Repair Power Plant Siding, Eareckson Air Station, Shemya Island, Alaska

Brice performed construction and engineering at Eareckson Air Station (EAS) on Shemya Island, Alaska, to repair dilapidated siding on the Power Plant (Building 3049). Bldg. 3049 is the sole source of primary power for EAS. The siding on the power plant is comprised of two layers of corrugated steel with batt insulation in between. The outer skin of the building was ravaged by the harsh Aleutian weather for almost 30 to 40 years, exceeding its life, resulting in corrosion at the seams and around the older penetrations.

Building 3049 is a pre-engineered building 187-feet-long by 120-feet wide, and 39 feet high to the eave. There is a 120-foot long by 6-foot wide covered walkway connecting Bldg. 3049 to Bldg. 3051. Bldg. 3049 had numerous wall and roof penetrations requiring removal of appurtenances and closures. Brice performed a site visit to inspect all dimensions, number of doors and their locations, and quantities of materials and equipment required to complete the work.

Once in the field, Brice performed asbestos and lead-based paint abatement on the buildings, with continuous air monitoring to ensure worker safety. We then conducted selective demolition and debris removal. Demolition included: removal and disposal of existing exterior siding and insulation on Building 3049 and the covered walkway. We removed 15 hooded openings, 18 large diameter pipes, 13 small diameter pipes, including framing, hoods, flashing, and louvers.

Per requirements, we also removed seven exterior personnel doors and frames from Building 3049. Before removal, we performed lead paint abatement on the door frames. We then installed seven new doors with closers and hardware, and one new double door on south end of building with closers and hardware capable of operating despite the 30 to 40 mph wind conditions that frequent at Shemya Island.

Demolition debris and materials were disposed of onsite in coordination with the Base Operations Support (BOS) contractor. Asbestos containing material was encapsulated and disposed of as directed by the BOS contractor.

To begin repairs, we removed standing corrosion. We rebuilt the sides starting with a layer of closed cell polyurethane insulation to interior skin in purlin cavity, and applied a 2-inch minimum depth sealing around all penetrations of wall, creating a water tight and air tight seal.

We installed a new aluminum style rib-exposed fastener wall panel system with Versacor® coating with rubber washer stainless steel screws, along with new retro fit pipe boots to remaining pipe penetrations, and new flashing on eve, corner, and door openings.

Shemya Island is located in the North Pacific, and is accessible only by air and limited barge service during the summer. We chartered small planes to mobilize field personnel, and two C-130 planes to move materials, supplies, and equipment. Brice coordinated with the BOS contractor to unload all aircraft and barge deliveries of material and equipment.

To enhance safety while working under constant wet and windy conditions, we devised small containments, including temporary tenting and tarping to keep the work area relatively dry and warm. We monitored the weather multiple times daily, and when feasible, worked in areas with the least wind. At times, we also stacked shipping containers, two high and three long, to create wind shelters.

Brice performed all project and construction management. We monitored daily progress against plans; maintained submittal register; and performed daily reporting. As part of closeout, a final inspection was performed. At project completion, Brice provided all manuals, as built drawings, and warranties, and construction completion report.

Performance Highlights

• Completed all construction work in accordance with the scope of work, and the Unified Facility Criteria and all other specifications, codes, and regulations
• Despite constant rain and windy conditions, completed the project ahead of schedule, on budget, with zero safety incidents, no disruptions to power plant operations, and allowing full access to Air Force staff throughout project execution
• Worked closely with the client to identify a higher quality, cost effective, robust, long-term insulation solution that exceeded the performance specifications provided in the design documents, and reduced long-term costs and simplified future repairs and maintenance work
• Received “Very Good” CPARs for Quality, Schedule, Management