Design Build Repair E-28 Arresting Gear Foundations, NAS El Centro, CA

Prime Contractor: Jacob Construction & Design, Inc.

Contract Number: N62473-15-C-3611

Contract Value: $598,253.00

Contract Award Date: 09/17/2015

Final Completion Date: 11/08/2016

Agency: NAVFAC SOUTHWEST, NAF El Centro FEAD, El Centro, CA

Project Goal

JCD provide NAF El Centro with the design and reconstruction of E-28 Arresting Gear Foundations.

Description

Jacob Construction & Design, Inc. provided the Naval Air Facility in El Centro, with the design and reconstruction of two Portland cement concrete E-28 arresting gear foundations.

Design Phase – The biggest priority of JCD’s design efforts was ensuring all concerns, requests, and conditions were absorbed before drawings and documentation were produced. Therefore, consultation with the A/E/C team and other consultants, facility personnel, and COR was promoted throughout all phases of the design process. Given the project type and sensitivity to dimensional tolerances of the arresting gear equipment, JCD’s design team worked closely with the geotechnical engineer to evaluate subgrade properties. JCD’s Geotechnical Coordination also included thorough Topographic surveying, including the existing site, the Runway Protection System, the Arresting Gear Foundations, and of all new construction. During the design development, construction specifications, structural drawings and details were drafted internally. When ready, Pre-Final Structural Drawings, Calculations, Specifications, and Basis of Design were submitted to the government for review with a Final Design submission process to follow.

Removal of Above Ground Items (performed inhouse) – All above-ground E-28 equipment was dismounted by JCD from the North and South foundations. Once disassembled, they were temporarily stored off site at a designated storage yard until JCD had completed the foundation and electrical requirements.

Demolition & Construction of Concrete Foundations (performed inhouse) a two feet width of asphalt was sawcut around the perimeter of the North and South concrete foundations by JCD personnel. Then, the existing foundation was removed by utilizing a 320 Excavator/Air Hammer and 310 Backhoe loader. Once removed, excavated dirt was relocated to occupy voids/holes and a foundation footprint was prepared for both locations. Form foundations were constructed in place and prefabricated rebar was transported in and installed in the designated footprints. Following a quality assessment, cement concrete of 4500psi was poured into the footprints monolithically to ensure high durability and strength of new foundations. Following the pour, all equipment pad surfaces and edges were given a smooth trowel finish and all strip/stack forms were removed/disposed of offsite. JCD then proceeded to import dirt to backfill the vacant cavities surrounding new foundation to meet subgrade before depositing bituminous pavement.

Fabricated Component – Fabricated Base Plates & Bolts To provide protection against corrosion and to ensure longevity of the fabricated steel base plates and bolts, a Flame-Sprayed Aluminum Corrosion Protection Coating was applied to the surface of the oversized plates/bolts. This unique flame spray process used oxygen/acetylene to melt aluminum wire and compressed air to propel the molten aluminum onto the base plates. After the coating had cooled sufficiently, a sealer was applied over the aluminum coating. This specialized thermal coating process had been proven to safeguard the plates from atmospheric and water related corrosion.

Electrical Work (performed inhouse) Electrical work commenced only after L.O.T.O. procedures had been carried out and successfully signed off by the government. During the demolition phase, the main priority for electrical consisted of disconnecting the control panel/lighting wiring as the Arresting Gear equipment was being dismantled. When all equipment had been removed from site, JCD proceeded to demo out and replace only the finish ring portion of the two pull boxes. Once complete, traffic rated lids were installed on each of the pull boxes. Once all E-28 Arrest Gear Equipment had been assembled atop the new foundations, JCD ensured all control panels and lighting were reconnected to transformer before the lockout/tag out was removed and the Arresting Gear system reenergized.

Once all returned equipment had been securely bolted down, the system was restored to full functioning capacity. At this point, JCD worked with the government to remove the lock-out tag-outs and proceed to re-energize required circuits and implement testing of the Arresting Gear, at which startup, testing, and final tuning were conducted before commissioning the system.

Given the status of the active base, rigorous scheduling needs and 115-degree weather, this project required night and day performance.