NAVFAC Replace Steam & Condensate Piping at Walter Reed National Military Medical Center in Bethesda, Maryland

General Synopsis

Meltech completed this project for the Naval Facilities Engineering Command Washington at the Walter Reed National Military Medical Center in Bethesda, Maryland. This project was for the replacement of the steam and condensate piping to Buildings 11, 13, 14 and 20.

The project consisted of replacing the steam and condensate piping to Buildings 11, 13, 14 & 20 for the Naval Facilities Engineering Command Washington at the Walter Reed National Military Medical Center in Bethesda, Maryland. The project consisted of replacement of direct buried steam and condensate piping between Utility Tunnel # 5 and the Building 14 Mechanical Room along a partially new alignment and the replacement of steam and condensate piping between Building 16 and Buildings 11 and 27 along the existing Loop # 4 alignment through Manhole STML3504 and a new alignment from Manhole STML3504 to Buildings 11 and 27. The work also included the addition of a manhole to serve future Building 13 and building 20 renovations and the replacement of the Building 27 Manhole STML0304. Sequencing was required to cross connect exiting Loop #4 and Loop #7 in the basement of Building 17 prior to the start of demolition to maintain steam to buildings downstream of Manhole STML1304 during construction. The work was directly completed for Buildings 11, 13, 14 & 20 however the work was located between Buildings 14, 16, 17, 27 and 11.

Further Details

The project started with the goetech and retaining wall engineering and MOT, SCE, AGIP, SSF and portable sediment tank installation. Meltech completed the following:

• Demolition of existing steam lines
• Supplied, fitted and insulated approximately 340′  of 5″ SCH  40,  543′  of  3″ SCH  40  and  83′  of  2″  SCH40   black  Multi-Therm 500  direct  buried Steam pipe,
• Supplied, fitted and insulated approximately 340′  of 3″ SCH 10 and 612′ of 3″ SCH   10 stainless Multi-Therm 500  direct  buried  condensate pipe,
• Supplied, fitted manhole  0904 insulation of new pipe with 2″ insulation and aluminum jacket,
• Supplied and fitted manhole  3504, new manhold North, new manhole South, Building 14, Building 11, Building 17, Building 27 insulation of new pipe with 2″ insulation  and aluminum jacket,
• Building   27  interior  connections  to  new  steam   and  condensate lines exclude  any isolating flanges, scales pockets, condensate drain lines, shut off  valves,  check valves,  steam traps, etc. 
• Provided   sump   pump  unit  for  new  north  and  south manhole and up to 40′ of 2″ piping to closest storm drainage     
• Access  ladders  for  new  north  manhole,  south manhole and 3504 man holes includes vents and vent caps for new north and south manholes
• Shop drawing  for buried pipe system (provided  by pipe manufacture)
• Shop drawings for pipe system located in Mechanical rooms of building 11 and 14 where applicable.
• Opening up of  valve  in  manhole   1104  after  work  in  building   11  and  17 
• Replaced Sidewalk and Curb where demoed and Flag Pole Foundation
• Repaired Spalding Concrete Manhole
• Reinstallation of the Bike Rack, paving where demo’d, retaining wall across from Bldg. 17 that was demo’d and seeding and mulching of all disturbed areas.

Additional services performed included the geotechnical, concrete thermostat blocks and kickers, provided As-Built Drawings, performed the excavation and removal, welding inspections, imported the backfill materials for utilities, provided landscaping, test pits, sediment and erosion control, installation of temporary construction fence and temporary ADA compliant sidewalks, cathodic protection, sump pump installation and demolition and reinstallation of minor electric.

The main aspects of the work were:

• Furnishing, installing and insulating approximately 340 feet of 5-inch SCH 40, 543 feet of 3-inch SCH 40, and 83 feet of 2-inch SCH 40 black Multi-Therm 500direct buried steam pipe.
• Furnishing, installing and insulating approximately 340 feet of 3-inch SCH 10 and 612 feet of 3-inch SCH 10 stainless steel Multi-Therm 500direct buried condensate pipe.
• Furnishing and installing a number of items, as shown on diagrams, in about one dozen manholes. All new piping to be insulated with 2 inches of insulation and aluminum jacket.
• Furnishing and installing in Buildings 11, 13, and 14 a number of items as specified in the plans. All new piping to be insulated with 2 inches of insulation and aluminum jacket. Building 11 contained a condensate return unit.
• Demolition of existing steam and condensate lines.
• Connections included isolating flanges, scales pockets, condensate drain lines, shut-off valves, check valves, steam traps, etc.
• Provide sump pumps for identifies units and up to 40 feet of piping to nearest storm drains
• Provide access ladders, vents and vent caps for identified (on plans) manholes
• Provide shop drawings for buried pipe system and for pipe systems located in mechanical rooms of Buildings 11 and 14
• Maintaining strict adherence to, and “paper trail” for compliance with, the American made Act for all steel, pipe, carbon fittings, carbon valves
• Demolition of asphalt curb and sidewalk covering areas with lines
• Excavation the areas to install new lines
• Demolition of old lines
• Installation of new steam and condensate lines
• Backfilling of trenches, installation of stone, replacing asphalt, concrete sidewalks and curbs.
• Supplying Maintenance of Traffic for all operations including road plates
• Excavation of areas for, and installation of, cathodic protection on newly emplaced lines
• Final stabilization on excavated area including seed and mulch

Initial activities included:

• Set up of erosion and sediment controls including super silt fence
• Set up of temporary construction fence, orange safety fence, and tree-protection fence
• Provision of portable sediment tank and dumpster
• At-grade storm drain inlet protection
• Geotechnical testing

In addition there was demolition of an existing site retaining wall, and subsequent replacement of the wall (concrete wall, 7 feet high) plus provision of 30 inch wide wooden walkways.

Related work included:

• Demolition of then-existing site retaining wall across from Building 17 and subsequent re-installation
• Removal of flag pole with crane and subsequent reinstallation
• Demolition of flag pole base and replacement with new base
• Demolition of five existing light poles and associated equipment
• New foundation and concrete for five existing light pole bases
• Removal of bike rack, then reinstallation
• Demolition of asphalt, curb, paving and sidewalk as appropriate with saw cutting included, and subsequent replacement
• Supplying Maintenance of Traffic for all operations including steel road plates
• Demolition of five trees and root pruning of two others, plus demolition of a number of bushes
• Replacement of bushes
• Protection of trees
• Seeding and mulching
• Set up of erosion and sediment controls including super silt fence
• Set up of temporary construction fence, orange safety fence, and tree-protection fence
• Provision of portable sediment tank and dumpster
• At-grade storm drain inlet protection