WVA B. 110 Phase 1 Repairs D-B RFP - Final - Field Report (App F).pdf

Department of the Army

New York District

Corps of Engineers

26 Federal Plaza, RM 16-300

New York, NY 10278-0090

FY25 PN 106580 Building 110 Repairs – D-B RFP Phase 1

Watervliet, New York

U.S. Army Corps of Engineers, New York District

Contract No.: W912DS19D0012

Order No.: W912DS24F0100

Final Design-Build Request for Proposal

Appendix F Field Investigation Report

April 2025

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DEPARTMENT OF THE ARMY

NEW YORK DISTRICT, CORPS OF ENGINEERS

NEW YORK, NY

FIELD INVESTIGATION REPORT

Recapitalization of Building 110

Watervliet Arsenal, New York

Contract No.: W912DS19D0012 Task Order No.: W912DS23F0097

December 2023

408.009.001 - Watervliet B. 110 Recapitalization Study 1 December 2023 Field Investigation Report Watervliet, NY

TABLE OF CONTENTS

SECTION PAGE

CERTIFICATION OF BASIC AND INDEPENDENT TECHNICAL REVIEW 4

1.0 INTRODUCTION 5

2.0 LIFE SAFETY 6

2.1 Summary of Existing Conditions 6

2.1.1 Building Type and Occupancy Separation 6

2.1.2 Crane Cabs and Platforms 6

2.1.3 Fixed Ladders 7

2.1.4 Upper Level Areas 7

2.1.5 Pits 7

2.1.6 Construction Separations 7

2.1.7 Other 8

2.2 Applicable Codes and Design Criteria 8

2.3 Recommendations 9

3.0 HAZARDOUS MATERIALS 11

3.1 Findings 11

3.1.1 Findings - Asbestos 11

3.1.2 Findings - Lead 12

3.1.3 Findings - Metals 13

3.1.4 Findings - PCBs 13

3.1.5 Findings - Radon Assessment 13

3.2 Recommendations 13

3.2.1 Recommendations - Asbestos 13

3.2.2 Recommendations - Lead Based Paint 13

3.2.3 Recommendations - Metals 14

3.2.4 Recommendations - PCBs 14

3.2.5 Recommendations - Radon 14

4.0 ARCHITECTURAL 15

4.1 Summary of Existing Conditions 15

4.1.1 History 15

4.1.2 Accessibility 15

4.1.3 Building Envelope 16

4.1.4 Interior Spaces 17

4.1.5 Physical Security 18

4.1.6 Built-In Equipment 18

4.2 Applicable Codes and Design Criteria 19

408.009.001 - Watervliet B. 110 Recapitalization Study 2 December 2023 Building Assessment Report Watervliet, NY

4.3 Recommendations

5.0 STRUCTURAL

5.1 Summary of Existing Conditions

5.1.1 History

5.1.2 Masonry description

5.1.3 Existing Structural Systems

5.1.3.1 Gravity Framing

5.1.3.2 Lateral Framing

5.1.3.3 Foundations

5.1.4 Existing Condition Assessment

5.1.4.1 Brick

5.1.4.2 Cast Stone and Concrete Sills

5.1.4.3 Wood

5.1.4.4 Steel

5.1.4.5 Concrete Masonry Units

5.1.4.6 Foundation Pit

5.2 Applicable Codes and Design Criteria

5.3 Recommendations

6.0 MECHANICAL

6.1 Summary of Existing Conditions

6.2 Applicable Codes and Design Criteria

6.3 Recommendations

7.0 PLUMBING

7.1 Summary of Existing Conditions

7.2 Applicable Codes and Design Criteria

7.3 Recommendations

8.0 ELECTRICAL

8.1 Summary of Existing Conditions

8.1.1 Electrical Service Entrance Power

8.1.2 Electrical Distribution Power

8.1.3 Electrical Fire Pump Power

8.1.4 Lighting

8.1.5 Telecommunications

Colby Company

Engineering

3 December 2023

8.2 Applicable Codes and Design Criteria

8.3 Recommendations

9.0 FIRE PROTECTION

9.1 Summary of Existing Conditions

9.1.1 Existing Automatic Wet Pipe Fire Sprinkler Systems

9.1.2 Existing Preaction Fire Sprinkler Systems

9.1.3 Flammable Liquid Storage Container Fire Suppression System

9.1.4 Existing Manual Dry Standpipe System

9.1.5 Existing Automatic Fire Pumps

9.1.6 Historic Flow Test Data

9.1.7 Existing Fire Alarm System

9.2 Applicable Codes and Design Criteria

9.3 Recommendations

9.3.1 Fire Alarm

9.3.2 Mass Notification System

9.3.3 Fire Protection

9.3.4 Fire Rated Construction

9.4.1 Fire Alarm

9.4.2 Fire Protection

10.0 CIVIL

10.1 Summary of Existing Conditions

10.2 Applicable Codes and Design Criteria

10.3 Recommendations

Colby Company

APPENDICES

Appendix A - Photos Appendix B - Existing Floor Plans Appendix C - Hazardous Materials Report Appendix D - Action Item List Appendix E - Utility CCTV Report

408.009.001 - Watervliet B. 110 Recapitalization Study

Watervliet, NY

408.009.001 - Watervliet B. 110 Recapitalization Study 4 December 2023 Building Assessment Report Watervliet, NY

CERTIFICATION OF BASIC AND INDEPENDENT TECHNICAL REVIEW

We, the undersigned, certify that all aspects of this submittal have undergone technical reviews to ensure that they fully meet the prescribed requirements and expectations of all project sponsors and customers and comply with laws, regulations, and sound technical practices of the disciplines involved.

Reviewed and Concurred by:

Ben Townsend

Project Manager

408.009.001 - Watervliet B. 110 Recapitalization Study 5 December 2023 Building Assessment Report Watervliet, NY

1.0 INTRODUCTION

Colby Company Engineering (CCE) has prepared this Field Investigation Report in support of the Recapitalization of Building 110 at the Watervliet Arsenal in New York.

The original construction of Building 110 Big Gun Shop (originally Sea Coast Gun Shop) occurred in 1888‐ 1892, with subsequent additions from 1917 to 1941. Building 110 is a 213,799 square foot industrial and manufacturing building. It hosts numerous manufacturing processes in a partial 2‐story, red brick, modified rectangular plan, 1245 feet in length, and 125 feet wide (except where widened by 1‐story, brick annexes).

Recent exterior improvements include roofing, fenestration and doors on the East and West elevations, which completed construction in 2015. Subsequently, fenestration and doors along the North and South elevations were replaced, completing construction around 2020. Additional recent improvements include a new fire suppression system including fire pumps, replacement of all lighting fixtures throughout and associated wiring leading to and from the lighting panels, as well as exhaust fans and wiring, and lighting load center(s).

This report constitutes the Field Investigation Report which includes the following items:

● Review of Existing As-Built Drawings and On-Site Field Verification of Existing Conditions.

● Photos of the existing conditions and spaces are contained in Appendix A.

● Existing Drawings of Building 110 are contained in Appendix B.

● The Hazardous Materials Report is contained in Appendix C.

● A utility CCTV survey was completed and results are contained in Appendix D.

● Building conditions and known deficiencies noted in the Statement of Work (SoW) are summarized with a narrative of the condition noted, and recommended corrective measures.

● This assessment report is separated by discipline.

The following additional investigations are planned to be completed:

● Thermal Roof Scan Completed via Drone

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2.0 LIFE SAFETY

2.1 Summary of Existing Conditions

The building within this project consists of a base-scope for a mixed-use non-separated three-story building. The occupancies on each floor are as follows:

● First Floor

○ Moderate Hazard Factory Industrial / Group F-1

○ Business / Group B

○ Low Hazard Storage / Group S-2

● Second Floor

○ Business/ Group B

● Third Floor

○ Business/ Group B

A Fire Protection Risk and Safety Assessment was previously conducted by CCE in February of 2020. The objective of that project was to provide engineering surveys, review of existing documentation, and develop recommendations for the repairs and/or replacements to roof fall protection, crane cabs/platforms, and fixed ladders for code compliance and safety. The CCE team conducted site visits during the week of October 21, 2019; and it was observed that the recommendations in the final report had not been implemented as of CCE’s October and November 2023 site visits. CCE’s 2023 field investigations are the basis for this updated life safety review.

The main concerns that were most prevalent during on site investigations were ladder clearances, lack of roof fall protection where required, deteriorating wooden crane access platforms, inadequate crane cab fall protection, and unprotected stair enclosures. Colby Company was not able to analyze the shrinking pits below the manufacturing floor.

2.1.1 Building Type and Occupancy Separation

The existing building is Type IIIB/unprotected combustible construction and is classified as a single-use building with accessory business and storage uses. Maximum allowable Quantities (MAQ) of hazardous materials will be reviewed in preparation for the design charrette. Compressed gas cylinders are required to be secured to prevent them from falling or being knocked over, and should be secured against accidental dislodgement and against access by unauthorized personnel.

2.1.2 Crane Cabs and Platforms

Building 110 is equipped with five 60-ton cranes, two 15-ton cranes, and four 10 ton cranes. The majority of these cranes are accessed via wooden catwalks which were observed to be deteriorating in several instances, causing a safety concern. The crane cab railings differ in height but many of them have a top railing of 35” which conflicts with NFPA 101 section 7.2.2.4, which states railings shall be 42”.

There is a lower and high-level catwalk that spans the entire length of Building 110. The lower catwalk is constructed of wood, and the high catwalk consists of steel construction. There are multiple access points to these catwalks throughout the building. Some of these access points have fixed ladders, but most of them have a set of wooden stairs leading to the lower catwalk, and then steel stairs to the high catwalk. To access the high cranes, personnel have to climb over the high catwalk railing and onto the crane. There is no OSHA standard that addresses this scenario directly, however it poses a safety risk because the personnel could fall over the edge of the railing. The crane catwalks are made of deteriorating wood as well.

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2.1.3 Fixed Ladders

Thirty-two fixed ladders were observed throughout Building 110. Approximately ten of these ladders provide access to the lower and high catwalks that span the length of the building. All of the gantry access platform ladders appear to be code compliant. The other twenty ladders access mechanical platforms, and catwalks located up near the ceiling of the building in the center high bay. Four of these ladders do not meet the OSHA required 7” toe side clearance distance and three of them have objects obstructing the ladders that did not meet OSHA requirements. Lastly, there are five ladders that are damaged at the bottom, likely due to a fork truck or crane load colliding with them. There are also columns that were damaged in a similar way.

2.1.4 Upper Level Areas

The stair up to the second floor offices on the west side of the building is not enclosed, though it is intended for use as an egress stair. Also, located on the second floor in this area is a door at the end of the corridor which locks automatically, preventing reentry and egress during an emergency. Lastly, the second floor IT/Communication Room is provided with two doors that require traversing through adjacent office spaces in order to access the exit access corridor.

The stair up the second floor spaces on the east side of the building is constructed of wood, is unenclosed, and does not comply with NFPA 101 requirements for existing stairs. Access up to the third floor level from this area is via a non-conforming, metal, spiral staircase. These second and third floor spaces have been abandoned in their current condition due to safety concerns such as code non-compliant egress and fall hazards. Fall hazards include open floor penetrations, gaps between the floor and wall/window glazing, and missing platform guardrails.

2.1.5 Pits

Condensate pit grating and guardrails throughout the building are in disrepair. The life safety conditions of the existing shrinking pits were not observed at the time of CCE’s site visits.

2.1.6 Construction Separations

The North Sprinkler Pump room 101A and South Sprinkler Pump room 104 are required to be constructed as one hour fire rated rooms (UFC 3-600-01, section 9-5.1.2; NFPA 20, Table 4.14.1.1.2). The doors are labeled as 90 minute fire doors, which is consistent with a two hour fire rating. However, there are firestopping issues which must be addressed at the head of wall joints, and through penetrations. Domestic water equipment and pipework to the adjacent janitor's closet room 103 is present within the South Sprinkler Pump room 104, as permitted by NFPA 20, section 4.14.1. No storage, other equipment or penetrations unrelated to the fire pump equipment are permitted within the fire pump rooms (NFPA 20, section 4.14.1.1.6).

There are three substations, North 2A2 (West bays 2-3), Central 1A3 (West bays 21-25, and external) and South 2B1 (West bays 60-64, which is understood to be relocating as part of a separate project). North 2A2 and South 2B1 substations are dedicated electrical spaces separated from adjacent areas with locked fences, with 6 foot clearance above equipment or to suspended ceiling in accordance with NFPA 70, section 110.26(E)(1) and horizontal clearance in accordance with NFPA 70, Table 110.34(A). However, protection from overhead wet piping is required to prevent leaking or broken pipes from causing electrical hazards. Locked, fenced-in areas are permitted, which restrict access to qualified personnel, in accordance with NFPA 70, section 110.31 and 110.34(C). Central substation 1A3 is partially located external to the building and internally switchboards, switchgear, UPS transformer and panelboards are located in combined storage areas with temporary walls with locks. Working spaces are required to be clear of storage, in accordance with NFPA 70, section 110.26(B).

Transformers require fire rated construction separations as outlined in NFPA section 450, based on transformer type and construction. For example, dry-type transformers not greater than 35,000 volts, with Class 155 or

408.009.001 - Watervliet B. 110 Recapitalization Study 8 December 2023 Building Assessment Report Watervliet, NY higher insulation systems and separated from combustible materials by a fire resistant, heat-insulating barrier or by not less than 6 feet horizontally and 12 feet vertically, or where completely enclosed except for ventilating openings, are not required to be installed in a separate fire rated transformer room (NFPA 70, section 450.21(B)). FM DS 5-4 would permit FM approved transformers to be installed in rooms with noncombustible enclosures.

Telecommunications/IT/UPS room 138 and 138A are not fully fire separated from adjacent areas. The ceiling, one door and portions of the wall enclosure are not fire rated, and the ceiling has combustible elements of construction. Cabling is also being run to an adjacent room above a portion of room 138, which is not fire rated.

NFPA 75 would require one hour fire rated separation for Information Technology Equipment rooms (NFPA 75, section 6.1.3.2). NFPA 76 would require two hour fire rated separation for Telecommunications Facilities in multiple tenant buildings (NFPA 76, section 6.1.4.2). Internal separations depending on the types of telecommunications signal processing equipment, cable entrance areas, power equipment, battery systems may also be required depending on the critical nature of the equipment and data (NFPA 76, chapter 6). The Uninterrupted Power Supply (UPS) system is permitted within the same room as the equipment it supports (NFPA 855, section 9.5.1.2.1.1). Rooms containing energy storage systems must be separated from other areas of the building by two hour fire separation (NFPA 855, section 9.6.4).

2.1.7 Other

There is an exterior door adjacent to Break Room #139, that discharges directly out to a courtyard containing high voltage electrical equipment. Exit signage between Storage Rooms #133 and #141 is misleading, and suggests that this exterior door is intended for egress, while the door itself is labeled “NOT AN EXIT”.

Penetration firestopping is not installed at all wall penetrations into Sprinkler Pump Rooms #101A and #104.

2.2 Applicable Codes and Design Criteria

The following are references to applicable Codes Standards. UFC 1-200-01 Section 1 describes the order by which guidance takes precedence in the instance of a conflict. The Standard Design Development Guide has ultimate precedence in the event of a conflict. The applicable edition of each code or standard will be determined based on project milestone dates as required by UFC 1-200-1, Section 1-3.1.

● NANP-1110-1-1, US Army Corps of Engineers, New York District (NAN) Manual of Standard Procedures for Planning and Design, August 2009

● COE Engineering Regulations, Manuals, Engineering Technical Letters (ETL) and Pamphlets (current editions)

● Engineering and Construction Bulletin 2004-05, Mass Notification Systems in Military Construction Projects

● Watervliet Installation Planning Standards, May 2017

● Watervliet Arsenal Installation Design Guide, 2009

● Watervliet Arsenal Real Property Master Plan Long Range Component, October 2015 Information

Processing Center DA PAM 415-28

● Information Systems Processing Center DA PAM 415-28

● Echelons Above Brigade (EAB), Command and Control Facility DA PAM 415-28 General Instruction

Building DA PAM 415-28

● Occupational Safety and Health Administration (OSHA) Standards, EM 385-1-1 International Standard

Plumbing Code

● National Institute of Occupational Safety and Health (NIOSH) Standards EM 1110-1-1002, Survey

Markers & Monumentation

● EM 385-1-1, U.S. Army COE Safety and Health Requirements Manual

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● Applicable Occupational Safety and Health Administration (OSHA) Safety and Health Standards

● TIA/EIA-569-B

● Information Infrastructure Architecture (I3A) Technical Guide

● Army Regulation AR 405-70, Utilization of Real Property

● UFC 1-200-01, DoD Building Code, With Change 2, 06/12/2023

● UFC 3-600-01, Fire Protection Engineering for Facilities, With Change 6, 05/06/2021

● UFC 3-601-02, Fire Protection System Inspection, Testing and Maintenance, 10/07/2021

● UFC 4-010-01, DoD Minimum Antiterrorism Standards for Buildings, With Change 2, 07/30/2022

● UFC 4-171-05, Design: Guide for Army Reserve Facilities, With Change 3, 01/01/2005

● UFC 4-022-01, Security Engineering: Entry Control Facilities / Access Control Points, 07/27/2017

● UFC 4-023-03, Progressive Collapse, With Change 3, 11/01/2016

● IBC, International Building Code, 2021

● IEBC, International Existing Building Code, 2021

● NFPA 1, Fire Code, 2024

● NFPA 10, Standard for Portable Fire Extinguishers, 2022

● NFPA 13, Standard for the Installation of Sprinkler Systems, 2022

● NFPA 14, Standard for the Installation of Standpipe and Hose Systems, 2024

● NFPA 20, Standard for the Installation of Stationary Pumps for Fire Protection, 2022

● NFPA 24, Standard for the Installation of Private Fire Service Mains and Their Appurtenances, 2022

● NFPA 25, Standard for the Inspection, Testing and Maintenance of Water-Based Fire Protection

Systems, 2023

● NFPA 30, Flammable and Combustible Liquids Code, 2024

● NFPA 33, Standard for Spray Application Using Flammable or Combustible Materials, 2021

● NFPA 70, National Electrical Code, 2023

● NFPA 72, National Fire Alarm and Signaling Code, 2022

● NFPA 75, Standard for the Fire Protection of Information Technology Equipment, 2020

● NFPA 76, Standard for the Fire Protection of Telecommunications Facilities, 2020

● NFPA 90A, Standard for the Installation of Air-Conditioning and Ventilating Systems, 2024

● NFPA 91, Standard for Exhaust Systems for Air Conveying of Vapors, Gasses, Mists, and Particulate

Solids, 2020

● NFPA 101, Life Safety Code, 2024

● NFPA 170, Standard for Fire Safety and Emergency Symbols, 2024

● NFPA 241, Standard for Safeguarding Construction, Alteration, and Demolition Operations, 2022

● NFPA 291, Recommended Practice for Fire Flow Testing and Marking of Hydrants, 2022

● NFPA 850, Recommended Practice for Fire Protection for Electric Generating Plants and High Voltage

Direct Current Converter Stations, 2020

● NFPA 855, Standard for the Installation of Stationary Energy Storage Systems, 2023

● FM Global Data Sheet 5-4

2.3 Recommendations

● All wooden catwalks and gantry crane platforms should be replaced with steel grating.

● A new top rail should be welded onto the crane cab railings, meeting OSHA requirements.

● Damaged ladders should be replaced with new steel ladders and all obstructions should be removed.

Additional consideration should be given to replacement and reconfiguring existing ladders such that the OSHA required clearances are met.

● Demolish the existing wood stairs up to the second level on the east side of the building. The existing metal spiral staircase may be required to remain abandoned in place due to it contributing to the historic nature of the building. Reconstruct a new code compliant staircase and one-hour rated exit enclosure from the upper levels.

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● Renovation will modify the floor plan to enclose the existing second floor stair at the west end of the building with 1-hr rated construction. Provide rated exit access doors and frames and code compliant exit hardware.

● Programmatic renovations to provide additional break room spaces, rework existing storage spaces, and access/fit out second level areas will trigger a Level 2 Alteration per IEBC and Modification requirements per NFPA and the UFC. For the design charrette report, exit circulation will be reviewed and paths of travel may need to be modified to maintain under the maximum travel distance requirements required by code.

● Determination of how the exit and upper level exit access stairs will be enclosed and fire rated, per code, will be determined as part of the new floor plan and programming effort for the design charrette report.

● Firestop all penetrations into 1-hour rated Fire Sprinkler Pump Rooms #101A and #104.

● Provide 2-hour fire rated construction for the IT/telecommunications/UPS rooms 138 and 138A: fire rated doors, fire rated ceiling, and fire rated doors and enclosure of the second floor telecom room above.

● If required based on transformer types, provide fire rated construction separations. Ongoing relocation project and scope to be discussed at design charette.

● Remove all existing misleading or abandoned in place life safety and hazard signage. Replace any faded or paper signage with permanent fixed signage.

● Infill pits.

● Replace condensate pit grating, guardrails, and signage throughout the building. Restripe perimeter of pits after necessary slab repairs.

● Provide appropriate Exit signage at all exit doors.

● Provide appropriate signage identifying fire extinguisher locations.

● Update floor markings separating walking paths from work areas, where programming has changed.

● Clear working spaces of storage around electrical equipment as required by NFPA 70.

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3.0 HAZARDOUS MATERIALS

3.1 Findings

A hazardous materials survey was conducted on October 16, 2023 through October 19, 2023 for asbestos-containing materials (ACM), lead-based paint (LBP), PCB sampling, materials sampling, and radon sampling.

The hazardous material reports are included in Appendix C.

3.1.1 Findings - Asbestos

The laboratory analytical results of the bulk samples collected during this survey found asbestos at greater than (>) 1 percent (%) present in the following building materials, which were determined to be ACMs:

● HA-64; White transite backer board, Crane Repair Shop, 10 square feet.

● HA-67 and HA-68; 12” Gray floor tile and associated mastic, underneath flammable locker 3 area, 280 square feet.

Previous survey findings (confirmed and/or assumed to be positive)

● HA-2: White/Gray Mudded Fitting Insulation Associated with 1-6” Pipelines.

● HA-3: Gray Cloth Wrap on 1-6” Pipelines.

● HA-4: White/Gray Mag Insulation Associated with 1-6” Pipelines.

● HA-5: Gray/White Mudded Fitting Insulation Associated with 1-6” Fiberglass Pipeline

● HA-7: Gray Cloth Wrap on 13-24” Mag Insulation Pipeline

● HA-8: Mudded Fitting Insulation Associated with 13-24” Mag Insulation Pipeline

● HA-9: Gray/White Mag Insulation Associated with 13-24” Pipelines.

● HA-14: Yellow Wrap Over Mag Insulation on 1-6” and 7-12” Pipelines.

● HA-15: Mag Insulation Associated with 1-6” and 7-12” Pipelines.

● HA-16: Mudded Fitting Insulation Associated with HA-15 (Assumed ACM)

● HA-17: Floor Expansion Joint Caulk

● HA-23: Gray HVAC Duct Caulk

● HA-24: 12” Black and Brown Patterned Floor Tile

● HA-25: Black Mastic Associated with HA-24

● HA-28: 1”x 2” Patterned Ceramic Floor Tile Adhesive (Assumed ACM)

● HA-30: Beige/Gray Mastic Associated with 12” Light Gray Floor Tile (Assumed ACM)

● HA-32: 12” Orange Floor Tile

● HA-33: Black Mastic Associated with HA-32

● HA-35: Adhesive Associated with 1” x 1” Ceramic Floor Tile

● HA-41: Black Mastic Associated with 12” White with Gray Streaks Floor Tile

● HA-51: Exterior Window Caulking (North/Entrance)

● HA-56: Gray/White Exterior Window Caulk at Bottom and Sides (South Side)

● HA-57: Exterior White Window Glazing (South Side)

● HA-60: White Window Glazing Associated with Small 4’ x 5’ Windows (West Side)

● HA-61: Electrical Components/Wire Wrap (Assumed ACM)

● HA-62: Flange Gasket Insulation (Assumed ACM)

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● HA-63: Roofing Systems (Assumed ACM)

The following HA has been determined to be contaminated with asbestos and should be managed as ACM:

● HA-1: Brown Dip Lag on 1-6” and 13-24” Pipeline.

● HA-40: 12” White with Gray Streaks Floor Tile

The following HAs had been determined to contain trace amounts of asbestos, i.e., one percent or less (1% or <1%) by laboratory analysis and their disturbance is regulated by OSHA:

● HA-23: Gray HVAC Duct caulk.

3.1.2 Findings - Lead

A total of eight paint samples were collected and submitted for lead content analysis. The following paint/coating contained detectable quantities of lead:

● L-04: Yellow paint on metal lockers

● L-08: Off white paint on metal railing

● L-09: Black paint on metal stair riser

Previous survey findings:

● LP-1: Beige Paint on Brick Wall

● LP-2: Gray Paint on Wood Floor

● LP-3: Gray Paint on Wood Ceiling Deck

● LP-4: Green Paint on Brick Wall

● LP-6: Yellow Paint on Concrete Floor

● LP-7: Blue Paint on Wood Exterior Door

● L001: Green paint on Brick Wall

● L002: Tan Paint on Brick Wall

● L003: Green Paint on Metal Column

● L004: Silver Paint on Metal Column

● L005: Silver Paint on Metal Column

● L006: Green Paint on Metal Column

● L008: Green Paint on Brick Wall

● L009: Tan Paint on Brick Wall

● L011: Green Paint on Brick Wall

● L012: Tan Paint on Brick Wall

● L013: Yellow Paint on Concrete Floor

● L014: White Paint on Wood Ceiling

● L015: Tan Paint on Brick Wall

● L016: Tan Paint on Brick Wall

● L017: Beige Paint on Brick Wall

● L018: Green Paint on Brick Wall

● L020: Tan Paint on Brick Wall

● L021: Green Paint on Brick Wall

● L022: Green Paint on Wood Door

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3.1.3 Findings - Metals

Five out of the seven wipe samples analyzed for hexavalent chromium had detectable concentrations of hexavalent chromium ranging in value from 0.13 µg/100cm2 to 0.32 µg/100cm2 – all of which exceed the housekeeping target level of 0.05 µg/100cm2. Mercury and Silver was not detected in any of the collected samples.

3.1.4 Findings - PCBs

Analytical results show that the caulking from the samples collected did not contain PCBs above the 40 CFR 761.62 limit of 50 mg/kg to be considered a bulk product waste (definition provided in 40 CFR 761.3).

3.1.5 Findings - Radon Assessment

As presented in Appendix C, the radon sample laboratory results indicated concentrations of radon in all locations sampled to be less than 4 picocuries per liter. EPA recommends remedial efforts be employed if radon levels are found to be greater than or equal to 4.0 picocuries per liter.

3.2 Recommendations

3.2.1 Recommendations - Asbestos

As presented in Table 1, in Appendix C the asbestos survey confirmed the presence of ACM (materials classified as containing> 1% asbestos) at the building surveyed. Current USEPA NESHAP regulations require that all Regulated ACM (RACM) be removed prior to being disturbed. RACM are defined as:

● Friable ACM.

● Category I non-friable ACM that has become friable.

● Category I non-friable ACM that has been or will be subjected to sanding, abrading, grinding, or cutting.

● Category II non-friable ACM that has a high probability of becoming friable or crumbled, pulverized, or otherwise reduced to powder by demolition or renovation activities.

● Additionally, materials were determined to contain asbestos below 1% and are regulated for the purposes of worker protection by the Occupational health and Safety Administration (OSHA):

ACM identified that may be disturbed during renovation and/or demolition activities must be removed by a licensed asbestos abatement contractor utilizing industry standard work procedures in accordance with all federal, state, and local regulations governing asbestos.

3.2.2 Recommendations - Lead Based Paint

As presented in Table 2 and 2A, in Appendix C, LBP was identified at the site. In the event of renovations that will disturb these painted surfaces, it is recommended that the general contractor and any subcontractors be advised of the presence of LBP and the requirements for compliance with the OSHA Lead in Construction standard.

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Any work that could disturb a known or suspected LBP should be conducted in such a way to minimize and control dust, including a thorough clean up by the contractor.

3.2.3 Recommendations - Metals

Any demolition must account for the presence of hexavalent chromium and other metals on surfaces and the appropriate precautions should be implemented by OSHA/NIOSH guidance. Cleaning should be conducted using a combination of hand methods, mechanical brushing, HEPA vacuums, and pressure washers, as applicable. Engineering controls should be implemented to control potential dust hazards prior to the start of cleaning activities. Staff should use designated decontamination areas and points of ingress/egress.

3.2.4 Recommendations - PCBs

No recommendations are warranted as these materials can be disposed of at an approved facility that accepts this waste.

3.2.5 Recommendations - Radon

All radon samples were analyzed and found to be below the EPA action level recommended for mitigation procedures of <4.0 picocuries per liter. Radon sampling procedures are recommended to be conducted on an annual basis to assure radon levels remain below the EPA recommended action level.

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4.0 ARCHITECTURAL

4.1 Summary of Existing Conditions

As previously mentioned, Building 110 Big Gun Shop is a 213,799 square foot industrial and manufacturing building, hosting numerous manufacturing processes in a partial 2‐story, red brick, modified rectangular plan.

Ceilings in production areas are open to the underside of roof structure with top of roofs ranging from 35 to 117 feet high. The main interior production room includes a bridge crane on an independent structural steel frame extending the length of the building. The center of the building contains a high central bay, a former shrink pit and rail access into the building. The lower ceiling annexes have overhead cranes running in portions of the spaces. A small two-story area occurs toward the center on the west side of B110 and houses IT/Communications equipment in a secured server room on the first floor, break room on the first floor, and offices on the second floor. Materials and finishes are typical of office space including painted gypsum drywall partitions, carpeting, vinyl tile and suspended acoustical ceilings. The second-floor offices are accessed by a single stair and are not currently occupied. A small three-story area occurs in the center and on the east side of B110.

Observed architectural deficiencies which are further described below include, but are not limited to: masonry and mortar, water intrusion at abandoned pit(s), exterior doors, overhead coiling doors, security systems, asbestos and lead based paint, floor surfaces and concrete slabs at select locations, and wooden platforms/catwalks throughout the facility. Some windows also had failing sealant around the perimeters and were lacking weeps in the sill sealant. (Some sills had no sill sealant altogether and you could see up under the window frame). There is also suspected deterioration of the roof deck at select locations. Additional deficiencies include underutilized spaces which the user would like to program. Refer to the Life Safety section for additional findings and recommendations. The ultimate goal is to recapitalize the building and associated building systems to achieve a 40-year lifespan.

4.1.1 History

Building 110, historically known as the Seacoast Cannon Shop, consists of three sections: the north wing, the central bay, and the south wing. The north wing, 400 feet long, was completed in 1890, as was the 166-foot long central section. The south wing was completed in 1893. The total length of the building, including a World War One addition, is 1,245 feet. Subsequent annex additions were constructed from 1917 to 1941, widening the building to 125 feet. The building is qualified as contributing to the historic Watervliet Arsenal district listed on the National Register of Historic Places.

The two major wings of the building were designed to house the various lathes, borers, and other tools used on gun construction, while the higher central section contained the boiler house, engine room with a shrinkage pit fifty feet deep, offices and tool room. The building is still actively utilized for repairing and producing large guns, although expansions and revisions have been made to cope with the advances of technology. For example, the shrinkage pit was deepened an additional 40 feet less than twenty years after its construction.

Recent exterior improvements include replaced roofing, as well as fenestration and doors on the east and west elevations, completing construction in 2015. Subsequently, fenestration and doors along the North and South elevations were replaced, with construction finishing in 2020. Restrooms and locker rooms were renovated and a new sprinkler pump room was created on the north end of the building as well at this time.

4.1.2 Accessibility

Since Building 110 qualifies as a historic building, accessibility upgrades may be limited according to ABAAS, where the State Historic Preservation Officer or Advisory Council on Historic Preservation determines that

408.009.001 - Watervliet B. 110 Recapitalization Study 16 December 2023 Building Assessment Report Watervliet, NY compliance with the requirements for accessible routes, entrances, or toilet facilities would threaten or destroy the historic significance of the building or facility, the exceptions for alterations to qualified historic buildings or facilities for that element shall be permitted to apply. Where recommended programmatic alterations will occur, the path of travel to the altered area, including rest rooms and drinking fountains serving the altered area, will be updated to be accessible to and usable by individuals with disabilities, unless such alterations are disproportionate to the overall alterations in terms of cost and scope as determined under criteria established.

Accessible means of egress currently exists via several man doors surrounding the perimeter of the building.

Within existing Tenant Space #160, there is a section of built-up plywood flooring that exceeds 1/4" without treatment. Changes in level can be up to 1/4” without treatment or 1/2” if beveled with a slope no steeper than 1:2.

The existing restrooms and locker rooms were recently renovated in 2019, and were generally observed to be barrier-free. Existing drinking fountains are not accessible and should be replaced with compliant fixtures, quantified based on the building occupant counts.

Two-way communication will be required at upper level stair locations prior to occupancy. Door hardware replacements are required to be Architectural Barriers Act (ABA) compliant.

4.1.3 Building Envelope

Exterior walls consist of uninsulated, multi-wythe brick construction, painted on the interior. A green colored paint is typically utilized as a wainscotting around the interior perimeter, with cream colored coating above.

Results of hazardous materials testing, including lead and asbestos, are summarized in Section 3.0. The brickwork was observed to be deteriorated in many areas of the building, both on the exterior and interior. There were several open holes and unsealed penetrations found in the exterior walls, with significant heat loss visible with infrared imagery. Refer to the structural section for additional masonry conditions and recommendations.

Large arching windows at each structural bay flank the west and east sides of the building, and the south and north facades are predominated by floor to ceiling, arched fenestration. Each window opening is provided with a formed concrete window sill, which is detailed with kerf cuts and sloped end dams to promote drainage. Many of the original concrete sills appear to have been replaced at various times, however some of the original sills do remain and are showing signs of deterioration. The original concrete sills do not appear to be thermally broken, based on infrared imagery. Several of the original window openings on the facade of the west annex have been infilled with a painted plywood bead board. The paint at these locations is chipping and showing significant signs of wear.

Windows throughout the building were recently replaced using a multi-year, multi-phased approach starting around 2015 and ending construction in 2023. Fenestration consists of aluminum framing with operable awning windows at the south, east, and west facades. Large double hung windows are located on the north facade.

Single-pane laminated glazing is installed where there is a 25 meter standoff from the building, in accordance with AT/FP requirements. The remaining windows consist of thermally broken, double-pane glazing. Heat loss in the heating season as well as security concerns exist due to manual window operation. Drawings for the recent window replacements, dated 7/31/2019, depict different head, sill, and jamb details than were observed during CCE’s 2023 site visits. It appears that the new windows were installed without the use of wood bucks, as intended in the design documents. Additionally, several window openings on the east side of the building were missing a single course of brickwork around the entire window perimeter. It is assumed that this brickwork was removed to facilitate the window installation at those locations, but the missing inner course is negatively impacting the thermal performance of the mass wall surrounding the window openings.

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Several coiling overhead doors and metal exit doors surround the perimeter of the building. Generally, all man doors appear to be at the end of their useful service life, with the exception of those replaced with the 2019 window replacement project. This includes bi-parting doors on the north elevation, which are a modern equivalent in order to visually match the original historic doors. Significant heat loss was typically visible at aluminum framed transoms above exterior doors. Several of the overhead doors, specifically at the south end of the building, have dented and bent panel sections. Historic railway tracks run under the overhead doors near the central section of the building, which prevent the overhead door sill gaskets from sealing the building envelope at the slab. The overhead door sill at Bay 39 consists of metal grating, which is damaged and bent.

The south and north exterior walls at the center section of the building are clad in corrugated metal siding. The coating on the metal siding is significantly worn. The north wall has a large rectangular expanse of glazing. A catwalk was visible below this window opening, with no visible access ladder. Insulation levels are unknown at these upper walls, but assumed to be negligent based on thermal imaging. A parge coating which appeared to be cementitious coats the interior of the north wall. Lathe ties could be seen supported from the metal framing beyond. The corrugated metal siding appeared to be directly attached to the metal framing on the south wall.

While there is no glazing on the south wall of the center section, a metal access door and equipment platform, accessed via caged ladder, was observed. Significant heat loss could be seen at the junction between the upper walls and roof.

The primary gable and annex shed roofs are east and west facing, with a gray TPO membrane visible at the primary, central section, and east annex shed roofs. The west annex and east central section roof appear to have a newer, white TPO membrane. The gray TPO shows signs of wear and bunching, indicating possible adhesion failure and air movement below the membrane. This condition renders the roof ineffective as an air barrier system. Roof insulation levels are unknown. Fiberglass batt insulation was observed in the interstitial ceiling cavity above the third level space at the central section.

The roof edge condition at the primary roof consists of a painted brake metal coping with riveted joints. The coping paint has varying colors, indicating several past coating layers. A few locations observed where the gasketed sealant joint between the coping and the brick had failed and was seen pulling away from the building.

The lower west annex roof has a modern profile consisting of flat brake metal coping. All roof levels are equipped with snow guards. No gutters were visible, however there are built-up crickets above each overhead and man door opening to help divert water away from the building opening.

Water damage to the interior roof deck was observed in bays 61, 62, 65, and 67. In bay D slight water damage was observed for most of the length, and in bay E slight water damage was observed in bays 62 and 67. With infrared imaging, heat loss was typically visible at the top of wall/roof junction, through roof fastener penetrations, and at gaps between roof purlins and deck boards. Paint on the interior of the roof deck is chipping and showing signs of significant wear. Suspected areas of past water damage include rooftop equipment penetrations and at the juncture between the upper brick wall, corrugated metal wall, and roof intersection at the northwest corner of the central section.

4.1.4 Interior Spaces

Interior program on the first floor is limited due to the industrial use of the building, but includes: a paint booth planned for replacement, offices, storage rooms, restrooms, a break room, crane repair shop, and other enclosed tenant spaces. CCE was not able to access Secure Area #138, as this space requires keypad access and is equipped with a X10 lock. Restrooms throughout the building were recently renovated in 2019 to be accessible.

New restroom furnishings and interior finishes were provided at this time including ceilings, paint, floor/wall tile, and toilet partitions. Second floor locker rooms are located above Men #112 and Women #113, with open stair access internal to each restroom. Locker rooms were renovated the same time as the restrooms below.

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Breakroom #139 and Office Area #114 also appear to be recently renovated with new countertops, vinyl flooring, and acoustical ceilings. The existing break rooms are intended for staff members and are currently deficient in size.

Crane Repair Shop #105, located between bays 57 and 60, is constructed of painted plywood wall partitions and doors, secured with a chain and padlock. This room is partially secure with metal mesh mounted to wood framing above the solid plywood walls. Storage Areas #134, 133, 130, 131, 132, 142, 141 are also typically constructed of painted plywood with a mix of plywood and wood doors. Generally, wood doors have knob door hardware and plywood doors are secured with chains and padlocks. Tenant Spaces #156 and #160, both occupied by Benet Labs, are constructed as metal-clad enclosures, accessed by secure hollow metal and overhead doors.

Welding operations occur within the west annex of the building, surrounded by several free-standing offices and support spaces (#150, 151, 152, 153, 154). These rooms are constructed of hard gypsum partitions and FRP wall finishes, and are protected from forklift damage by metal guards. Oils and lubricants for machinery are stored on the east end of the building, with a hazardous materials storage locker provided. Metal chain link fence enclosures are scattered throughout the building. The confines of these enclosures are moved and reworked regularly as the needs of the building change. Clearance pathways painted on the slab had not been re-striped at the time of CCE’s site visit to reflect recent changes in fence enclosure perimeters.

Underutilized office spaces were observed at the second level near the central section on the west side of the building. These offices over the Server/Comm room are currently used as make-shift storage and swing space.

Interior finishes include newer acoustical ceilings, outdated wall to wall carpeting, and hollow metal doors and frames with vision panels. On the east side of the building, at the central section, are two upper levels of underutilized and abandoned rooms. Finishes in these areas are currently in disrepair. Refer to the Life Safety section for additional observations, including egress, at underutilized upper level locations.

The existing floor finish is sealed concrete throughout the industrial areas of the building. A four foot wide circulation path is delineated with painted stripes. There is a small section of wood flooring adjacent to Room #114. Trenches and steam pits are located throughout the building, which are typically covered with metal grating. Metal grating had vehicular damage at several locations.

In general, the building is in need of a thorough cleaning, including pest removals. Evidence of small rodent and bird habitation was found throughout the building, especially at areas with limited access, such as the upper levels of the central section and elevated platforms.

4.1.5 Physical Security

According to UFC 3-301-01, Table 2-2, Building 110 is a Risk Category III (3), as it is a “Facilit(y) protecting high-value equipment”. The operation of awning windows with manual locks poses a security concern, especially when users leave windows open at the end of day. Exterior door access is also inconsistent with key pads at only a few exterior doors.

4.1.6 Built-In Equipment

Built-in equipment includes several crane structures, two oil waste dumping pits, a substation planned for relocation, and a paint booth pending replacement. Observed crane structures were as follows:

● Bay A contains a 2-ton underhung crane.

● Bay B contains two cranes, but only one appears to be operating. The operating crane is a 30-ton plus

10-ton top-running crane.

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● Bay D contains a 5-ton underhung crane that runs from bay 69 to 65, with the path interrupted by the existing paint booth at bay 66. Bay 59 and to the north contains a 2-ton underhung crane.

● Bay E contains a 5-ton top-running crane.

4.2 Applicable Codes and Design Criteria

● UFC 1-200-01 DoD Building Code, With Change 2, 06/12/2023

● UFC 1-200-02 High Performance and Sustainable Building Requirements, with Change 2, 06/01/2022

● UFC 3-101-01 Architecture, with Change 3,…