Fort Detrick and Forest Glen Occupancy Sensors

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U.S. Army Corps of Engineers Baltimore District Frederick National Laboratory of Cancer Research (FNLCR) Occupancy Sensors, 200 kWPV, and Thermostats at Fort Detrick in Frederick, MD and Forest Glen Annex, Maryland

This project was for the installation of occupancy sensors at the Fort Detrick and Forest Glen Annex for the reduction of energy usage garrison wide through the use of occupancy sensors and modified boiler controls. The projects objectives were to reduce energy usage garrison wide through the use of occupancy sensors and modified boiler controls by providing roof mounted solar array on Building 693 in an effort to meet Federal renewable energy production goals. Crystalline solar panels installed on the southwestern facing roof via clamps and supports made for use with standing seam metal roof material.

The existing roofing system and its attachment to the existing structural roof framing system were evaluated and modified, to support the 200 kW roof mounted PV system. Meltech provided modifications to the existing roof system design and construction for the entire facility roof system, and including all necessary ancillary and incidental work necessary to maintain a watertight roof system installation while allowing for the installation of the 200 kW roof mounted PV system. We coordinated with system manufacturer to maintain existing system warranty. We followed all manufactures written recommendations and recertified the roof following construction.

We provided a roof mounted solar array on Building 693 in an effort to meet Federal renewable energy production goals. Crystalline solar panels were provided on the southwestern facing roof via clamps and supports made for use with standing seam metal roof material. The project consisted of three distinct parts: installation of occupancy sensors in 27 different buildings throughout the base and one at the Forest Glen Annex, installation of a roof mounted solar array on Building 693, and modifications to two boiler control sequences in Building 1532. Various types of occupancy sensors were utilized based on the construction and configurations of the rooms in which the lighting fixtures are going to be controlled. A blend of wall mounted, ceiling mounted, wireless, line voltage, and low voltage sensors were used. The buildings have were surveyed and the most beneficial and cost effective occupancy sensor applications were been identified. Wireless occupancy sensors were designated where wired sensors would result in significant architectural wall repair and disruption during construction. Low voltage sensors with power packs were specified where the coverage of multiple occupancy sensors to control one lighting circuit was required. Line voltage ceiling mounted sensors were provided where exposed conduit and conductors make interception of existing circuits a relatively simple matter. Wall mounted switch type occupancy sensors were provided in private office and other small rooms where existing switches can be replaced in existing outlet boxes to achieve appropriate coverage. Meltech provided modifications to existing area lighting systems consisting of fluorescent, metal halide, and incandescent, lighting to include occupancy sensors for automatic shut-off of fixtures in unoccupied spaces.

The work was completed on the following buildings:

Bldg. 243 – Bacteriology Lab
Bldg. 374 – Greenhouse Facility Lab
Bldg. 810 – Headquarters
Bldg. 1077 – CDMRP Building
Bldg. 1405 – AAFES / Post Exchange (Mini Mall) PX/Military Clothing
Bldg. 1430 – Unaccompanied Enlisted Personnel Housing
Bldg. 1529 – Community Activities Center
Bldg. 1533 – Unaccompanied Enlisted Personnel Housing Barracks
Bldg. 1534 – Unaccompanied Enlisted Personnel Housing Barracks
Bldg. 1535 – Unaccompanied Enlisted Personnel Housing Barracks
Bldg. 1536 – Unaccompanied Enlisted Personnel Housing Barracks
Bldg. 1538 – Unaccompanied Enlisted Personnel Housing Barracks
Bldg. 1540 – Certification Testing Information Assurance Training Center
Bldg. 1541 – Civilian Personnel Advisory Center
Bldg. 1545 – Administrative Offices
Bldg. 1546 – Administrative Offices
Bldg. 1674 – Procurement Division Building

 

 

Fort McNair National Defense University

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US Army Corps of Engineers National Defense University Fort McNair Marshall Hall South Plaza in Washington, DC

General Synopsis 

Meltech completed this important project for the US Army Corps of Engineers Baltimore District for the National Defense University George Marshall Hall at Fort Lesley J. McNair in Washington, DC. The project included the demolition, construction and landscaping (with environmental aspects) in the South Plaza immediately adjacent to Marshall Hall. 

In length of service as an Army post, Fort McNair ranks third and is the home of the National Defense University (NDU). Marshall hall is part of NDU and operations continued uninterrupted at the building throughout the project.

Meltech’s contract consisted of a two-part base bid. The first part of the base bid was for the demolition of concrete paving, utilities, plants, and all other demolition-related site work as shown on plans and specified. The second part of the base bid consisted of construction of an extended sidewalk and re-planting in the area west of 5th Avenue, and other related construction on the Marshall Hall South Plaza together with surrounding landscaping and storm-water management construction.

Since 90% of the buildings on Fort McNair’s 100 acres are historic buildings (built, reconstructed or remodeled prior to 1908) Meltech’s work was, as with that at Arlington National Cemetery above, subject to extremely vigilant oversight by the U.S. Army Corps of Engineers. For example, backfill materials had to be placed adjacent to all types of structures, and compacted to at least 90 percent laboratory maximum density for cohesive materials or 95 percent laboratory maximum density for cohesionless materials, in order to prevent wedging action or eccentric loading upon or against the structure. Compaction had to be finished by sheepsfoot rollers, pneumatic-tired rollers, steel-wheeled rollers, vibratory compactors, or other approved equipment. Similarly the placement and treatment of bedding, graded stone, various sands and gravels and other fill materials, was strictly controlled and overseen. 

Further Details 

Divisional work associated with the base bid included:

  • Division 2 work consisted of demolition, deconstruction, dismantling, reconditioning and disposal of existing building materials, equipment and utilities as a part of new construction or renovation work, placement of select fill and topsoil layers for landfill cover systems on geosynthetic materials.
  • Division 3 work consisted of cast-in-place concrete, precast concrete wall panels with normal-weight aggregate Portland cement concrete, conventional reinforcing, and smooth surface or exposed aggregate facing 
  • Division 4 work consisted of reinforced and non-reinforced masonry.
  • Division 7 work consisted of applying sealants for normal building construction.
  • Division 10 work (Specialties) consisted of a pre-manufactured fabric covered steel shelter structure and vertical metal treillage device that allows for plant and vine support. 
  • Division 12 work consisted of miscellaneous site and street furniture and furnishings including shelters, waste and recycle receptacles, ash urns, tables, and chairs. 
  • Division 26 work consisted of general electrical work at the site, installation of photoconductive lighting control devices for use with exterior lighting systems, and installation of exterior lighting systems.
  • Division 31work consisted of earthwork activities, clearing and disposal of trees, stumps, clearing fences, buildings, and other structures and disposal of debris, trash, and materials resulting from clearing operations, clearing and grubbing.
  • Division 32 work consisted of plant material and irrigation during the establishment 
  • Period, concrete sidewalks and curbs and gutters, constructing a concrete block pavement, seeding, exterior planting, storm drainage piping systems using concrete, clay, steel, ductile iron, aluminum, polyvinyl chloride (PVC), and polyethylene (PE) pipe, sub-drainage systems for drainage of water from under the ground.

 

Meltech received an outstanding performance evaluation for the base bid work and as a result two further optional items were exercised. The first option item was for supply and installation of “Bioswale plantings”, procuring and replacing an electrical manhole ring, refinishing some existing structural elements, and addition of a ground neutral line in the panel box feeding the lights and outlets on the site. Bioswales are landscape elements designed to remove silt and pollution from surface runoff water. They consist of a swaled drainage course with gently sloped sides (less than six percent) and filled with vegetation, compost and/or riprap.  The water’s flow path, either a meandering or almost straight, with wide and shallow ditches, maximizes the time water spends in the swale, thus trapping pollutants and silt. Biological factors also contribute to the breakdown of certain pollutants. This work involved a modification to provide and install an extension of the existing irrigation sprinkler system to two new areas adjacent to the South Plaza and Bioswale. 

The second option item involved the supply and installation of exterior furniture at the site. The major scope elements of the options work were:

  1. Field investigation and measurements for the work
  2. Preconstruction/technical/product submittals and shop drawings
  3. Rigging and hoisting for the work
  4. Protection of existing surfaces
  5. Coordination with other trades
  6. Layout for the work
  7. Site demolition as necessary
  8. Third party testing of the work
  9. Provision of full-time on-site superintendent
  10. Daily cleanup of all trash and debris generated by the work
  11. Hauling and removal of all trash and debris
  12. Coordination, inspection and identification of underground utilities
  13. Furnishing and installing all erosion and sediment control systems
  14. Furnishing and installing all tree protection
  15. Furnishing and installing inlet protection
  16. Furnishing and installing a stabilized construction entrance 
  17. Furnishing and installing all concrete sidewalks, seat walls and footers
  18. Furnishing and installing all paver systems
  19. Furnishing and installing striping
  20. Furnishing and installing all plantings including shrubs  and trees
  21. Furnishing and installing all seeding
  22. All rough and fine grading
  23. Furnishing and installing all perforated under-drain piping
  24. Furnishing and installing all rip-rap and miscellaneous stone
  25. Furnishing and installing all mulch
  26. Ancillary support (permits, licenses, Davis-Bacon, certified payrolls, applic. taxes, etc.)

 

Fort Belvoir Historic Rehabilitation

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US Army Design Build Exterior Rehabilitation of Historic Buildings at Fort Belvoir in Fort Belvoir, Virginia

General Synopsis

This initial contract was for the design and historical rehabilitation of five (5) separate historic buildings located at Ft. Belvoir, VA. Buildings 212, 213, 219, 240 and 256 were rehabilitated in a manner consistent with the Secretary of the Interior’s Standards and Guidelines for Rehabilitation. Work on this historic rehabilitation project included the replacement of storm windows, painting windows, tucks pointing, masonry repairs, brick replacement and power washing. The contract cost increase was due to the client adding two (2) additional buildings to the scope. Meltech received an outstanding rating on this project on this high-profile command interest project. Meltech self-performed approximately 30% of the work on this project including project management, supervision, QAQC, Safety, and general conditions, window installation, painting and power washing. The client was extremely satisfied with Meltech’s work and added 2 additional buildings to the original scope of work.

Meltech provided 35%, 65%, and 95% design documents for the completion of all tasks.

Challenges that were successfully overcome included the fact that lead-based paint was presumed to be present on all buildings, so all loose and flaking paint had to be removed prior to any work being undertaken. Paint chips resulting from the removal work were treated as hazardous material and were disposed of by the client.

Further Details

Building 212 had a general scope of rehabilitation that included:

  • cleaning of the building exterior,
  • repair of damaged and failing masonry (including improvements to past improper repairs)
  • painting and repairs to wood elements such as windows and cornice, dormers and trim
  • foundation and concrete wall repairs including repair of all general cracking with injection grout
  • foundation preparation, priming and painting of the concrete foundation wall and porch to match surrounding structures,
  • painting of metal rails
  • Repairs to brick walls including
    1. Removal of heavy bituminous staining and paint splatter from brick surfaces
    2. Removal and repair of all extraneous penetrations which included pipes, nails, attachments and anchors
    3. Provision of copper chimney cap to cover and seal uncapped chimney
    4. Repointing and stabilization of brick chimney
    5. Replacing poor and failing masonry repairs with brick and mortar
  • Repairs to windows and doors including reparation, priming and painting of all exterior wood doors, trim and associated transom

Building 213 was in a similar state and had similar needs to building 212 above with the addition of:

  • Repairs to a slate roof including:
    1. Repair/replace/rehanging of all copper gutters and downspouts and installation of leaf guards
    2. Repair of damaged downspouts and replacement with in-kind materials
    3. Reconnection of all downspout as to subterranean drainage system
    4. Installation of missing cast iron downspout boots
  • Porch, step and ramp repairs including caulking the junctures between steps, ramps, landings, and building foundations and adjacent sidewalks

Building 219 had originally been a theater and gymnasium and now featured administrative space in lieu of the gymnasium. The building had a complex footprint and employed two different roof types – a one story brick hyphen connecting to two two-story brick wings, with the hyphen terminating in a side gable roof with gable dormers. The repairs to this building were of similar type to buildings 212 and 213 above but required extra awareness of the roof geometry. The suite of repairs for this building included:

  • Cleaning (10,000 sf)
  • Foundation repairs
  • Wood cornice, eaves, siding, parapet, column, pediment, pilaster and trim repairs
  • Brick wall repairs including replacement of a number of damaged bricks, removal of all abandoned electrical conduit/pipe , repair of spalling masonry at door surround keystone
  • Concrete wall repairs
  • Window and wood repairs, similar to two buildings above, but including in addition replacement of failed glazing compound, repair and replacement of rotted wood as needed, provision of exterior storm windows with low-emission glass coatings and screens
  • Porch, step and ramp repairs
  • Site work
  • Roof repairs
  • Exterior lighting including repair and rewiring of historic lights and carriage lamps and demolition of existing security lights and conduit and replacement with new fixtures with interior wiring incorporating full cut-off and LED wall packs

Building 240 had a general scope of repair similar to the above buildings but required that stucco elements of design be addressed and work on a rear loading dock and main entrance façade be included. The suite of repairs for this building included:

  • Cleaning
  • Stucco, cornice, eaves, siding, parapet, column, pediment, pilaster and trim repairs, including repair, treatment and painting of a stucco tower
  • Brick wall repairs including full suite as in building 219 above plus verification and confirmation of pointing on an existing stone chimney cap
  • Concrete and precast repairs including suite of repairs as in building 219 plus repairing a concrete failure on a rear loading dock, repairing concrete cracking on a rear loading dock, and installing rubber bumpers on a rear-loading dock.
  • Window and wood repairs
  • Porch, step and ramp repairs
  • Site work
  • Roof repairs

Building 256 had a general scope of rehabilitation that included:

  • Cleaning
  • Foundation repairs
  • Wood cornice, eaves, siding, and trim repairs
  • Brick wall repairs similar to building 240 above also but including cleaning heavy dirt/organic/chemical staining
  • Window and wood repairs, similar to buildings 204 and 219 above, but including in addition
    1. Replacing an existing steel door with a custom made replacement unit, frame and locking mechanism manufactured to fit in the existing opening and including all flashings, door sweeps, threshold and weather stripping,
    2. Removing an existing double doors and frame and replacing with new steel doors, frame and locking mechanism, with all similar in detail to the historic entrance doors
    3. Replacing a rotted/ rusting exterior door and frame with a replacement similar in historic detail with a four-paned window,
    4. Restoring a fanlight window above a ceremonial entrance
    5. Removal of a set historically inaccurate replacement windows
    6. Replacement of a set of ordinary windows with historically sensitive steel hopper industrial windows,
  • Site work
  • Gable roof addition repairs
  • Exterior lighting

Smithsonian Steven F. Udvar-Hazy National Air and Space Museum

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Smithsonian Institution Steven F. Udvar-Hazy National Air and Space Museum Design Build Construction Services for Improvements to the Parking Access and Revenue Control System (PARCS) Upgrades at the Parking Entrance in Chantilly, Virginia

This project was for the design build construction services for improvements to the Parking Access and Revenue Control System (PARCS) upgrades at the parking entrance at the Smithsonian Institution Steven F. Udvar-Hazy National Air and Space Museum. The work included the reconstruction of vehicular entry and exit lanes to modify the current (4) lanes to expand to (8) lanes to include a bus lane, ground mounted directional lane change, expansion of entrance gate to accommodate (8) lanes, new ground sensors for new lanes at entrance gate, additional 6X8’ LED electronic information message signs at various locations throughout the parking garage and entrance and exit areas, installation of (4) Pay-On-Foot pay stations inside garage, installation of (5) new light poles, demolition of (3) security booths and installed (2) new security guard booths and construction of a retention pond. 

This project was completed at the Smithsonian (SI) Steven F. Udvar-Hazy National Air and Space Museum (NASM) in Chantilly Virginia. The National Air and Space Museum is the largest of 19 museums included in the Smithsonian Institution. The NASM is located near Washington Dulles International Airport in Chantilly, Virginia, is a massive structure with open, hangar-like settings that accommodate large aircraft and spacecraft, as well as entire collections of aviation and space artifacts. The NASM is located on Metropolitan Washington Airports Authority (MWAA) leased property. All work completed at the NASM was not only done in accordance with SI but also with MWAA. All work required inspection from both SI and MWAA. The project was completed while the museum was open. The work was completed during normal business hours with the parking garage remaining open. Meltech coordinated multiple construction activities to include visitor safety and access to museum and garage and traffic management into garage. We maintained a clear and safe path at all times to allow circulation.

Fort Detrick Building 362

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Leidos Biomedical Research Facility (Leidos) Frederick National Laboratory for Cancer Research (FNLCR) Ft Detrick Building 362 Parking Lot Paving and Drainage

Meltech completed this project for the paving and drainage for the Leidos Biomedical Research Facility Inc., in support of the Frederick National Laboratory for Cancer Research at Fort Detrick in Frederick, Maryland. The purpose of this project was to removal the deteriorated road surface, redirect the through-traffic flow, improve the area drainage and re-pave the access road and parking lot in the Building 362 area. The project will collect the storm water runoff and direct the storm water into the existing storm pipe and inlet structure at Miller Drive. 

Further Details 

This work required a new trench drain in front of Building 362 and a new trench drain at the parking lot entrance at Miller Drive. Meltech completed the installation of a new concrete swale at the trench drain in front of Building 362 and a new trench drain to facilitate the water migrating to the existing storm pipe and inlet structure at Miller Drive. The project impacted several buildings on the Fort Detrick base: Buildings 362, 363, 361, 359, 319, 324, 322, 323, 318, 390, and 374. Although the service lane and the parking lot was closed during construction, the buildings being served by the roads/lanes remained operational during construction. The coordination of the construction vehicles and the staging/storage area was required to ensure and safe work site and to minimize disruption to the building occupants. Meltech maintained access for both pedestrians and rolling carts at all times. The buildings were not able to be vacated as there are animals in many of the service lane buildings. Access was required from these buildings to the tunnel washer located in Bldg. 1021. The APA buildings house laboratory animals and the animal cages, bedding material, etc. will be transported between buildings and the tunnel washer in Bldg. 1021 during construction. Phasing and extensive coordination were required to facilitate the LASP animal program operations. Additional noise and vibration were also factors affecting the animals’ health environment. Measures were taken to ensure that noise and vibration did not affect the animal science work being completed in the APA buildings. 

The project was completed with several phasing constraints. This project was for paving and drainage of several areas on the Fort Detrick base. The project was completed in phases: APA Phase II, Bldg. 362 Parking Lot; Bldg. 350; and Option Work. The new curb, subbase restoration and new base first to allow limited traffic on Cain Street. Upon completion, Meltech completed the demolition and paving restoration in the Building 362 lot. Meltech was responsible for contacting Washington Gas to determine the exact location of the existing gas lines that runs through the parking area. 

APA Paving Area: The purpose of this project was to remove the deteriorated road surface, sub-surface and repaving of the service lane on the two service lanes that run from 1026/1027 to Boyles St. and from 1029 to Boyles St. The project was to ensure proper storm water collection and drainage, and repair/replace head walls. 

The APA Phase II work consisted of the paving and drainage and all other construction services to pave the two APA Phase II service lanes, rock removal transport and testing, demolition of concrete encased existing storm drain piping and concrete retaining wall. The project included paving to the road and parking lot at Bldg. 362. The worked included the excavation of the existing service lanes down to the desired depth; removal of any obstructions encountered to include concrete; installation of erosion and sediment control measures; removal of the retaining walls and rebuild with stackable blocks. Meltech installed a new asphalt service lane consisting of 6” stone base, 4” asphalt base, and 1-1/2 surface course. We widen the service lanes as much as possible without removing the pipe stations and removed all of the existing drain pipes. We completed the rebuild and reconfiguration of the service lane to eliminate, or minimize, the pinch points at the pipe sanctions. Meltech rebuilt the Boyles Street entrance to remove the pinch or hourglass configuration and installed the curb and gutters. We completed the installation of a new storm drain inlet directly above the new storm water pipes under the new services lanes at two sections and completed the new inlet tie into the new storm pipe. We installed a slotted drain pipe at two locations and relocated one guy wire. We completed the removal of the existing traffic signs and reinstalled upon completion. We completed the removal of the manhole and drain pipe from the swale at Building 1044 and extended the swale and installed new pipe. Finally we completed the break of three (3) existing concrete steam vaults to grade and fill with gravel and installed the line stripping as indicated. 

The Bldg. 362 Parking Lot work consisted of the paving of the Bldg. 362 road and parking lot. The work included the excavation of the existing road; installation of new asphalt road consisting of 6” stone base, 4” asphalt base, and 1-1/2 surface course; raising of all sewer cleanouts, manholes, and water valve boxes to above grade; installation of new curb and gutter; removal of existing gravel and installation of new concrete pads for the existing dumpsters; installation of new storm water trench drains; installation of new concrete swale; construction of new concrete apron at trench entrance; installation of new piping from trench drain to new concrete swale; reconfiguration of center island to redirect traffic around the parking lot; removal and installation of new sidewalks; removal and installation of new wood handicap ramp; Mill Beasley Drive and tie in new asphalt roadway; slope grade away from new curb and gutter; installation of pavement markings and install new signage; removal of existing drain pipe at Beasley Drive; removal of existing 6-inch drain pipes that run under the sidewalk; and installation of new asphalt sealer over the remaining pavement at the Carpenter Shop Dust Collection area. 

The Bldg. 350 work consisted of the regarding of the grassy area outside of Bldg. 350 to eliminate ponding; removal of unsuitable materials; import, placement, compaction and testing of suitable; paving and all other construction services to pave the two APA Phase II service lanes; to pave the road and parking lot at Bldg. 362. The work consisted on the removal of the existing sidewalk from Bldg. 349 to Bldg. 350. Meltech completed the reinstallation of the sidewalk at a new location towards the main parking lot and further away from new swale to avoid the sidewalk from acting as a dam from Bldg. 350 to the new swale. The work consisted of the removal and installation of two (2) new concrete picnic table pads; removal of a portion of the sidewalk from Bldg. 350 to the main parking lot and from Building 350 to Ware Drive; reinstallation of the sidewalks in the same location but elevated to be above the drainage area; removal handrails at the Bldg. 350 entrance; grind smooth and paint; reconfiguration of the existing retaining wall and add one additional 6×6 timber to the top of all the retaining walls to provide a greater slope away from the Bldg. 350 to prevent new backfill material off of the new building EIFS. Meltech completed the removal of part of the existing asphalt surface in the nook between Bldg. 349 and 350 to the main parking lot and of the existing drain pipe connected to the downspout off of Bldg. 350 and installation of new pipe at new elevation and the connection of two existing to the new pipe. Meltech regarded the area to create a new swale from the Building 349 parking lot to Ware Drive. We install a new under-slab trench drain under the new sidewalk that runs from Building 350 to the main parking lot and removed the curb and sidewalk to allow the installation of the new trench drain. The trench drain conveyed the surface runoff from the new swale to the storm system under Ware Drive. Meltech also relocated one tree out of the swale area.