20241108_USDA_DFRC_RTA_ECI.pdf

Engineering Considerations and Instructions for Field Personnel (ECIFP)

RTA

USDA Agricultural Research Service

Contract Number W9128F21C0023

New Dairy Forage Research Center

Prairie du Sac, Wisconsin November 8, 2024

Engineering Considerations and Instructions for

Field Personnel (ECIFP)

RTA

November 8, 2024

USDA Agricultural Research Service

New Dairy Forage Research Center Prairie du Sac, Wisconsin

3001 Washington Boulevard, Suite 200 Arlington, Virginia 22201-2117 703.518.8500

Curry-Wille and Associates 425 S 2nd St.

Ames, IA 50010 515.232.9078

3116 N. Dries Lane, Suite 100 Peoria, IL 61604 309.693.7615

USDA DFRC

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

Engineering Considerations and Instructions for Field Personnel (ECIFP)

HDR Architecture, Inc.

Project Information Project Title: New Dairy Forage Research Center Project Number: W9128F21C0023 Project Type: Design-Bid-Build Contract Vehicle:

Version:00 Revision History

Revision No.

Implemented By Revision Date Approved By Approval Date Description of Reason

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

Table of Contents

Revision History

Table of Contents

1.0 PROJECT FEATURES AND SUMMARY

2.0 POINT OF CONTACT INFORMATION

3.0 DESIGN AND DESIGN BUILD CONSIDERATIONS

3.1 Civil/Site

3.2 Structural

3.3 Architecture and Interiors

3.4 Mechanical and Plumbing

3.5 Fire Protection

3.6 Electrical and Communications

3.7 Cybersecurity

3.8 Environmental

4.0 SPECIFICATION CONSIDERATIONS

5.0 PERMIT/ UTILITY INFORMATION

5.1 Permits

6.0 QUALITY ASSURANCE (QA)

7.0 ADVERTISEMENT

8.0 DESIGN/BUILD ROLES AND RESPONSIBILITIES FOR ENGINEERING DIVISION

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

1.0 PROJECT FEATURES AND SUMMARY

• The proposed new Dairy Forage Research Center (DFRC) facility consists of dairy production and research, animal housing, operations, and maintenance facilities, and supporting infrastructure.

The overall facility is divided into multiple buildings and connected by covered walkways.

• The dairy production facilities include a conventional milking parlor, robotic milking units, milking support areas, cattle holding area, lactating cow housing, dry cow housing, special needs & maternity, calf barn, cattle working areas, and cattle feed storage. The animal buildings will provide housing and milking facilities for a maximum stall capacity of 452 head of lactating dairy cows (240 head robotic milking + 160 head conventional milking freestalls + 48 head tiestall + 4 head air emissions chambers). The overall facility can accommodate up to 452 lactating cows (maximum).

• The dairy research facilities will include Advanced Animal Nutrition (AAN), animal emission chambers, a laboratory, administration, and a visitor’s center. Per USDA’s initial project vision to provide community outreach, the visitor’s center will have an education center, including a conference room and other educational components for the local community and visitors. This building will connect public visitors to the farm and provide them with exposure to the research activities at the new DFRC.

• The facilities will also feature the manure system facilitating the collection, transfer, sand bedding separation, recycling, storage conditioning, and storage of dairy manure for utilization as an organic fertilizer on DFRC cropland. The cattle feed storage facility will provide storage of silage, hay (consisting of a gravel pad), and other feedstuffs produced from the DFRC cropland and purchased from outside sources. The field equipment storage and maintenance facility will include fertilizer, pesticide, and non-pesticide storage.

• 8 permanent researchers and staff, up to 12 operations and maintenance personnel, and up to 8 student researchers will occupy the facilities.

2.0 POINT OF CONTACT INFORMATION

Agency Name E-mail Address Telephone Number

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

3.0 DESIGN AND DESIGN BUILD CONSIDERATIONS

3.1 Civil/Site

Critical Civil/Site Items:

• Segregate and conserve excavated on-site soils by type and use including:

1. Cohesive soils for the compacted clay liner candidate materials classifying as CL and CH.

2. Other cohesive soils to be used for berms and exterior slopes and including topsoil to be placed on the surface and slopes for seeding.

3. Non-cohesive soils including sands and gravels to be used for structural fill areas.

• Pavement was designed in accordance with UFC 3-250-01 requirements which reference using state standards (Wisconsin), which uses AASHTO criteria and using WisPav 4 design software for calculations.

o Coordinate all asphalt paving and associated base and subgrade preparation prior to beginning work.

o Coordinate all concrete paving and associated base and subgrade preparation prior to beginning work.

• Water system altitude valve and pressure tank settings and field adjustments are critical to operation of system.

• Coordinate the decommissioning and removal of existing features.

• Coordination of phases on adjacent sites.

• Verify current use of facilities and features prior to demo.

• All areas to receive fill should be proof-rolled to identify soft areas or expansive clays.

• All other utility connections and reroutes must be coordinated to minimize impacts on surrounding facilities.

• Coordinate concrete material submittals and mix design proportioning studies well in advance of paving schedule. All materials for the concrete mix must be approved prior to developing the mix designs. All lab testing to be completed by a Government validated laboratory.

• Contractor to maintain all stormwater structures within the Project Limits and clean them all at completion of construction prior to turn over of the site to the Government.

General Construction Items for the Site:

• Pre-Construction o Become familiar with notification requirements to Installation and user when shutdowns or other impacts to the site are required.

o Become familiar with time requirements for notifications.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

• General Construction Management o Review preconstruction submittals per specification sections including mix design.

o Verify Contractor is following the approved Quality Control Plan – particularly with respect to timely provision of test reports.

o Verify that Contractor is maintaining working as-builts and photo log of construction progress as required by specifications.

o Verify that Contractor coordinates with Installation Operations and Contracting Officer to facilitate safe operations and access to controlled areas.

o Use of explosives on site is not permitted.

• Haul Route o Ensure pre- and post- construction photos and videos are documented and submitted.

o Contractor shall adhere to speed limit on haul routes and be aware of potential for emergency vehicle crossings.

o Control access gates to prevent unauthorized entry to project site – no personal vehicles are permitted on site.

o Steel tracked equipment shall not be allowed to cross any pavement to remain.

o Emergency service vehicles have right of way.

• Construction Area Safety/Security o Work requires opening of gates or fences that protect the site. Pay particular attention to ensure security at these locations is maintained and coordinated escorts provided where required.

o Contractor shall comply with all applicable state and federal occupational health and safety procedures per the contract documents.

o If applicable, all obstructions shall be lit in accordance with construction specifications.

o Construction barricades shall be placed as shown in the plans or as directed by site management and the Contracting Officer.

o Contractor personnel shall stay within specified work zones.

o Contractor shall coordinate work activities with Site Manager and Contracting Officer.

o Contractor shall coordinate with Contracting Officer and Installation for scheduling of work that impacts operations.

o Contractor shall ensure that all personnel are wearing personal protection equipment at all times.

o Work on electrical systems/equipment shall be done in accordance with plans and specifications. In addition, Contractor shall ensure that equipment is de-energized prior to the start of work by coordinating lockout/tagout with the base electrical group.

o Utility protection shall be in accordance with plans to prevent damage and or interruption to service to other facilities.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

• Erosion Control o Ensure use, monitoring, and upkeep of erosion control measures to control sediment in accordance with approved NPDES, NOI, and SWP3.

• Survey Control o Confirm survey control prior to layout of pavement and other structures.

• Underdrains o Ensure underdrain installation and materials are per plans and specifications, and that installed drains are free of sediment/blockage.

o Carefully monitor placement of underdrain pipe by requiring level readings to ensure continuous positive slope/drainage, as this is easy to quickly hide and hard to determine visually.

• Demolition o Contractor shall comply with Federal, State, and Local hauling and disposal requirements.

o Contractor shall perform a utility sweep of the work area prior to demolition activities to confirm location of utilities shown on plans.

o Contractor shall protect utilities to remain as shown and directed.

o Contractor shall keep up to date records of all recycled information.

o Contractor shall coordinate with Contractor Officer for storing and delivery of salable timber.

• Excavation/Grading o Ensure contractor utilizes geotechnical engineer to validate subgrade conditions.

o Ensure contractor utilizes geotechnical/materials engineer to segregate excavated soil including borrow material and stockpiles, document placement and testing (e.g., clay liner, structural fill soils, topsoil, etc.

o Carefully monitor excavation areas to ensure all unsatisfactory materials have been removed and replaced or recompacted including previously disturbed soil fills, topsoil, etc.

o Provide adequate temporary drainage of subgrades using weep trenches or sump locations to minimize weather impacts during construction.

o Ensure all fill areas are compacted to meet minimum requirements in accordance with the Specifications and per the geotechnical report recommendations as appropriate.

o Ensure subgrade preparation is completed in accordance with plans and specifications.

Improperly constructed subgrade and base layers can result in early age pavement failures.

o Contractor shall comply with Federal, State and Local hauling and disposal requirements.

o Stockpile materials per plans and specifications.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 o Ensure contractor is not provided with notification of substantial completion prior to acceptance of fine grading, topsoil placement, and seeding by Installation.

• Sanitary Sewer and Storm Drainage o Check shop drawing to verify the elevations and sizes match plans.

o Field verify that manholes and inlets are set to plan invert grades.

• Water – Altitude Valve and Pressure Tanks o Check shop drawing to verify the elevations and sizes match plans.

o Field verify that valve and tanks are adjusted to meet design pressure settings.

• Water Mains and Services o Contractor shall coordinate with local utilities for connection to Bluffview public water supply system.

o Contractor shall field verify that pipes are installed to lines and grades shown on drawings and that there is 67” of minimum cover from finished grade to top of pipe.

o Contractor shall verify that 18” minimum vertical separation is achieved from sanitary sewer and storm drain lines. Water lines crossing under storm drains and sanitary sewer shall either be encased for 10’ in each direction from the crossing or the pipe that is being crossed under shall be water main quality (WMQ) pipe.

• Pavement Removal o Protect existing features to remain from damage during construction activities.

o Ensure double saw cut method is utilized and performed properly at the edges of all existing concrete pavements to remain.

o Monitor removal limits to prevent the undermining in adjacent pavement areas to remain.

Require correction per plans before accepting the area for placement of new material.

o Monitor Contractor materials to confirm the approved submittals.

• Pavement Construction (Driveways and Parking Lot) o Paver

• String line the pan to check for warp/damage or check crown (if applicable). Hold several washers of known thickness on each end of pan and pull string over the washers. Check the distance between the pan and string at multiple locations to confirm pan trueness.

• Check paver for hydraulic leaks (there will be some). Use drip pans or repair to prevent oil from contaminating PCCP.

• Check side/slip forms for adjustment and cleanliness. These forms are typically canted in at the top to provide a vertical face to the slip form edge.

• Check vibrators for operation and frequency. The frequency requirements are usually indicated within the specs. Most pavers have vibrators that may be individually adjusted for tuning. Once you have checked them and they are set, Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 watch the operator because he may attempt to adjust the frequency down especially at the location of an air test behind the paver.

o Make sure the straight edge is straight, mags, floats, edgers are in good working condition, and a hand vibrator/generator is available.

o Require QC results from the contractor and perform QA testing and inspections in accordance with project specifications in a timely manner.

o Construct pavement per plans and specifications, including compaction, layer thicknesses, slopes, mix design, placement and curing requirements.

o Allow new pavement surfaces to cure for a period of not less than 30 days before the application of pavement markings.

Residual Risks

• Construction on top of the expansive clays that are not properly identified during the proof-rolling process must be avoided.

• Utility services are routed throughout the site and require coordination with the equipment and pads.

Assumptions

• Recycled Concrete will not be used for any final product construction activities.

3.2 Structural

Laboratory and Admin Building

• Shear walls are designed considering openings shown on shear wall elevations. Prior to the erection of wood shear walls, the contractor is to coordinate all trades especially Mechanical, Electrical, and Plumbing (MEP) and approval from AE is required for all openings through shear walls.

• Cross laminated timber (CLT) panels on roofs require full coordination of all trades especially MEP to determine exact locations of openings required at roof prior to fabrication of CLT panels. CLT panels are expected to be fabricated with all required openings at the manufacturing plant. Approval from AE for all penetrations on CLT roof panel is required.

Animal Facilities

• B1-Air Emissions Building o Coordinate with Air Emissions Chamber manufacturer to ensure equipment fits through provided building openings.

o Coordinate Air Emissions Chambers placement with drawings and as-built conditions for proper location of chambers.

o Coordinate post placement with placement of foundations and slabs to match gate layout shown on equipment plans.

o Coordinate with gating and panel supplier and installer to ensure proper gates, latches and hinges are installed and coordinated with posts and wall hinge/latch locations.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 o Coordinate with metal building submittals prior to installation of footings and foundations.

o Buildings B1 and B2 are a single building with a divider wall between the two spaces.

Coordinate metal building submittal accordingly.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

• B2-Advanced Animal Nutrition o Coordinate with gating and panel supplier and installer to ensure proper gates, latches and hinges are installed and coordinated with posts and wall hinge/latch locations.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Coordinate cross-bracing with fan locations in walls.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

o Tiestall post and divider locations are critical to cow comfort. Confirm spacing is per drawings.

o Confirm post shields/guards are installed and located properly.

• B3-Convetional Freestall o Coordinate with gating and panel supplier and installer to ensure proper gates, latches and hinges are installed and coordinated with posts and wall hinge/latch locations.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

o Confirm post shields/guards are installed and located properly.

o Confirm concrete floor grooving is performed after concrete is set but before reaching 28-day compressive strength. Grooving should be performed by an experienced contractor.

o Coordinate metal building cross bracing with sidewall curtain systems.

• B4-Milking Parlor o Confirm floor and deck elevations in parlor and holding area prior to pouring concrete.

o Coordinate with gating and panel supplier and installer to ensure proper gates, latches and hinges are installed and coordinated with posts and wall hinge/latch locations.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

o Confirm post shields/guards are installed and located properly.

o Confirm concrete floor grooving is performed after concrete is set but before reaching 28-day compressive strength. Grooving should be performed by an experienced contractor.

o Coordinate metal building cross bracing with sidewall curtain systems.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 o Coordinate fan and lighting locations with metal building supplier to confirm loads are included in structure design.

o Coordinate penetrations in cow deck and milkers pit with milking equipment installer prior to pouring concrete.

o Water stopping at cold joints.

• B5-Special Needs and Maternity o Coordinate with gating and panel supplier and installer to ensure proper gates, latches and hinges are installed and coordinated with posts and wall hinge/latch locations.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

o Confirm post shields/guards are installed and located properly.

o Confirm concrete floor grooving is performed after concrete is set but before reaching 28-day compressive strength. Grooving should be performed by an experienced contractor.

o Coordinate metal building cross bracing with sidewall curtain systems.

• B6-Robitic Milking o Coordinate with gating and panel supplier and installer to ensure proper gates, latches and hinges are installed and coordinated with posts and wall hinge/latch locations.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

o Confirm post shields/guards are installed and located properly.

o Confirm concrete floor grooving is performed after concrete is set but before reaching 28-day compressive strength. Grooving should be performed by an experienced contractor.

o Coordinate metal building cross bracing with sidewall curtain systems.

o Coordinate robotic milker installations and equipment with robotic milker supplier and installer.

• B7-Calf Building o Coordinate with gating and panel supplier and installer to ensure proper gates, latches and hinges are installed and coordinated with posts and wall hinge/latch locations.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

o Confirm post shields/guards are installed and located properly.

o Confirm concrete floor grooving is performed after concrete is set but before reaching 28-day compressive strength. Grooving should be performed by an experienced contractor.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 o Coordinate metal building cross bracing with sidewall curtain systems.

o Confirm floor slopes match structural drawings.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

• B8-Agronomy Building o Coordinate installation of dryers prior to installation of metal building structure.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

• B9-Feed Center o Coordinate elevations of bin foundations with finished floor elevation.

o Coordinate loading dock retaining wall with location of loading dock.

o Coordinate location of bunker walls with walk-in freezer location.

o Coordinate tunnel location and size with equipment submittals.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

• B10-Silage and Hay Storage o Coordinate bunker wall locations, sizes and types with drawings.

o Coordinate with site drawings.

• B11-Machine Shop and Machine Storage and Pesticide o Confirm liquid pesticide area slopes to sump prior to pouring concrete.

o Coordinate building cross bracing with door locations.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

• B12.1 and B12.2-Connector and Sorting Buildings o Coordinate with gating and panel supplier and installer to ensure proper gates, latches and hinges are installed and coordinated with posts and wall hinge/latch locations.

o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

o Confirm post shields/guards are installed and located properly.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 o Confirm concrete floor grooving is performed after concrete is set but before reaching 28-day compressive strength. Grooving should be performed by an experienced contractor.

o Coordinate metal building cross bracing with sidewall curtain systems.

• B13-Milk House o Coordinate with metal building submittals prior to installation of footings and foundations.

o Pre-engineered metal buildings may have a long lead time. At the time of this writing, lead times are 12 months.

o Confirm floor slopes match drawings prior to pouring concrete.

o Confirm location of milk tank and drain with milking equipment manufacturer.

• B14-Fuel Storage o Coordinate fuel storage slab size designed with actual tank sizes purchased.

• B15-Commodity Storage o Confirm commodity storage floor slopes down from south to north.

Residual Risks

• Precise installation of flush flume with connected building foundations with metal building structures and gate posts due to the multiple layers of coordination.

• Foundations for pre-engineered metal buildings are designed based on assumed loads.

Confirm foundations are adequate at the time of pre-engineered metal building submittals with

EOR.

Assumptions

• Foundations are designed and detailed per documented recommendations in the geotechnical report provided by Soils & Engineering Services, Inc dated November 28, 2022.

Manure Facilities

• Cantilever retaining walls were designed in both the Solid Stack Building (C2) and Solids/Sand Separation Facility (C3). Correct placement of vertical reinforcement bars and dowel bars is imperative to the functionality of these walls.

• Waterstops will be installed in the Liquid Storage Cell Liners (C1), Solid Stack Building (C2), and Solids/Sand Separation facility (C3) to provide water-tightness of these structures.

Selected waterstop product specifications shall be submitted to the Engineer of Record (EOR) for approval prior to ordering.

• Constant and precise slopes shall be maintained as noted on the sand lane of the Solids/Sand Separation Facility (C3) for proper system velocities to settle sand and to ensure there are no low spots that allow water to collect or pond.

• Ensure proper concrete surface texturing has been provided on the settling tank ramps of the Solids/Sand Separation Facility (C3) and on the access ramp in cell 1 of Liquid Storage Cells

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

(C1) for safety and functionality purposes.

• 6” of compacted crushed aggregate fill must be used under the ramps of the settling tank and sand lane of the Solids/Sand Separation Facility (C3) and the floor of the manure/sand stack building (C2).

Residual Risks

• Solids/Sands Separation Facility (C3) structure may have bearing on varying soil layers increasing the potential of differential settlement. The potential need exists to over excavate on-site soils and place structural fill materials in accordance with the recommendations in the geotechnical report.

Assumptions

• Foundations and slabs on grade are designed, detailed, and specified in accordance with geotechnical recommendations based on the subsurface investigation.

• Solid Stack Building (C2) foundations were sized based on preliminary building reactions. A submittal package for the steel framed building, including building reactions, will need to be reviewed by the EOR to verify the foundation sizes are adequate.

• For the Solids/Sand Separation Facility (C3) structure, it was assumed that the settling tank and eastern portion of the sand lane would be constructed and backfilled first before proceeding with the construction of the sand stacks and western portion of the sand lane.

• Foundations and slabs on grade are designed, detailed, and specified in accordance with geotechnical recommendations based on the subsurface investigation.

3.3 Architecture and Interiors

Laboratory and Administration Building

• Design Principles The primary intent of the above facility for the new DFRC will be to provide the routine lab research and staff office spaces, with the secondary use being education related seminars and occasional meetings. Both programmatic elements support the goals and priorities of the facility to operate a state-of-the-art dairy forage research facility while educating visitors about the research. The design of this project conform to the requirements of the Omaha District Design Guide (ODDG) and the ARS Facilities Design Standards, any deviations must be brought to the USACE’s construction team’s attention through Requests for Information (RFI)

• Exterior Wall Assembly will require coordination of engineering and design details, involving stud framing sizes, metal panel system types, and concrete-faced panels as well as the integration of windows into the wall assembly. Well-coordinated and detailed shop drawings will be required for the design team’s review and approval. The contractor must submit all material samples and any substitutions comprising the exterior wall assembly for the architect’s approval.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

• The acoustics treatment strategy focuses on creating an environment conducive to concentration and collaboration in relevant areas of the building. It is vital to ensure the sealing of the acoustical flanking paths (convenience outlets, etc.) for airtightness in sound-rated assemblies during construction, which requires detailing the engineering design solutions for those assemblies through shop drawings for the design team’s approval.

• Electrical and IT devices floor boxes and their associated conduit installed and recessed in the floor slab should be coordinated before the construction with associated trades and owner furnished system furniture to ensure they are accessible and hidden from view.

• Biological safety is critical to the design of laboratory spaces and must meet the requirements of BSL-2 as defined in Biosafety in Microbiological and Biomedical Laboratories. Special attention must be given to developing the shop drawings and coordination with other trades for the biosafety elements such as fume hoods, exhaust systems, ventilation connections, piped services, etc.

• Light fixtures installed in floor slabs should be located a proper distance from walls they are illuminating and must be installed per manufacturer recommendations. Particular attention must be placed on assuring that the fixtures are installed flush with the slab to ensure that tripping hazards are not created.

• Specific attention should be given to the coordination of services within and the locations of Integrated Service Panels in the Laboratory ceilings. Integrated Service Panels should be located directly above the confluence of four mobile lab benches. Great care should be taken in laying the ceiling with respect to the layout of mobile benches.

Animal Facilities

• Design Principles New dairy facilities will have the character and appearance of typical modern agricultural buildings. The design of this project will conform to the requirements of ARS Facilities Design Standards, and “Guide for the Care and use of Agricultural Animals in Agricultural Research and Teaching” Generally, dairy facilities will be single story above grade pre-engineered metal building structures with steel roof, steel siding and operable curtain siding. Interior materials will consist of metal liners, fiberglass reinforced plastic laminate on plywood, sealed concrete and dairy cow handling and housing systems.

Milking systems will consist of a double eight rapid exit parallel system and four robotic milkers. Milking systems will feed into a common milkhouse located between the milking parlor and the robotic freestall building.

Residual Risks

• Standing seam metal roof o Laboratory and Administration Building roofs are more than 45 and 70 feet long and installation should allow good thermal movement.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 o Field formed metal panel without seam is specified.

• Possible snow drift during and after construction o Snow draft will be expected. Roof must be watertight during and after construction.

• Polished Concrete Mock-up

Mockup finish and sheen should be reviewed and approved by architect.

Assumptions No significant assumptions.

3.4 Mechanical and Plumbing

Area A - Laboratory and Admin Building

• The chilled water system is an air-cooled system containing 45% propylene glycol solution. The glycol solution requires the contractor to take appropriate measures to ensure no contamination occurs upon installation, maintenance, and operation of the chilled water system.

• The contractor is to maintain accessibility and serviceability for all equipment.

• Boilers require acid neutralization. Ensure proper devices are installed prior to startup. The contractor is to note that laboratory ductwork is of stainless-steel type, and the labs are serviced by 100% dedicated outdoor air units.

• The contractor is to coordinate the routing of hydronic piping with electrical equipment to provide compliance with the NEC and any other applicable code.

• The corridors and office areas will have exposed ductwork. The contractor is to keep ductwork in the best possible condition during installation to maintain aesthetics.

B Buildings

• B1-Air Emissions o Four (4) air emissions chambers individually environmentally controlled. Common fresh air intake from building B1 interior space with modulating damper from central air handling system and relay to central air handling system to ramp up air to the air emissions chambers.

o Central DX cooling system and gas fired heat to ground mounted RTU.

• B2-Advanced Animal Nutrition o Central air system in laboratory spaces from B1 o Research area with positive pressure sidewall fans for both summer and winter ventilation. Gas-fired radiant tube heaters along the center aisle to maintain manure above freezing for collection.

• B3-Conventional Freestall

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 o Curtain sidewalls with powered exhaust ridge ventilators to maintain minimum winter ventilation and required summer ventilation and stir fans. Sidewall curtains are split into an upper section and lower section with both sections opening upward.

• B4-Milking Parlor o Central DX cooling system and gas fired heat to ground mounted RTU to serve shop, restroom, utility and office spaces.

o Sidewall exhaust fans for winter and summer ventilation in the milking parlor area and gas fired radiant tube heater over milking pit. Fabric overhead door between holding pen and milking parlor.

o Sidewall curtains in holding area with ventilation fans directed from the milking parlor to the connector lane. Soaker system in holding area for evaporative cooling of cows.

• B5-Special Needs and Maternity o Central DX cooling system and gas fired heat to ground mounted RTU to serve storage, office and procedure areas.

o Sidewall curtains and stir fans for maternity area and special needs pen.

• B6-Robotic Milking Building o Curtain sidewalls with powered exhaust ridge ventilators to maintain minimum winter ventilation and required summer ventilation and stir fans. Sidewall curtains are split into an upper section and lower section with both sections opening upward.

o Multizone mini-split systems for research, utility, and research spaces with electric heat strips.

• B7-Calf Building o Curtain sidewalls and PPTV (Positive Pressure Tube Ventilation) system at calf pen area. Sidewall curtains are split into an upper section and lower section with both sections opening upward. PPTV system is designed to operate constantly at winter air design conditions.

o Solid sidewalls with 10’ x 10’ rollup doors adjacent to each bedded pack pen and two

(2) PPTV systems, one for each row of bedded pack pens. PPTV system is designed to operate constantly at winter air design conditions.

o Multizone mini-split systems for rooms B7-101, B7-102 and B7-103.

• B8-Agronomy Building o Gas fired radiant tube heat and tunnel ambient ventilation. Ten (10) custom designed drying rooms with adjustable ventilation and electric heat.

• B9-Feed Center Building o Single zone mini-split system for room B9-101.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

• B10-Silage and Hay Storage o No mechanical systems.

• B11-Machine Shop/Machine Storage/Pesticide Building o Gas fired radiant tube heat and adjustable ambient ventilation in room B11-105 shop area, unit heater in room B11-102 liquid storage containment area, multizone mini-split for rooms B11-106 and B11-107.

• B12.1 and B12.2-Sorting and Connector Buildings o Curtain sided side walls with both curtains rising up. Stir fans.

• B13-Milk House Building o Gas fired radiant tube heat and adjustable ambient ventilation.

• B14-Fuel Storage o No mechanical systems.

• B15-Commodity Storge o No mechanical systems.

Plumbing systems are as follows:

A Building

• Domestic cold and hot water are supplied to tempering valves for safety showers and eyewash fixtures.

• A separate laboratory cold and hot water system with backflow preventers serve the laboratory fixtures and equipment.

• Natural gas service from the site serving the emergency generator, two boilers and the domestic and laboratory water heaters. Contractor is to coordinate final procured equipment loads with design load to ensure adequate service and pipe sizes.

• Contractor to coordinate final locations of air intake and exhaust at roof from gas-fired condensing domestic and laboratory storage type hot water heaters. Ensure proper clearances are provided.

• Contractor is to ensure the laboratory waste system pH monitoring systems is calibrated for reading proper pH levels. The pH level and alarms will be monitored by the BCS.

• Contractor is to ensure the final location at the roof of the exhaust from the packaged vacuum system for laboratory has proper clearances from air intakes.

• The installation and cleaning by the contractor of the purified water piping system is to be supervised and accepted by the purified water equipment vendor.

• The contractor is to coordinate final locations of the manifold vent at roof to ensure it has

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 proper clearances from air intakes.

• Storm drainage will be provided by use of gutters and external leaders spilling to grade.

• Plumbing contractor is to coordinate final floor drain locations with coordinated shop drawing equipment locations prior to setting drains.

• Plumbing contractor is to coordinate all final roof penetrations with structural and architectural roofing design.

B Buildings

• B1-Air Emissions Building

• Coordinate with air emissions chambers equipment supplier for location and connections to cow waterer systems within chamber.

• Place wash down spigots out of rissler cart paths.

• B2-Advanced Animal Nutrition Building

• Coordinate plumbing service from B1 to B2.

• Install barbed fitting with flexible reinforced tubing to animal bowl waterers.

• B3-Conventional Freestall Building

• Coordinate installation of water intake measuring system with other building construction.

• Confirm all animal waterers are installed with shutoff valves.

• B4-Milking Parlor

• Coordinate with milking equipment supplier on installation of water, compressed air and vacuum system hookups.

• Install hose reels and hydrants away from animal access.

• Confirm all plumbing piping is outside of animal access areas.

• B5-Special Needs/Maternity Building

• Confirm all animal waterers are installed with shutoff valves.

• Install hose reels and hydrants away from animal access.

• B6-Robotic Milking Building

• Coordinate with milking equipment supplier on installation of water, compressed air and vacuum system hookups.

• Confirm all animal waterers are installed with shutoff valves.

• B7-Calf Building

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Contract Number W9128F21C0023

• Confirm all animal waterers are installed with shutoff valves.

• Confirm trench drain slopes to building outlet from each end of building.

• B8-Agronomy Building

• Coordinate installation of sink drain to trench drain sump.

• B9-Feed Center

• Confirm installation of freeze proof hydrant is outside the path of tractor and feed wagon.

• B10-Silage and Hay Storage

• No plumbing

• B11-Machine Shop/Storage/Pesticide

• Coordinate installation of trench drain with drain to sump in room B11-102.

• B12.1 and B12.2

• Confirm flush flume grate to flush with top of concrete, coordinate with grate submittal prior to pouring concrete.

• B13-Milk House Building

• Coordinate with milking equipment supplier for plumbing utility hook locations and sizes.

• B14-Fuel Storage

• No plumbing

• B15-Commodity Storage

• No plumbing

Residual Risks Overall the amount of coordination for the project may be cumbersome to many contractors.

Need to confirm contractors work off IFC drawings and not from the 95% bid set. Some of the systems may be unfamiliar to many contractors.

• The structural system used in the Admin Building (mass timber), consists of larger elements than associated with steel framing. The contractors should be aware that pathways shall be limited. Coordination of ductwork, piping and equipment located in the building critical. Space is very limited, and the components are not easily relocated or rerouted.

• There are structural shear walls throughout the building. Any penetration of ductwork or piping through these elements needs careful coordination of penetration size and location to avoid issues with the structural systems.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

• Plenum space in in short supply due to the above. Where ACT ceilings or hard lids are installed, the contractor should pay careful attention to access and maintenance considerations for terminal devices, valves, dampers, and other items needing interaction.

• Air-cooled chilled water systems need to be installed, controlled, and balanced correctly to ensure proper cooling.

• FCU-A-1, FCU-A-2, FC-A-3, and RF-A-1 are suspended mechanical equipment. Coordination for access is important, there are structural access platforms, the piping and duct connections need to keep these clear.

Assumptions Assumptions were made related to utilities and airflows for the following government furnished equipment:

• None at this time.

3.5 Fire Protection

• All fire protection systems are delegated designs, meaning that the contractor is responsible for the final design. Contract documents being issued indicate system performance requirements and initial coordination. Contactor is responsible for final locations, sizing, design, etc. of all systems.

Residual Risks

• The Qualified Fire Protection Engineer (QFPE) for this project shall be responsible for all fire suppression, fire alarm and life safety matters.

• Perform acceptance testing as required by DIVISION 21 specifications.

• Perform acceptance testing as required by DIVISION 28 specifications.

• The contractor is responsible for designing an intelligible fire alarm system and shall include a chart of acoustically distinguishable spaces (ADS) in accordance with NFPA 72. This chart shall note whether the space is achieving audibility and/or intelligibility in each ADS.

• Confirm dry-type sprinkler system is installed to allow for the complete drainage of system.

• Submittals shall include all information needed for a complete review, including, but not limited to, shop drawings, calculations, and product data.

• Ensuring complete packages are submittal is critical in maintaining schedule during construction as delays for review may delay installation of systems.

• Final fire pump selection must be closely coordinated for interface with domestic booster pumps due to shared underground water main for animal use and fire water use.

• Coordinate delivery lead times to ensure all fire suppression materials will arrive without negatively affecting the construction schedule.

o Special consideration needs to be given to the fire water storage tank and pre-packaged

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023 fire pump house.

• Coordinate delivery lead times to ensure all fire alarm materials will arrive without negatively affecting the construction schedule.

• All fire stoppings shall be verified by a special inspector.

3.6 Electrical and Communications

Electrical systems are as follows:

• Contractor to coordinate with Alliant Energy to provide the locations of the two (2) new utility medium voltage transformers

• Coordinate with the Alliant Energy regarding all the utility meter requirements located at the primary side of the transformer.

• Contractor to coordinate all new locations of the underground electrical ductbanks with any existing or new site utilities.

• Coordinate the exact locations of the plumbing and mechanical equipment prior to installing or routing the empty conduit to the local disconnect serving the respective unit.

• Contractor to coordinate all electrical equipment with their respective manufacturer prior to pouring for the concrete pads.

Residual Risks

• Due to the amount of plenum space located in the admin building, further coordination with all the contractors is required in the field to ensure the electrical contractor has enough space to route all the conduits serving the receptacles and lighting throughout the admin area.

• Contractors will need to coordinate all delivery lead times especially for large electrical equipment such as transformers, generators, lighting control panels & devices, and power panels due to the equipment shortages.

• Contractor to perform all acceptance testing as required by DIVISION 26 specifications.

Assumptions If the contractor coordinates and plans to install systems correctly, risks will be mitigated.

3.7 Cybersecurity

Contractor to coordinate cybersecurity work activities with Cybersecurity POCs:

Information System Security Manager (ISSM)/Information System Security Officer (ISSO): TBD Facility-Related Control Systems (FRCS) System Owners:

Building Control Systems (BCS): Scott Davis, USDA Fire and Life Safety (FLS): Scott Davis, USDA Facility Operations Systems (FOS): Scott Davis, USDA Electronic Security Systems (ESS): Scott Davis, USDA

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

3.8 Environmental

All the Badger Army Ammunition Project (BAAP) structures on the eastern side of the new DFRC project site were demolished between 2005 and 2008. Demolition of slab foundations was ongoing as of 2010 but all foundations had been removed by 2015 (Sauk County 2021). At present, there are no standing structures of any kind and no known foundations within the project development site. The eastern half of the project site consists of a level ridge top largely devoid of trees and disturbed by the demolition of the ammunition plant structures and infrastructure. The western half of the project development site consists of a wooded slope with some marked underground utilities likely associated with the ammunition plant.

The HAZMAT survey was conducted during multiple site visits between June and July of 2021; please refer to the Hazardous Material Survey Report submitted separately. The survey identified that the demolition activities can generate respirable crystalline silica dust at the new DFRC site (formerly, the Badger Army Ammunition Project (BAAP) area).

Contaminated soils shall be managed and disposed of in accordance with the following specifications:

• 02 41 00 Demolition and Deconstruction

• 02 56 13.16 Clay Waste Containment

In the event any additional suspected hazardous materials are encountered during the demolition activities, work on those materials must stop immediately and remain undisturbed until testing confirms the presence or absence of asbestos or other hazardous material.

4.0 SPECIFICATION CONSIDERATIONS

• Seismic bracing requirements for non-structural components are specified in the contract documents such as in the spec section, 23 05 48.00, VIBRATION AND SEISMIC CONTROLS

FOR HVAC PIPING AND EQUIPMENT.

• The fire suppression specification is performance-based, which is standard for the industry.

• Specifications/submittals to be reviewed by the AE (if applicable) including the extensions of design submittals, such as:

o Precast architectural concrete drawings and calculations.

o Miscellaneous metal fabrication drawings, ladders, stairs, and associated calculations.

5.0 PERMIT/ UTILITY INFORMATION

5.1 Permits

• The A-E is responsible for preparing applications for all Storm Water Management, Erosion and Sediment Control, and National Pollutant Discharge Elimination System (NPDES) permits from the appropriate Authority Having Jurisdiction (AHJ).

• Please refer to the Design Analysis Report, Section 2M, Permit, for construction and operating permits required by the project known at the 95% design phase, including a list of each utility and the utility companies providing the service, and a point of contact (POC) at the company.

Prairie du Sac, Wisconsin

Contract Number W9128F21C0023

• The contractor is responsible for obtaining the construction, operating and utility permits and training to comply with all federal, state, and local regulatory requirements. The contractor will evaluate all state and/or local regulations to determine if monitoring devices are needed, involving any operating permits.

6.0 QUALITY ASSURANCE (QA)

• Cantilever retaining walls were designed in both the Solid Stack Building (C2) and Solids/Sand

Separation Facility (C3). Inspect vertical bars and dowel bars in the cantilever walls to verify bars are placed in the correct face of the wall and within the placement tolerances as specified in specification 03 30 00. Correct placement of vertical bars and dowel bars is imperative to the functionality of these walls.

• Waterstops will be installed in the Liquid Storage Cell Liners (C1), Solid Stack Building (C2), and Solids/Sand Separation facility (C3) to provide water-tightness of these structures.

Waterstops shall be submitted to the EOR for approval prior to ordering.

• Verify that all waterstops in the Liquid Storage Cell Liners, Solid Stack Building (C2) and Solids/Sand Separation Facility (C3) are installed per the manufacturer’s recommendations (i.e joints and intersections welded for PVC type, positioned correctly at slab wall interfaces, etc.) to form a continuous watertight seal.

• Verify that waterstops or mechanical joints have been properly installed around all pipe penetrations through waste storage walls, slabs, concrete liners, and lift stations.

• A constant slope shall be maintained on the sand lanes within the Solids/Sand Separation Facility (C3) to ensure there are no low spots that allow water to collect or pond.

• Contractor shall field verify that all manure system pipes are constructed to the lines and grades as shown on the construction plans.

• Cast-In- Place anchor bolts for the Solid Stack Building (C2) shall be secured in place and their location and embedment verified prior to pouring the concrete walls and piers.

7.0 ADVERTISEMENT

To be completed by USACE NWO once that process and schedule are determined.

8.0 DESIGN/BUILD ROLES AND RESPONSIBILITIES FOR ENGINEERING DIVISION

Not applicable; this is a design-bid-build project.