Week 2 - My Active Projects
- Sal Randazzo
- Jan 14, 2018
- 7 min read
Week 2! I hope everyone is having a great year so far and are setting goals to smash in 2018. This week I posted a voting option to write about my active projects or my current diet. Many of you wanted to hear about my active projects so I hope you enjoy!
Project #1 - Repair Base Operations/Command Post, Building 169:
This project is a multi-story, multi-scope renovation. The work for this project has a primary mission of replacing the entire HVAC system, leaving the existing chiller in place, but replacing two 1600+ CFM Air Handling Units (AHUs), and 32 Variable Air Volume (VAV) Boxes with all associated ductwork and insulation. The work also includes major demolition and renovation of the electrical & communications system, walls, ceilings, lighting, flooring, and doors. Four commercial restrooms and three smaller individual restrooms are being renovated including ceramic tile, toilet partitions, and plumbing fixtures. We are also to install very specific cabinetry and casework in the flight planning section to accommodate specialized computer equipment and maps.
As you can see above, this building has no windows which presents a unique challenge with demolition and renovation work. No chutes can be built from the second floor and the elevator can only be used to haul material. (Note: Since the Fire Alarm Panel is put in “test mode” during the renovation, people cannot ride the elevator because the Fire Department is not being notified in case of an emergency). Unfortunately, no elevator repairs or maintenance is covered in our contract and halfway through demolition phase, the elevator became inoperable.
Some other challenges this project presents (other than the elevator) includes the renovation of two vaults - one on each floor. Vaults are always tricky as they come with special code requirements. We have to provide new lighting, communication outlets, HVAC, and wall finishes in these rooms, but they have solid concrete floors, walls, and ceilings. Cutting in louvers for the mechanical system is always tricky as you must get outside of the vault and cut through reinforced concrete ceiling from above. Another challenge we are presented with is to repair a leaky roof without knowing where the problem exists (a good use for the drone!). After we demolished the ceilings and ductwork, we were able to narrow the roof issue to one specific area (highlighted below). We believe the through-wall flashing is failing where the vertical brick meets the lower sloped roof, and water is leaking behind the red brick and getting in the building.
(RPIC: Sal Randazzo, Interior Flight, Reg #: FA3AARWW43)
I was able to fly my smaller drone inside the building, above the ceiling, around the conduit and decking to identify exact locations of water intrusion. You can see the water staining the CMU blocking inside the building. I have submitted an airspace waiver (since this building is a solid 9-iron shot away from the runway) to fly in Class-C Airspace. These take approximately 90-days to review and approve through the FAA. Once approved, I’ll be able to fly and survey the exterior of the building right up against that vertical wall to determine the exact cause of water intrusion. This facility does not have roof access, so without the drone, we would need to rent a lift and have a specific fall protection plan in place (anchor points, lanyards, harnesses, etc.) in order to physically get on the roof. I’ll post a video of that inspection once it happens - stay tuned!
This project is valued at $1.9M and scheduled to complete on 22 July 2018. Right now, there are a few unforeseen site conditions and modifications to the contract so hopefully we’ll be able to extend the completion to later in the year.
Project #2 - Repair/Add IMC Fire Suppression System:
This project includes the installation of 4,980 linear feet of 20-inch, 18-inch, and 16-inch fire suppression piping approximately 8-feet underground. This new fire suppression line will serve three aircraft hangars for C-17 maintenance and repairs. Additionally, this project includes the replacement of four diesel fire pumps, a 750,000-gallon water tank, and a 75-kVA transformer, duct bank, and wire upgrades.
This is the existing 750K-gallon water tank that will be demolished and replaced with two 150K-gallon water tanks. The water must be drained after the 4,980-feet of new line is installed, deconstructed, and foundation prepared for the new tanks.
These are the four diesel fire pumps being replaced with electric fire pumps. These fire pumps will be turned over to our client for salvage. The existing concrete floor will be demolished and new concrete pads will be installed for the four new electric fire pumps. Floor grating will be installed in the slab to ensure the new fire suppression line is accessible for maintenance and repairs.
Various sizes - 20”, 18”, & 16” PVC Fire Suppression piping in 20-ft lengths. We ordered the material to pre-stage in our laydown yard.
Myth regarding PVC degradation due to UV Exposure: The pipe we ordered (standard PVC) is formulated with titanium dioxide to limit damage from UV for two-years of exposed outside storage in the US & Canada. Uni-Bell PVC Pipe Association provided a technical report stating that pipe with standard PVC material and exposed to UV radiation from the sun for two years suffers no adverse effects on the tensile strength or modulus of elasticity. There is some decrease in the impact resistance, but levels remained above the minimum prescribed by industry standard. (Impact resistance would negatively affect above-ground pipe). Discoloration of the pipe does not indicate UV degradation.
This project has various challenges and hurdles. As you can see, the pipe is manufactured and delivered in 20-ft sections. Each section must be pushed together and braced properly to withstand a hydrostatic test up to 200-psi for over 2-minutes. Additionally, where the pipe changes directions, the appropriate fittings, valves, and gaskets must be secured properly as to not leak. As I mentioned before, this is all done 8-ft below ground. Since we’re excavating to a depth greater than 5-ft, the appropriate shoring measures must be in place before we can put pipe in the ground. We’re using a combination of trench boxes, plates, and sloping throughout this project.
Where our pipe crosses underneath a taxiway or tow-way we are having to jack & bore under these areas. Jack & Bore is a combination of tunneling and directional drilling. Here is an awesome animation depicting the process of Jack & Bore from McLaughlin Underground:
The key to Jack & Bore is to not disturb the surface elevation in any fashion during construction. This will allow our customer to continue aircraft maintenance while we put our pipe in the ground.
While this seems like a lot of work, the fire suppression piping is only half of the project. The other half is in the two new 150,000-gallon water tanks, fire suppression pumps, and the underground electrical upgrades. We will have to deconstruct the existing 750,000-gallon water tank and prepare a new foundation for two, 28-ft, 6-inch wide by 36-ft tall welded steel water tanks. These water tanks will provide fire suppression water to the four new fire pumps which will pressurize the new line and provide fire suppression to the three aircraft hangars. The new electric fire pumps will require an upgrade in wire size than what is existing and replacing the 75-kVA transformer with a 1500-kVA transformer. The new underground electrical line from the fire pumps to the transformer will have to be buried in concrete duct bank.
As I mentioned before, I applied for an airspace waiver to fly in Class-C airspace through the FAA. Under this waiver, I will be able to fly and survey the fire suppression piping and coordinate our as-built drawings against the Computer Aided Design (CAD) files. Using Ground Control Points (GCPs), I will be able to determine the elevation that our piping is installed and update the drawings for our client. Additionally, I will be able to survey, inspect, and document the two water tanks being installed. If requested, I would be able to provide 3D models and a topographic survey of the foundations for these tanks. I will be able to inspect the welds and coatings on the top of these tanks as well as inside the tanks without having to provide fall protection measures or a confined space entry program. In the end, this will save our client costs and we will be able to provide high-resolution video evidence of the work accomplished.
This project is valued at $5.5M and scheduled to complete on 19 March 2019.
Each of these projects has a dedicated Superintendent, Quality Control Manager (QCM), and Site Safety and Health Officer (SSHO). The Superintendent is responsible for coordinating subcontractors and in-house labor to stay on schedule and provide daily on-site supervision for all personnel. The QCM is responsible for ensuring the material and workmanship is completed in line with the provided specifications and drawings from our client. The SSHO is responsible for ensuring all personnel are completing their assigned daily task in accordance with the EM 385-1-1 U.S. Army Corps of Engineers safety manual. The QCM and SSHO have a dedicated Quality Control Plan and Accident Prevention Plan that is reviewed and updated as the project progresses through multiple phases.
These projects are managed by a team of certified professionals with over 100 years of combined experience. None of these projects would be accomplished without the team’s valuable experience and I am extremely proud and humbled to lead these individuals.
As a side-note, I sent out a call to my company for anyone that wants to come to the gym and get some one-on-one training/advice for eating right and working out safely. A co-worker and friend of mine decided to take control of his health and fitness and comes to the gym with me regularly. I hope he continues his journey and recognizes that it's not just a 2018 resolution but a change in his way of life.
Thanks for reading!
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About Sal Randazzo:
Sal is a defense contractor, entrepreneur, and fitness enthusiast. His Blog is designed to share his life with his followers. His YouTube channel & Blog is a gallery of his work and personal life. Enjoy!
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