect thermal re-sistance leading to a significant reduction in energy efficiency, and promote mold growth that can degrade indoor air quality. Replacing wet insulation should be a part of any roof repair.

ROOFER cannot identify the cost of each maintenance option available, only the cost for repairing each individual distress. The actual repair costs will vary according to the maintenance philosophy applied. If the distress data is provided to an A&E or construction contractor as supporting documentation for the development of a maintenance or repair contract, the report costs may differ from those developed by the contractor. When mobilization, overhead and profit charges are added to individ-ual roof distress repair costs, the cost may increase to a point where replacement may be the better option even though ROOFER recommends repair. The data must be evaluated to ensure that any replacement is justified. Set-up charges and mobiliza-tion fees are not included in the individual roof section repair costs, but are included in the Total Cost on the Roof Inspection Summary, shown on page 7.

Low-severity roof distresses do not indicate roof leaks. These minor roof distresses do not trigger a computer-generated recommendation and ROOFER does not compute repair costs for them. Low-severity distresses are recorded to indicate undesirable or substandard design, construction or maintenance practices that should be avoided.

Low-severity distresses are also used to indicate maintenance liabilities that may not be current problems, but that can be expected to deteriorate rapidly without regular inspections and service. In those cases, the recommended actions are semi-annual inspections and periodic maintenance.

To reduce the costs and prevent the consequences of roofing system deterioration, a base-wide roof management program is recommended. The program should include annual roof inspections by a trained roofing technician. If repair materials are avail-able, many roof distresses can be corrected before water infiltration and damage can occur. Pitch pans require frequent maintenance and can be filled and crowned to drain whenever the pitch becomes low. Small areas of damage to membrane roofing systems such as small splits or holes can be repaired before water infiltration can occur. Minor damage to the flashing at roof edges, vent penetrations, equipment curbs and parapet walls can also be repaired. Fasteners that are loose or have backed out and corroded fasteners should be replaced. All debris should be removed from the roof surfaces, roof drains and gutters to prevent clogging and ponding of water.

The current inspection did not include roof maintenance.

ROOFER projects roof replacements based on the expectation of a twenty-year ser-vice life for all roof types except metal and recommends replacement after twenty years, regardless of roof condition. Metal roof service life varies from fifteen to forty years depending on seam type. The Roof Data Summary only includes a recommen-dation of replacement and the projected cost of replacement if the recommended re-placement year is less than five years from the inspection date or an exception can be justified. The replacement recommendations assume that the replacement system will be similar to the existing roofing system.

Additional Service Life (ASL) is computed by ROOFER SMS and is the additional life that should be expected from the roofing system after repairs are made. If no repairs are identified, no additional service life is indicated.

The Adjusted Repair/Replace (AR/R) cost ratio is a cost-effectiveness ratio used by the ROOFER SMS to develop repair or replacement recommendations. The ratios and their associated recommendations are:

0 to 0.8 Repair

0.8 to 1.2 Marginal

Greater than 1.2 Replace

When a setup charge is added to minor repair costs, the AR/R ratio may indicate replacement, although replacement may not otherwise be warranted. The data must be evaluated to ensure that any replacement is justified.

The ROOFER SMS Roof Condition Index (RCI) is a numerical rating based on the quantity and severity of the distresses noted in each roof section. The RCI ratings and their associated recommendations are further discussed in the Roof Systems Management section of this report.

ROOF SYSTEMS MANAGEMENT

Air Force Instruction (AFI) 32-1051 identifies the requirement and provides guidance for establishing and maintaining a Roof Management Program. During Compliance Inspections (CI’s), inspectors will require that a Roof Management Program be in place and current.

In accordance with AFI 32-1051, Civil Engineering personnel are tasked with devel-oping, maintaining and managing the Roof Management Program. The objective of a Roof Management Program is to reduce life cycle costs of facility roofs through pe-riodic inspections, routine maintenance and repair, and correct application of quality roofing products. This report provides the data needed for BUILDER SMS, and can provide budget and project data to assist with maintaining a Roof Management Pro-gram in accordance with AFI 32-1051.

It is important to understand that a low RCI (<60) alone does not necessarily warrant a replacement. It must be evaluated in conjunction with the AR/R. For example, a low RCI combined with a low AR/R may conclude that repairs are still the best option.

Conversely, a high RCI (>84) combined with a high AR/R may conclude that replace-ment is the best option. This data has been analyzed and recommendations are shown in the Roof Inspection Summary found on pages 3 - 6 of this report.

It is also important to understand that the following color coded installation drawing represents a maintenance management plan associated with the calculated RCI and is not always in direct correlation to maintenance or repair priorities and associated costs calculated by ROOFER SMS. Engineering judgment as well as repair/replace-ment cost analysis and how it relates to the life expectancy of the roofing materials that have been applied to each roof or roof section must be considered for the final project.

Building 16 Admin/Training/Ops: This is a 5 year old combination SP and SSM roof, with SP making up the majority. Overall the roof is in satisfactory condition, with some minor repairs required. Of the most concern is the lightning protection (LP) cable that has pulled loose on section A. It is also evident that the workmanship of the installer should have been more closely monitored during construction. There are numerous lumps beneath the SP membrane on sections B, C, and D indicating the surface was not properly cleaned prior to installation. There is also a large area on section D where water ponds due to inadequate slope to the drain, it appears either the insulation boards were not tapered correctly or they were not fastened to the deck properly or a combination of both. Either way the result is a dam that causes water to pond. In addition the seams on the SSM roofs although they may be water tight appear not have not been properly crimped (poor workmanship). Also on section A there is a section of metal cap missing, it appears it was never installed by the con-tractor.

Building 18, AES/SFS/Storage: This SSM roof is 12 years old and is in a degraded condition due to numerous backed out fasteners and some localized surface deterio-ration (minor corrosion). Recommend repairing as soon as possible.

Building 20, Temp Trailer: This 6 year old SP roof is in satisfactory condition.

Building 21, Vehicle Maintenance/Storage: For being 54 years old this CM roof is only in degraded condition. Mostly due to many fasteners along the lap seams being loose/backed out, they should be removed and a larger fastener installed. Also the fiberglass skylights are badly deteriorated and should be replaced.

Building 22, Fuels Systems Maintenance: This building has a 51 year old MB roof with one section being ballasted SP (27 years old and in degraded condition). All other roof sections are in unsatisfactory condition and are beyond repair. We recom-mend replacement of the entire roof due to its age, the number, and type of distresses found. Polyurethane foam could be applied as a stopgap.

Building 23 Vehicle Maintenance: This SP roof is only 2 years old and is in satisfac-tory condition.

Building 24, AGE: This BUR is 28 years old and although it is still in satisfactory condition based on ROOFER, it is beginning to show its age. Continued maintenance will carry it through a few more years but eventual replacement is on the horizon (5- 7 years).

Building 26, Hazmat Storage: This ballasted SP roof is 35 years old and should be replaced as soon as possible. There are holes (tears) through the base flashing around the entire perimeter as well as the curbs.

Building 27, Disaster Preparedness: This building has an 11 year old SP roof that is in satisfactory condition.

Building 30, Dining Facility: This building has a combination SP and SSM roof and it is in satisfactory condition with some repairs required on the SP roof including holes in the base flashing and removing debris off the roof. Trees should be trimmed back away from the SSM roof as well.

Building 31, Base Civil Engineer: Sections A and B are 28 year old ballasted single ply and are in satisfactory condition despite their age. The paint is peeling on the majority of the metal cap flashing, but there are no signs of corrosion. Sections C and D are newer (6 year old) fully adhered SP membrane and are also in satisfactory condition.

Building 32, Star Base: This is a 35 year old ballasted single ply roof that is in satis-factory condition. The base flashing is beginning to pull away from the parapets, numerous fasteners (nails) are backing out in the metal cap flashing. Another item noted is the condensation drains for the roof top air handlers should be piped to a drain (scupper) to eliminate continuous moisture on the roof.

Building 33, Fire Station: This 11 year old combination SSM and SP roof and is in satisfactory condition with the exception of section B. Section B is fully adhered SP and is in degraded condition. Water has infiltrated the roof resulting in wet insula-tion. A combination of wind and water has loosened the membrane over roughly one quarter of the section. Wind flutter continues to increase the damaged area. This area should be repaired/replaced as soon as possible. It should be noted that this roof is still under warranty.

Building 34, Avionics: This building has a 25 year old ballasted single ply roof. There are many distresses along the base flashing, and roof penetrations, which accounts for its degraded condition. Repairs should be made to this roof as soon as possible to bring it up to a satisfactory condition. Without proper repairs to this roof it will re-quire replacement within the next 5-7 years.

Building 35, Corrosion Control: Sections A, B, and C are 25 year old single ply roofs.

Section B is in satisfactory condition. Sections A and C are in degraded condition and require some work to bring them up to satisfactory condition. These sections are nearing the end of their life and without proper repairs they will need to be replaced within the next 5-7 years. Sections D and E are 14 year old SP roofs and are in satisfactory condition, only requiring some base flashing and metal cap repairs.

Building 36, Squadron Operations: This 11 year old roof has a combination of me-chanically attached SP and SSM roofs, they are all in satisfactory condition. Not many actual roof distresses, but it was noted that there is ponding around most of the overflow drains, this standing water may prematurely deteriorate the membrane

Building 22, Fuels Systems Maintenance

There are patches through-out the main field of the roof on all sections, the above photo is Section A.

The joint covers on the expansion joints are deteriorated, many have been patched as seen here, but they are still open and allows water to penetrate. The base flashing as shown above right is deteriorated as well. (Section A)

Building 22, Fuels Systems Maintenance (cont)

The mod bit roof covering is deteriorated to where a minor impact can puncture the membrane surface. The fiberglas reinforcement fibers are visible along the edges of the edge of the membrane due to detrioration. (Section A)

There are several holes like the one pictured above left. A large split was previously patched. However the patch has deteriorated leaving a large hole in the membrane.

(Section E)

Building 22, Fuels Systems Maintenance (cont)

The membrane is split the entire length of the edge metal along the NW edge of the roof. Notice the gravel beneath the metal flashing. This is leaking. (Section F)

The base flashing on all the curbs are open and allows water to penetrate into the building. (Section F)

Building 31, BCE Building

The reinforcement strip covering the lap seam on the base flashing is loosened and should be re-glued. Also the base flashing is beginning to pull away from the parapet wall. (Section A)

The paint is peeling off the metal cap flashing. (Sections A&B)