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HANCOCK VOR/DMER

ROOF REPLACEMENT

HANCOCK, NY

Provide the material equipment and labor necessary for the replacement roof at HANCOCK VOR/DME facility located in Kelsey, NY.

PART I - SECTION B

SCOPE OF WORK

The work items listed below serve only as a statement for the general work to be done under this contract. In no way does it limit the amount of work required under this contract.

The work shall include, but is not limited to the following:

1. The contractor shall hire a licensed asbestos/environmental testing company to test the existing roofing system and teepee joint caulking for asbestos. The interior equipment room ceiling shall be tested for lead paint. A minimum of three (3) samples of the roofing system shall be taken and analyzed by a certified lab and a minimum of two (2) samples of paint shall be taken. The contractor shall submit the appropriate licenses/certificates for the testing company and testing lab to the FAA prior to performing the sampling. The holes left by the sampling shall be properly patched by the contractor immediately after the samples are taken.

NOTE: Demolition work shall not start until after all testing results have been reviewed by the FAA and permission given to start work. If any of the samples test positive for asbestos or lead, the contractor must notify the FAA immediately and request guidance on how to proceed with the project.

2. The removal and disposal of the existing mechanically fastened PVC roofing system (metal terneplate to remain).

3. Removal and storage of the VOR mounting brackets/keystones (antennas to be removed by the FAA). Licensed NYS surveyor to record and mark the location/orientation of each antenna.

4. Remove, store and secure fiberglass VOR teepee. Contractor to provide the appropriate rigging to remove the teepee. Remove all gasket and caulking material from the teepee/cap to allow for the installation of new gaskets and caulking. Contractor may remove existing cap, if necessary, for the VOR teepee removal.

5. Provide temporary tarps for entire VOR roof area and ploy for inside equipment.

6. Install new ¾” plywood and fully adhered EPDM roofing system over existing metal terneplate.

7. Paint exposed decking and support assembly nailers.

8. Fabricate and install new monitoring antenna support assemblies and brackets (See Drawing S001 for details). Location/orientation of the brackets to be confirmed by NYS licensed surveyor.

9. Reattach any grounding that was disconnected for the roof replacement.

Fall Protection: The existing flat roof does not have a parapet; therefore, the contractor must provide the appropriate fall protection for workers. The fall protection plan must be included in the contractors Health and Safety plan and submitted to the FAA for review (see Division 1).

Location: Off Sands Creek Road (CR 67) – Approximately 1.25 miles south of CR10

PART 1 - SECTION C

DESCRIPTION/SPECIFICATION

TABLE OF CONTENTS

DIVISION 1 - GENERAL REQUIREMENTS

Section Title Page #

1-1 Summary of Work

1-2 Construction Limits and Use of Facilities

1-3 Temporary Facilities

1-4 Submittals

DIVISION 2 – SITE WORK

2-1 Demolition

2-2 Teepee Removal

2-3 Monitoring Antenna Brackets

DIVISION 7 - THERMAL AND MOISTURE PROTECTION

Section Title

7-1 Membrane Roofing - Single Ply

7-2 Flashing

7-3 Walking Pads

7-4 Temporary Moisture Protection

DIVISION 10 - SPECIALTIES

10-1

DIVISION 1 - GENERAL REQUIREMENTS

1-1 SUMMARY OF WORK

1-1.1 General

These specifications, together with the referenced specifications, standards and drawings specified in the Contract Documents, cover the requirements of the Federal Aviation Administration, hereinafter referred to as the Government or FAA, for all work associated with the roof replacement for the Hancock VOR facility located in Kelsey, NY.

1-1.2 Intent of Specifications

This specification identifies all labor, materials and equipment necessary to perform the required work.

1-1.2 Pre-Bid Site Visit

The Contractor should make a site visit prior to submitting a bid. The Contracting Officer will provide the date and time of meeting. Contact Joseph Henn at joseph.henn@faa.gov to confirm attendance.

1-1.3 Health and Safety Plan

The contractor shall submit a health and safety plan prior to the issuance of the notice to proceed.

Plan must contain a section on fall protection and COVID.

1-2 CONSTRUCTION LIMITS AND USE OF FACILITES

1-2.1 Construction Limits

The Contractor shall confine operations, activities, storage of materials and employee parking within the areas designated by the RE. Space is limited at the site, therefore, the Contractor shall work coordinate all activities with the site preparation contractor. Any additional space the Contractor deems necessary shall be obtained off the site, at no additional cost to the Government.

1-2.2 Damage to Site

Damage to existing pavement, landscaping, structures or underground facilities caused by the Contractor's activities shall be repaired. All costs of such repairs shall be paid for by the Contractor. After notice to proceed and prior to commencement of construction, the Contractor and Resident Engineer (RE) shall conduct joint inspections of the existing areas affected by the construction. Existing damage or defects shall be noted and will be used as the basis for determination of damages caused by the Contractor's operations.

1-2.3 Contractors' Use of Premises

The Contractor shall have use of the premises within the construction area limits (as defined on the drawing) for the execution of his work and shall assume full responsibility for the protection and safekeeping of products and materials stored on the site.

The Contractor and subcontractors shall maintain the job site in a neat and orderly condition. This includes the daily removal of rubbish, waste, tools, equipment, and materials not required for the work in progress.

1-2.3 Work Schedule

The VOR facility must be taken out of service prior to starting the project construction. The contractor shall provide the FAA a project start date a minimum of 45 days in advance to allow for proper coordination of the VOR outage.

Normal work hours will be from 7 am to 4:00 pm, Monday through Friday. All work outside of the normal timeframe will be coordinated with the RE a minimum of 48 hours prior.

The Contractor will have seven (7) calendar days to complete the project.

Work will not be permitted during periods of rain. The Contractor will provide necessary covering for exposed areas.

1-2.4 Site Access

The FAA must escort the contractor to and from the site each day. Each worker must have a current valid Government identification (i.e. driver’s license, passport) to enter the worksite.

The FAA will provide an escort from the entry gate to the site at 7:00 am and from the site at 4:00 pm. If additional escorts are required during the workday, the contractor shall notify the FAA a minimum of 48 hours in advance.

1-2.5 Vehicle Marking

All contractor vehicles must have the company name and/or logo fixed to the vehicle.

1-2.7 RUBBISH REMOVAL

The Contractor shall require each subcontractor engaged upon the work to bear full responsibility for cleaning up during and immediately upon completion of his work. All rubbish, waste, tools, equipment and other apparatus caused by or used in the execution of the work shall be removed. This shall in no way be construed to relieve the Contractor of his primary responsibility for maintaining the site clean and free of debris, and leaving all work in a clean and proper condition acceptable to the RE.

1-2.7.1 Rubbish Removal

Immediately after unpacking, all packing material, case lumber, wrappings, or other rubbish, flammable or otherwise, shall be collected and removed from the site and disposed of in accordance with local regulations on a daily basis.

1-2.7.2 Overall Cleaning

Immediately before the final inspection, the surrounding areas shall be thoroughly cleaned by the contractor, including but not limited to the following:

a) For all construction facilities, debris and rubbish shall be removed from the site.

b) All tools, scaffolding, temporary utility connections or buildings, belonging to the contractor or used under his direction shall be removed from the site.

1-3 TEMPORARY FACILITIES

1-3.1 General

The Contractor shall provide and pay for all temporary services and facilities as specified below and as necessary for the proper and expeditious execution of the work.

1-3.2 Temporary Toilets and Sanitation

The Contractor shall provide ample and suitable on-site sanitary conveniences with proper enclosures for the use of all workers. Such conveniences shall be kept clean, be properly ventilated and shall be installed and maintained in conformity with requirements of all laws and ordinances governing such installation. Locations shall be subject to the RE's approval. After completion of the work, such conveniences shall be removed from the site.

1-3.3 Temporary Electric Lighting and Power

The Contractor shall provide and maintain a temporary lighting and power system for construction and inspection purposes. The Contractor shall make all necessary arrangements for temporary electrical services and shall provide and pay for all temporary work.

1-4 INSURANCE

Contractor shall provide insurance certificate prior to start of work. See contract clauses for additional details.

1-5 SUBMITTALS

1-5.1 Procedure

All shop drawings and/or product data shall be submitted to the FAA General Engineer via email in a .pdf format. A set will be marked up and returned to the Contractor via email within fourteen (14) days of receipt.

1-5.2 Shop Drawing Approval

Approval will not relieve the contractor of responsibility for any error which may exist. The contractor shall be responsible for the dimensions and design of adequate connections, details, and satisfactory construction of all work.

1-5.2.1 Approved as submitted - If "approved as submitted" is marked by the General Engineer, each copy of the shop drawings or product data will be identified as having received such approval by being stamped and dated. After submittal has been approved, no substitution will be permitted without written approval by the General Engineer.

1-5.2.2 Approved as noted - If "approved as noted" is marked by the General Engineer, the shop drawings or product data is satisfactory contingent upon

contractor acceptance of corrections, notations, or both and, if accepted, does not require resubmittal.

1-5.2.3 Approved as noted - resubmission required - If "approved as noted-resubmission required" is marked by the General Engineer, the shop drawings or product data may be satisfactory contingent upon contractor resubmission of corrections, notations, or both. The effect of the notations or corrections is such that resubmission is required in order to evaluate the corrected data or drawings. Contractor shall resubmit the corrected material, in the same quantity as specified for the original submittal.

1-5.2.4 Not approved - If "not approved" is marked by the General Engineer, the shop drawing or submittal data does not meet job requirements and the contractor must resubmit. If shop drawings or submittal data are disapproved, the contractor shall resubmit the corrected material, in the same quantity as specified for the original submittal.

DIVISION 2 - SITE WORK

2-1 Demolition

Care shall be taken with the removal of the existing roofing system. The existing metal terneplate has not been tested for lead, however, the contractor should assume the terneplate contains lead and shall wear the appropriate personal protective equipment.

The contractor shall properly dispose of the existing roofing system.

2-2 Fiberglass Antenna Shelter (Teepee) Removal

The orientation of antenna shelter door shall be noted prior to removal to assure reinstallation in the same relative position.

In addition to the lag bolts holding the antenna shelter to the roof, waterproofing material at the base was also incorporated in the original construction that will contribute to difficulty in removing the shelter. Such materials will include a circular gasket under the antenna shelter, flashing materials adhering to the roof and antenna shelter, and various caulking and sealant beads at this juncture. Carefully cut such materials free from the antenna shelter using knives and flush-cut surface saws, in such manner that the shelter is in no way damaged. Carefully remove the heavy residue from the shelter ensuring not to damage the fiberglass.

Contractor shall provide the COR a rigging plan prior to removing the teepee. Hoist cables shall be secured to the antenna shelter (teepee) system before hold-down bolts are removed to insure that shelter will not blow over in the wind. Shelter shall be carefully hoisted in an approved manner from the building roof to temporary storage on grade. Place antenna shelter on wood blocking and boards of sufficient area such that the weight of the antenna shelter is distributed over at least 50% of the area of the base flange to preclude damage to the relatively brittle shelter.

Immediately after placement of the antenna shelter on grade, it shall be anchored with at least four guy wires or ropes and posts driven into the ground to preclude this shelter from being blown over by the wind. This precaution is emphasized due to its occurrence in the past at substantial cost for replacement.

The existing teepee shall be stored on site.

2-3 Monitoring Antenna Brackets

Prior to removal of the 16 monitor antenna keystone angle brackets, the monitor

antennas and connecting cables will be disconnected and removed by the FAA. Do not remove the North bracket (identified by the COR) until a registered land surveyor has established facility North. The antenna brackets consist of 5" x 5" x

3/8" x 6" long aluminum angles fastened to the roof deck with four mechanical fasteners. Keystone (trapezoidal face) plates are attached to the azimuth positioner brackets which support the antennas by a wedging action. All of the monitor antenna brackets will be reused.

Each monitor antenna keystone angle bracket shall be covered with padding after it is installed to protect the tarpaulin roof covering from puncturing on the exposed sharp edges of the brackets during construction.

DIVISION 7 - THERMAL AND MOISTURE PROTECTION

7-1 MEMBRANE ROOFING - SINGLE PLY

7-1.1 General

7-1.1.1 Work Included

A. Furnish and install a fully adhered unballasted single ply EPDM membrane roofing and flashing.

B. Cleaning substrate.

C. Sheet roofing.

D. Flashing and sealing sheet at termination.

E. Equipment support flashing.

F. Pipe Flashing.

G. Inspection by membrane manufacturer.

H.15 year total roofing system warranty.

7-1.1.2 REFERENCES

A. ASTM D297 - Rubber Products, Chemical Analysis.

B. ASTM D412

C. ASTM D573 - Rubber Deterioration in an Air Oven.

D. ASTM D624 - Rubber Property - Tear Resistance.

E. ASTM D746 - Brittleness Temperature of Plastics and Elastomers by Impact.

F. ASTM D1149 - Rubber Deterioration Cracking in a Chamber.

G. ASTM D2240 - Rubber Property - Durometer Hardness.

H. ASTM E96 - Water Vapor Transmission of Materials.

7-1.1.3 Qualifications of Contractors

A. Contractors shall be required to show evidence of a minimum of 5 years experience in actual installation of similar products, on projects of similar scope, in the geographic area of this project. The roofing applicator shall be a manufacturer's authorized applicator.

7-1.1.4 Quality Assurance

The roofing system shall be installed in compliance with Shop Drawings as approved by the manufacturer. No deviations shall be made without prior written approval of the manufacturer.

7-1.1.5 Product Data

Submit manufacturer's instructions for surface conditioner compatibility, elastic flashing, joint cover sheet, and joint and crack sealants, with temperature range for application of roofing membrane.

7-1.1.6 Submittals

Prior to installation Shop Drawings are to be submitted to the RE and to the roofing system manufacturer. Manufacturer must supply approval of the final shop drawings to assure issuance of a fifteen (15) year warranty. All submittals shall be in accordance with Division 1.

7-1.1.7 Delivery, Storage and Handling

Deliver materials to the job site in original, unopened containers labeled with the manufacturer's name, brand name and installation instructions.

Materials are not to be stored exposed for prolonged periods.

Underlayment shall be kept dry and shall be protected from the elements.

Adhesive containers shall not be stored with opened lids.

7-1.1.8 Environmental Requirements

A. Do not apply sheet roofing during inclement weather.

B. Do not apply sheet roofing to damp, frozen, dirty or dusty roof surfaces unacceptable to the manufacturer.

7-1.1.10 Warranty

A. Roof Subcontractor shall provide a 15 year total roofing system written warranty covering the following:

1. Roofing and flashing (except metal flashing) shall be waterproof and weathertight for a period of 15 years after date of final acceptance.

2. Metal flashing shall be waterproof and weathertight for a period of two years after date of final acceptance.

3. Single sheet EPDM membrane roofing and flashing (except metal flashing) shall have 15 year written warranty provided by the membrane manufacturer.

B. Leaks or defects, such as blisters, cracks, tears, etc., which may occur during term of warranty shall be corrected within 48 hours after notification by Owner of their existence, at no cost to the Owner.

7-1.1.11 Standards

A. Roofing materials, insulation, and related components necessary to complete roof and deck system shall be as recommended for:

1. Underwriters' Laboratories, Inc. (UL): Class A Fire Hazard Classification.

2. Factory Mutual Systems (FM): Roof assembly Classification I 90.

B. Basis of design is:

1.Fully adhered, unballasted system; Carlisle Design A.

7-1.2 Products

7-1.2.1 Acceptable Manufacturers

A. Carlisle Tire & Rubber Company

B. Firestone

C. Or approved equal

7-1.2.2 Materials

A. Membrane: Black compounded elastomer non-reinforced (EPDM), .060 inches thick for adhered system, conforming to the following minimum physical properties:

PHYSICAL PROPERTY TEST METHOD SPEC. FR

Tolerance on Normal Thickness,% ASTM D 412 +/-10 +/-10

Tensile Strength, min, psi (MPa) ASTM D 412 1305(9) 1780

(12.3)

Elongation, Ultimate, min % ASTM D 412 305 495

Tear Resistance, min, lbf/in ASTM D 624 175(30.6) 215

(kN/m) (Die C) (37.6)

Factory Seam Strength, min Modified Membrane Membrane

ASTM D 816 Rupture Rupture

Resistance To Heat Aging ASTM D 573

Properties after 4 Wks @

240 deg. F.

Tensile Strength, min, psi (MPa) ASTM D 412 1200(8.3) 1800

(12.4)

Elongation, Ultimate, min% ASTM D 412 225 230

Tear Resistance, min, lbf/in ASTM D 624 150(26.3) 240

(k/N/m) (42.0)

Linear Dimensional Change,

max, % ASTM D 1204 +/-2 -0.4

Ozone Resistance

Condition after exposure to ASTM D 1149 No No

100 pphm Cracks Cracks

Ozone in air for 168 hours

@ 104 deg. F

Specimen is at 50% strain

PHYSICAL PROPERTY TEST METHOD SPEC. FR

Brittleness Temp., max, deg. F ASTM D 746 -75 -85

(deg. C) (-59) (-65)

Resistance to Water Absorption ASTM D 471

After 7 days immersion @

158 deg. F, Change in mass,

max, % 4 2.0

Water Vapor Permeability ASTM E 96 2.0 2.0

max, perm-mils (proc B or

BW)

Resistance To Outdoor ASTM G 96 No No

(Ultraviolet) Cracks Cracks

Weathering No No

Crazing Crazing

Xenon-Arc

4000 hours exposure,

176 deg. F black panel

temperature Sheet

Composition ASTM D 297

Weight percent of polymer

that is EPDM, min, % 100 100

Weight percent of sheet that

is EPDM polymer, min % 30 30

B. Flashing: 1/16 inch thick SURE SEAL Elastoform Flashing, as furnished by membrane manufacture.

C. Bonding Adhesive: As furnished by membrane manufacture. It shall be compatible with all materials to which the membrane is to be bonded.

D. Splicing Cement: As furnished by membrane manufacturer.

E. Lap Sealant: For sealing the exposed edge of the splices shall be trowel or gun consistency as furnished by membrane manufacturer.

F. Water Cutoff Mastic: As furnished by membrane manufacturer.

G. Prefabricated Accessories: As furnished by membrane manufacturer.

H. Sure-Seal Nite Seal: As furnished by Carlisle Tire & Rubber Company.

I. Water Pervious Fabric: "Confil Fabric" D-689 as manufactured by International Paper Co., "Sureseal HP Mat" by Carlisle, or other similar fabric approved for use in the Protected Membrane Roof System and for which a 15 year warranty is available.

J. Fasteners: Fasteners shall be as recommended by the membrane manufacturer for each type of substrate and shall be FM approved. Fasteners will be driven into structural concrete with a minimum pullout of 800 pounds per fastener.

K. Insulation: Not used.

L. Termination Bars: As recommended by membrane manufacturer.

7-1.3 Execution

7-1.3.1 Preparation

Roofing surfaces are to be thoroughly cleaned, smooth, dry, free of fines, sharp edges, loose and foreign materials, oil, grease, and fresh roof cement.

7-1.3.2 Installation

Application of the roofing system shall be done by a roofing contractor approved by the membrane manufacturer in order to obtain the 15 year warranty. Application is for Design "A" adhered system.

Nailers:

Install nailers and/or batten strips where recommended by the membrane manufacturer. Nailers shall be pressure treated for rot resistance, #2 or better lumber (Wolmanized or Osmose K-33). Asphaltic or creosote tested lumber is not acceptable. Nailers are to be installed with the top flush with the top surface of the membrane underlayment.

Plywood Installation:

Installation of plywood shall be in compliance with manufacturer's installation recommendations. Fastening is to be in accordance with approved shop drawings.

Install plywood butted together with no gaps.

Membrane Application:

Adhered System: Position Sure-Seal roofing membrane without stretching. Allow the membrane to relax for approximately one hour before bonding. Fold the sheet back 5 feet onto itself so that one half of the underside of the sheet is exposed. It is essential that the fold in the sheet be smooth, with no wrinkles or buckles, as these could result in wrinkling the sheet after it is bonded. Apply the bonding adhesive in accordance with manufacturer's published instructions, to both the sheet and the substrate, using a nine (9) inch, plastic core paint roller.

Apply the bonding adhesive evenly, avoiding globs and puddles. Allow the adhesive to dry until it does not string or stick to a dry finger touch. Roll the coated membrane into the coated substrate being careful to avoid wrinkles. Brush down the bonded half of the sheet with a soft bristle push broom to achieve maximum contact. Fold back the unbonded half of the sheet and repeat the bonding procedure.

Apply adjoining sheets in the same manner, lapping the edges a minimum of 3 inches.

Fold the top sheet back about 12 inches and clean both mating surfaces at the splice area using clean rags with Sure-Seal Splice Cleaner. Apply the splicing cement with a 3 inch roller at a rate of approximately 150 lineal feet of 3 inch splicing per gallon of splicing cement. Apply the cement in a smooth, continuous, even coat obtaining 100% coverage on both mating surfaces; the cement coat must be smooth with no globs or puddles. Allow the cement to dry until it does not string or stick to a dry finger touch. While the adhesive is drying install a bead of inseam sealant as per manufacture detail. Roll the top sheet toward the splice area until the cemented area is nearly touching the cement on the bottom sheet. Allow the top sheet to fall freely into place; avoid stretching and wrinkling. Roll the splice with a 2 inch wide steel roller, using positive pressure, toward the outer edge of the splice. Solvent clean the splice edge, extending at least 1 inch onto the top and bottom membranes. Apply a bead of lap sealant completely covering the splice edge, feathering the lap sealant with a putty knife or trowel.

Perimeter flashing and flashing around vents, curbs, drains, scuppers, etc., shall be done with "Elastoform" flashing, using the longest pieces practicable. Complete the splice between the flashing and the main roof sheet before bonding the flashing to any vertical surface. Seal this splice at least 3 inches beyond the fasteners which attach the horizontal membrane to the nailer. Apply bonding adhesive to both the membrane and the surface to which it is being bonded. After the bonding adhesive has dried to the point where it does not string or stick to a dry finger touch, roll the flashing into the adhesive. Take care to assure that the flashing is not bridging where there is any change of direction of the flashing.

Flash all projections (pipes, conduits, etc.) passing through the membrane. Prefabricated pipe seals shall be used to flash all pipes. Install all flashings and terminations in accordance with manufacturer's details.

Exercise care to ensure that water does not flow beneath any completed sections of roof, by temporarily sealing the loose edge of the membrane with "Nite Seal" when the weather is threatening and at end of each work day. Mix the two components

thoroughly according to the instructions on the label. Apply the Nite Seal at a rate of 100 lineal feet per gallon, 12 inches back from the edge of the sheet. It may be necessary to use a trowel to spread the material in order to achieve the prescribed coverage. After embedding the membrane in the Nite Seal, weight the edge, providing continuous pressure over the length of the cutoff. When work is resumed, pull the sheet free before the installation is continued.

7-1.3.5 Daily Seal

When the completion of flashings and terminations is not completed by the end of each work day, provisions must be provided to temporarily close the membrane to prevent water infiltration.

Temporarily seal any loose membrane edge down slope so that the membrane edge will not buck water. Caution must be exercised to ensure that the membrane is not temporarily sealed near drains in such a way as to promote water migration below the membrane.

Sure-Seal Nite-Seal shall be used for temporary sealing of membrane edges and shall be applied as follows:

After embedding the membrane in Nite-Seal, CHECK FOR CONTINUOUS CONTACT. Provide continuous pressure over the length of the temporary seal with 10 foot lengths of 2-1/2 inch diameter Sure-Seal Lay Flat Tubing filled with dry sand. Do not use wood nailers.

When work is resumed, pull the EPDM membrane free; trim and remove membrane where the Nite-Seal was previously applied before continuing installation of adjoining sections.

7-1.3.6 Clean-up

Upon completion of the work all materials, equipment and debris are to be removed from the roofs.

7-1.3.7 Manufacturer's Inspection

After completion of the roof system, the approved applicator shall submit to the membrane manufacturer a request for inspection within seven (7) days of job completion, in a form required by the manufacturer. An inspection shall be scheduled with the manufacturer, the applicator, Contractor and the RE. The inspection shall be conducted by the manufacturer's field technician to determine conformance with manufacturer's current specifications and details. Any areas found not to be in conformance shall be written up by the technician and repaired or replaced by the applicator to meet the manufacturer's current specification and details. Upon completion of any repairs or replacement, the applicator shall submit a warranty form to the manufacturer for review.

Submit a fifteen (15) year warranty to the RE.

7-2 FLASHING

7-2.1 General

This section specifies requirements for all metal facia/drip edge materials.

7-2.2 Submittal

Submit, in accordance with Division 1, manufacturer's product data, installation instructions and general recommendations for each specified sheet material and fabricated product.

7-2.3 Materials

All materials shall be 24 gauge galvanized steel sheet with PVC coating.

7-2.4 Execution

7-2.4.1 Installation

Except as otherwise shown on the Contract Drawings, comply with manufacturer's installation instructions and recommendations, and with SMACNA "Architectural Sheet Metal Manual." Anchor work in place with adhesives, setting compounds or other devices as recommended by the manufacturer. Install work with laps, and joints filled with sealant which will be permanently watertight and weatherproof. Where metal is directly over masonry concrete and/or wood, provide felt between metal and such materials.

7-2.4.2 Protection

Perform required procedures or surveillance and protection of flashings during construction to ensure that work shall be without damage or deterioration, other than natural weathering at time of issuance of the Certificate of Final Completion.

7-3 Walkway Pads

Preformed walkway pads shall be rubber, nonskid type, color white on gray fully adhered according to manufacturer printed instructions at locations shown on drawings. Roof walkway pads materials shall be approved for compatibility with primary roofing membrane manufacturer. Pads shall be 36-inches by 36-inches by 3/4 inch thick.

7-4 Temporary Moisture Protection

7-4.1 Roof

The Contractor will supply and install tarps each day to cover the VOR antennas and all areas that the roof has been removed. This will continue until the VOR teepee and new roof system are installed.

At no time shall roof and VOR antennas be left uncovered.

7-4.2 Equipment

Provide a protective moisture barrier plastic cover over all electronic equipment, control panels, and power panels.

Polyethylene film sheeting, six mils thick, transparent, and in width suitable to adequately cover the equipment.

Duct tape used to attach the polyethylene film sheeting shall be waterproof sealing type.

Carefully cover the equipment so that no water can enter the cabinets and damage the equipment. Equipment in service which generates heat and requires ventilation shall have a wood frame constructed above the equipment and covered with polyethylene membrane. All temporary polyethylene covering shall be approved by the COR.

All polyethylene shall be removed after the new roofing system is installed.

DIVISION 10 – SPECIALTIES

10-1 ANTENNA SHELTER (TEEPEE) INSTALLATION

This section covers the requirements for installing the existing VOR fiberglass antenna shelter, on the new roof. The contractor is cautioned that the VOR fiberglass antenna shelter can be damaged with rough handling. Care must be exercised when working with the shelter to maintain its structural integrity. In addition, the following specifications cover the requirements to furnish all material, equipment, labor, and supervision to accomplish the work described in this specification.

10-1.1 Materials

1) Caulking: Caulking shall be premium grade high-performance moisture cured, non-sag, and polyurethane-base elastomeric sealant 3M 5200 or approved equal.

2) Gaskets: See Appendix A for product specifications

3) Lag Bolts: To secure antenna shelter. Contractor shall reuse new existing

3/8" hex head lag bolts and washers and replace all bolts damaged during removal.

10-1.2 Shelter (Teepee) Repair (If Needed)

The contractor shall repair the VOR antenna shelter (Teepee) if it is damaged during the project at no additional cost to the Government.

All holes, cracks, damaged areas or areas where the protective resin coatings have worn away and have left the fiberglass surface exposed and weathered shall be repaired, as follows:

1) Cut away all ragged edges and corners from the damaged area of the panel to form an oval or round hole by using a router, rasp or other acceptable tool.

2) Feather the edge of the hole on the interior and exterior surface of the panel to a smooth, sloping contour approximately 3 inches beyond the edge of the hole.

3) Clean all abraded areas with solvent cleaner.

4) Cut fiberglass cloth patches approximately 2 or 3 inches larger than the hole formed in Step 1.

5) Apply premixed epoxy resin with a paint brush or spatula to the abraded surface and the feathered edge of the hole. See 10-1.2.1

6) Position fiberglass cloth patch on exterior surface of panel, and brush resin on outside of patch and around edges to produce a filled surface free of air bubbles.

7) On the interior side of the panel, cut a fiberglass cloth patch to fit the dimensions of the hole. Cut sufficient number of additional patches, in increasing sizes (in 1/2 inch increments) to obtain a patch thickness (when impregnated with resin) of slightly greater thickness than the original pane. Finally, cut and apply one patch 2 inches larger in diameter than the preceding patch.

8) After the resin has completely dried, sand the repaired areas smooth with a fine grit sand paper.

10-1.2.1 Resin Application (If needed)

Combine and mix resin in accordance with the manufacturer's instructions. Use extreme caution in handling the catalyst and accelerator as they are toxic and highly reactive. Catalyst and accelerator ratios depend upon many factors, including application method (two-part pressure spray, roller, or brush), ambient temperature, and humidity. The resin may be applied by means of a two-part pressure pot, rollers, or brushes. Apply one coat of uniform thickness to entire surface to be refurbished. Where the fiberglass is exposed and loose glass fibers stick out n the surface, apply the resin in a manner which will cause the fibers to lie flat on the surfaces and become embedded in the resin coating. Required final coating shall be five to six mils in thickness on surfaces which are not deteriorated to the point where the fiberglass is exposed. Do not apply resin to surfaces which are evidently damp, or have had insufficient drying time at lower humidity levels to assure evaporation of moisture from cracks and porous areas. Allow at least 20 hours of curing time for resin coating on any particular area of the surface before sanding and application of paint.

10-1.2.2 Antenna Shelter Painting (If Needed)

If applicable, apply two coats of white, QC-Resin. The first coat acts as both a primer and base coat, and requires the addition of a small amount of Methyl Ethyl Ketone Peroxide (MEK-P) activator. Apply paint with a brush or roller. The first coat shall be worked in and spread to achieve a 5 mil dry film thickness (DFT). The second coat, which contains most of the white pigment shall be applied to achieve 7 mil DFT. Contact PPC Coatings to obtain these two separate coats that will be prepared specifically for this FAA application. Follow the manufacturer's instructions for mixing and pot life.

10-1.3 Antenna Shelter (Teepee) Gasket

Apply to base of teepee just prior to final setting on roof. Bonding surfaces should be free of old gasket material and caulking (use paint scraper if necessary), and wiped clean prior to application. Apply firm pressure on the gasket to allow pressure sensitive adhesive (PSA) to adhere. Overlap the gasket material at the starting point, and make a single cut through the material with a sharp knife to form a tight seam where the ends meet. Gasket shall also be applied to top edge of teepee prior to installation of tap cap/dome. Once applied, drill use a ½ inch drill bit or step bit (preferred) to open the bolt holes in the gasket.

NOTES: Use caution when removing the gasket backing to avoid pulling off the PSA with the paper. If the PSA does not hold the gasket in place (due to temperature, dirt, or age of glue), use 3M Super 77 spray adhesive or similar to tac gasket in place. Recent improvements to the adhesive used on the gasket should help to alleviate these issues.

10-1.4 Antenna Shelter (Teepee) Installation

The antenna shelter shall be reinstalled atop the membrane in precisely the same location and orientation as existing before removal unless otherwise specified by the COR. The FAA will approve the final location and radial orientation of the teepee prior to drilling and fastening to the roof.

Prior to installing the antenna shelter with base gasket adhered, the contractor shall make reference marks on the roof in order to center the antenna shelter. The contractor shall set the antenna shelter on the roof using the established reference marks to center and orient the shelter in the same azimuth as it was before it was removed from the roof, or as directed by the COR. After the shelter location has been approved by the COR, the contractor shall drill a 1/4" pilot hole in the center of each teepee base bolt hole, 1 1/2" deep, and fill with caulking. The contractor shall then secure the teepee with Hex Head Lag Bolts, washers, and the (GFM) fastening strips. Torque bolts equally to only such tightness to provide a watertight seal and not to an extent where fiberglass will shatter or the gasket deforms excessively.

Apply caulking around the outer and inner edges of the teepee-roof seam to make a smooth bead.

10-1.5 Monitoring Antenna Positioner Brackets – Azimuth Installation

A registered licensed surveyor shall set a transit over the building center point and project a line through the center of the north azimuth positioner bracket to a mark on a wood hub driven flush with the ground approximately 200 feet north of the VOR building. Guard the hub with a 1" x 2" x 5'-0" (+/-) wood stake with a red flag tied to the top of the stake. This work shall be performed with care and the COR shall check and approve the reference point before the azimuth positioner brackets are to be removed. When the new monitor antennas support assemblies (contractor furnished) and keystone angle brackets (GFM) are ready to be installed, the transit is set up, as previously referenced, to the wood hub, and scribe reference lines 22.5 degrees apart (relative to facility North) are placed near the edge of the roof at each of the 16 bracket locations using the transit to certify the proper reference of true north and angles. After turning the transit scope 360 degrees, the cross hair must align precisely with the wood hub starting mark. The azimuth positioner brackets must be evenly spaced at 22.5 degrees apart on centers. The monitor antenna support assembly shall be installed per Drawing S001.

APPENDIX A

RUBATEX GASKET MATERIAL FOR VOR TEEPEE INSTALLATION

This product is used on both the top and bottom of the VOR shelter (teepee). The gasket material is cut straight (linear), but flexible enough to conform to the curvature of the teepee. The gasket does not come with bolt holes pre-drilled, making placement of the gasket easier.

The gasket is manufactured by the contractor to our specifications using blocks of Rubatex, so please allow sufficient lead time when ordering (normally 1 to 2 weeks).

Gasket Material: Rubatex R425-N High Density Neoprene with Pressure Sensitive Adhesive (PSA) on one side

NOTE: The PSA product used on the gasket has recently been improved for easier application and better adhesion.

Dimensions: 3/8" x 2-1/2"

Quantity: 50 Feet (will come in two rolls)

Supplier: Industrial Rubber and Plastic, Haverhill, MA

Point of Contact: John D., Telephone: (978) 374 -0156 (Tell him you are with FAA)