Design-Build Repair of 5 Storm Damaged Facilities, Eareckson Air Station, Shemya Island, Alaska

Brice performed the design-build of five storm damaged facilities at Eareckson Air Station (EAS) on the remote island of Shemya, located at the western end of the Aleutian Island chain, approximately 1,500 air miles southwest of Anchorage, Alaska. Our scope of work included: replacement of roofing systems on three buildings (POL, Communications, and Hangar 6), siding on three buildings, and flashing and hangar doors. Brice’s early involvement in the process allowed for the development of the most cost-effective and technically sound methodology and approach. We prepared a work plan, UFP-QAPP, and Site Safety and Health Plan.

Sophisticated logistics were required to source materials, equipment, and personnel from all over the country. We combined the logistics of multiple Brice-managed projects at EAS, mobilizing equipment, supplies, and materials in a single barge, resulting in over $500,000 in cost savings to client.

At project kickoff, we performed a site visit to evaluate Hangar 6 roof conditions. A structural engineer performed a survey and found a deficiency in the metal roof’s underlying deck layer that was causing corrosion due to constant high wind conditions at Shemya Island.

Brice negotiated a change order valued at $1.15 million with the client to perform selective demolition down to the existing steel frame and build a completely new roof system from the decking out to the aluminum roofing material using modern techniques. This would allow the structure to meet its intended lifespan of 50 years.

During selective demolition at Hangar 6, we discovered that additional purlins were needed. We modified our design to include additional purlins to meet the structural requirements for siding and had our registered engineer stamp the change with no impact to schedule.

To complete the project within the required schedule, Brice mobilized three field teams to perform the work: one team for the construction of Hangar 6 and the POL and Communications Buildings; one team to self-perform the siding removal and replacement on Hangar 6; and one team to repair the siding and the flashing on Hangar 8 and replace the roof drain assemblies on the POL and Communications Buildings. This approach minimized total field duration and maximized productivity during limited field season of Alaska. At project completion, we provided as-built drawings and O&M manuals.

Performance Highlights

• Completed the field work early despite initial barging delays (the fuel barge was docked at Shemya Island and takes precedence over supply barges)
• Reduced landfill waste by 75%, through selective demolition on Bldgs 515 and 618, removing only the insulation that was corroded
• Increased productivity and overall quality by applying a superior roofing membrane that could be applied in one-third of the time as the existing materials, and provided a better warranty and expected life
• Received the following CPAR: Quality and Schedule, Very Good; Cost Control, Satisfactory; Management, Exceptional; Regulatory Compliance, Satisfactory