NATIONAL AERONAUTICS AND SPACE ADMINISTRATION
CONSTRUCTION OF FACILITIES
FISCAL YEAR 1996 ESTIMATES
SUMMARY
REPAIR
Summary of Project Amounts by Location: Amount
--------
Ames Research Center...................................... $3,550,000
Dryden Flight Research Center............................. 1,320,000
Goddard Space Flight Center............................... 2,800,000
Jet Propulsion Laboratory................................. 2,600,000
Johnson Space Center...................................... 2,750,000
Kennedy Space Center...................................... 3,750,000
Langley Research Center................................... 4,270,000
Lewis Research Center..................................... 3,550,000
Marshall Space Flight Center.............................. 4,300,000
Michoud Assembly Facility................................. 1,350,000
Stennis Space Center...................................... 1,850,000
Wallops Flight Facility................................... 2,500,000
Miscellaneous Projects Not in Excess of $250,000 Each..... 410,000
Total............................................... $35,000,000
CONSTRUCTION OF FACILITIES
FISCAL YEAR 1996 ESTIMATES
PROJECT TITLE: Repair of Facilities, Not in Excess of $1,500,000 Per Project
INSTALLATION: Various Locations
FY 1996 Estimate: $35,000,000
FY 1994: $36,000,000 FY 1995: $30,000,000
COGNIZANT INSTALLATIONS/LOCATIONS OF PROJECT: Various Locations
COGNIZANT HEADQUARTERS OFFICE: Office of Management Systems and Facilities
SUMMARY PURPOSE AND SCOPE:
These resources will provide for critical repairs to facilities at NASA field installations and
Government-owned industrial plants supporting NASA activities. Included in the request are those
facility repair needs for FY 1996 that can be identified at the time of the submission of these
estimates and are not in excess of $1.5 million per project. The thrust of this program is to
restore facilities and components thereof, including collateral equipment, to a condition
substantially equivalent to their originally intended and designed capability. The request
includes the substantially equivalent replacement of utility systems and collateral equipment
necessitated by incipient or actual breakdown. This work also includes major preventive measures
that are normally accomplished on a cyclic schedule.
PROJECT JUSTIFICATION:
NASA is now experiencing block obsolescence where a substantial portion of the agencys
facilities have been in use for over 25 to 30 years. Repair costs for mechanical and electrical
systems in a typical building are almost three times higher after system operations exceed 15Ð20
years than they are during the initial years. Many electrical and mechanical components reach
the end of their serviceable or economic life at the 20 year point and should be replaced in the
interest of long-term economy. Continued piecemeal repair of these components is more costly in
the long run than replacement at the end of the economic life of the original components.
Approximately 90 percent of NASA physical plant has been in service for over 25 years.
A major thrust of this repair program is to help preserve the capabilities of the NASA physical
plant, which has a capital investment of $5.5 billion and a current replacement value of more
than $15 billion. This work must be addressed and progressively accomplished. Otherwise, risks
are increased and future repair costs will be significantly greater. More importantly, there
will be increased breakdowns, interruption of critical operations, and costly unscheduled repairs
incurred.
This program includes only facility repair work having an estimated cost not in excess of $1-
million per project. The work is of such a nature and magnitude that it cannot be accomplished
by routine day-to-day facility maintenance and repair activities. Repair projects estimated to
cost more than $1.5 million are included as separate discrete projects in the budget request.
PROJECT DESCRIPTION:
Proposed repair projects for FY 1996 totaling $35 million are described under ÒPROJECT COST
ESTIMATE. This repair program has been distilled from requests in excess of $54 million, and
thus represents a modest request in relation to the continuing backlog of this type of work. The
projects that comprise this request are of the highest priority based on relative urgency and
expected return on investment. Deferral of this mission-essential work would adversely impact
the availability of critical facilities and program schedules. Projects estimated to cost not in
excess of $250,000 have not been individually described or identified by Center. The total
request for this category is $410,000.
During the course of the year, it is recognized that some rearrangement of priorities may be
necessary. This may force a change in some of the items to be accomplished. Any such changes,
however, will be accomplished within total available repair resources. The following broad
categories of work are described further in the PROJECT COST ESTIMATE:
a. Utility Systems............................................. $9,850,000
b. General Purpose Buildings................................... 5,800,000
c. Technical Buildings/Structures.............................. 8,910,000
d. Pavements and Drainage...................................... 5,720,000
e. Building Exteriors and Roofs................................ 4,720,000
PROJECT COST ESTIMATE:
A. Ames Research Center (ARC)............................................................ $3,550,000
1. Repair Underground Sanitary Sewer System........................................... 580,000
Approximately 1,250 meters of sewer will be repaired in this project. Repairs will include
placing lining material in existing pipe and spot replacements. The system is over 40 years old
and has been subjected to earthquakes, encroaching tree roots, and other damage. The piping and
joints are cracked causing waste to seep into the ground and ground water to infiltrate into
system causing increased sewage treatment cost. Tree roots have caused numerous blockages severe
enough to cause waste to back up into buildings.
2. Repair of Pressure Systems (N229A)................................................. 660,000
This project will replace or repair as needed 21,000 kPa piping distribution systems and
interstage piping associated with the compressors located in the 3.5-foot Hypersonic Wind Tunnel
Auxiliaries Building (N-229A). The recently completed pressure systems recertification
inspections have revealed a major portion of the interstage piping for the compressors is of
substandard quality. If weld failure occurs, it would pose danger to the system, the building,
and to human life.
3. Repair Steam Vacuum System Lines (N234A)............................................ 400,000
This project will replace the high pressure steam lines in the Steam Vacuum System (SVS) of the
Thermal Protection Laboratory Boiler Building. The recently completed in-house inspection of the
high pressure steam lines in the SVS determined that all welds in the system were potentially
defective due to substandard welding procedures. Twenty percent of the welds were
radiographically inspected and all possessed non-acceptable weld defects that could result in
piping failures while in service. If failure occurs, it would pose a danger to the system and
human life.
4. Repair of 80 X 120 Wind Tunnel Access Doors......................................... 480,000
This project will improve the latching mechanisms and limit switches, and will provide
maintenance access platforms and ladders. In order to perform maintenance or safety inspections
on the doors, maintenance personnel currently must climb out onto the structures high above the
ground and crawl to the latching mechanisms to service them. This inherently unsafe practice is
not acceptable by NASA and OSHA standards. Failure to install ladders and platforms may result
in injury or loss of life.
5. Repair Water Distribution System.................................................... 580,000
This project will replace various components of the Ames and Moffett Field center wide potable
and fire water distribution systems. The majority of piping, valves, and regulators for the
water distribution systems are approaching 50 years of age. This, coupled with corrosive
subsurface conditions has degraded the components to an unreliable state. Failure to repair the
water distribution systems could cause damage to existing facilities, injury to personnel, and
contamination of potable water supply.
6. Replace Water Pumps (N234)......................................................... 460,000
This project will increase the reliability of the Thermal Protection Laboratory Cooling Water
System supporting the testing performed in N234A and N238, by replacing the high pressure cooling
water pumps, motors, and bases. These pumps provide critical cooling water to the high energy
Arc Jet Electrode Assemblies, Constricted Arc Column, Nozzle Throat Section, and Power Bus
Subsystem. Pump failure with a corresponding drop in cooling water flow-rate could create
catastrophic failure of equipment and danger to personnel.
7. Repair Duct Work (N239)........................................................... 390,000
This project will repair existing duct work in the Life Sciences Research Laboratory. Internal
sound insulation will be removed and ducts, air handlers, and components will be cleaned. Access
panels will be installed for duct and heating coil maintenance. A wall will be constructed
around the air intake vent to eliminate excess dirt and fume ingestion. Building N-239 lab areas
require 100 percent outside air. Over the years dirt and dust have accumulated in ducts and
equipment. The high velocity and air volume in the ducts disturbs the dust and creates
particulate flow throughout the building.
B. Dryden Flight Research Center (DFRC)................................................. $1,320,000
1. Repair Dryden Central Steam Plant (4886).......................................... 240,000
This project replaces the existing system with two new 112 kW natural gas fired steam boilers,
deÐaerator and condensate recovery system, associated piping, computerized water treatment
system, and an air pollution control system. Building 4886 is the main source of heat for
Building 4800, DrydenÕs largest building, and two of Drydens major hangars, Buildings 4801 and
4802. This system was constructed in 1954 and all components have exceeded their useful life
expectancy. The steam distribution system, including air handlers and distribution piping, is
already in place, but the boiler must be replaced in order to make the system efficient.
2. Repair Dryden 35,000 Volt Circuit................................................ 450,000
This project will replace an unreliable power transmission system between Substation 16 and
Building 4840 with a new six-way duct bank with individual cables feeding each transformer from
Substation 16. Manhole E-25A will be removed and replaced due to violation of National Electrical
Codes. If existing 35 kV feeder cables were to fail, the failure or explosion would damage the
duct, making it impossible to remove the damaged cable or to pull a new cable in the damaged
duct. The existing transformers have no separate over-current protection within the manhole, so
if one transformer fails, they all fail.
3. Repair Roads, Paving, and Main Parking Area...................................... 630,000
This project provides for the repair of roads, paving, and parking areas including some flight
line areas. The work includes the repair of cracked pavement and potholes, resurfacing
approximately 24,000 square meters of asphalt pavement, and the realignment of Forbes Avenue
roadway. This project is needed to bring the existing roads, paving, and parking areas back into
maintainable condition. Continued neglect of flight line areas will cause foreign object damage
(FOD) to aircraft engines, tires, and landing gear systems, and may cause damage to aircraft
ground equipment (making some areas unusable for aircraft). Forbes Avenue roadway safety is
compromised due to drainage problems and poor sight distances.
C. Goddard Space Flight Center (GSFC).................................................. $2,800,000
1. Replace Roofs, Buildings 28 and 17............................................... 700,000
This project provides for the repair of portions of roofs on Buildings 28 and 17. The work
involves the replacement of 4,500 square meters on the Technical Processing Facility (28) and
1,800 square meters on Administrative Support Building (17). The work includes removal of
existing roof assemblies down to the structure and their replacement with new insulation and
modified membrane roof system. These roofs have a history of leaks and drainage problems. The
new roofing system will remedy the defects and reduce maintenance costs.
2. Repair Exterior of Research Projects Lab (2)..................................... 900,000
This project will provide for the repair of building exterior components on the north side of the
Research Projects Laboratory (Building 2). The project includes replacement of existing exterior
metal panel systems and windows as well as masonry repairs. In addition, this project will
replace induction unit component parts, including modifications to the associated secondary water
systems and air handling units. Asbestos will be removed as required. This building shows
numerous signs of water damage due to deterioration of the exterior wall system. The proposed
work will restore facility integrity and minimize potential loss of government property due to
water damage.
3. Repair Air Handling Units and Controls, Buildings 16 and 26...................... 650,000
This project provides for the replacement of air handling unit components and related piping and
controls in Logistic and Supply Facility, Building 16 and Space Science and Data Center, Building
26. Asbestos will be removed as required. The existing control valves for the induction units
need to be replaced because they frequently malfunction after becoming clogged with scale. Other
components which have deteriorated and need to be replaced include the induction unit drain pans,
piping, and dielectric couplings. Heat exchangers need to be provided in Building 26 to prevent
contamination of the secondary water system by the primary system. The air handling units in
these buildings have exceeded their design life and are inadequate for their present usage.
4. Repair Electrical Systems, Various Buildings..................................... 550,000
This project provides for the replacement of motor control centers in Building 5. In addition,
replacement of individual wall mounted motor starters in Buildings 16, 17, 18, 19, 20, and 25
with centralized motor control centers is included. This project is required to replace
electrical equipment which is in poor condition due to age and excessive usage. The equipment is
obsolete and replacement parts are often not available. Replacement of this equipment will
improve maintainability and reliability.
D. Jet Propulsion Laboratory (JPL).................................................... $2,600,000
1. Repair Curtain Wall, Space Flight Support Facility (264)........................ 900,000
This project will repair approximately 2,200 square meters of existing curtain wall on the north
and east facades of this eight story building. A new curtain wall system will be attached to the
exterior of the existing system utilizing the existing vertical mullions for structural support.
The new system will include new glazing and gutters. The building has a severe leakage problem
and glass plates have fallen out. Hazardous conditions have resulted from water passing through
the curtain wall and soaking the carpet, electrical cords, and equipment.
2. Refurbish Corridors, Control Systems Laboratory (198)........................... 650,000
This project will replace approximately 730 square meters of deteriorated, outdated finish
details. The work includes replacement of ceiling panels, carpeting, and painting. New duct
work will be provided for the return air plenum. All doors will be replaced with 20 minute fire
rated doors. The building has been converted from laboratory space to offices with a significant
increase in building population. Renovation of the heating, ventilating, and air conditioning
system is required to eliminate the corridor as a return plenum. Return air registers at the end
of the corridors will be removed and openings closed. The corridors are being renovated to
provide fire rated ceilings and doors to conform with life-safety building codes.
3. Repair Exterior, Physical Science Laboratory (183).............................. 450,000
This project provides for the repair of approximately 2,900 square meters of the exterior surface
of Building 183. The project will remove existing coatings, and repair and reseal plaster
panels. Included is caulking and flashing around doors, windows, and other openings. The east
and west masonry walls will be cleaned, repainted, and waterproofed. All window wall glazing in
the lower lobby area will be removed and replaced. The existing plaster walls have deteriorated,
cracked, and peeled. Mortar joints in the masonry walls are pitted. Caulking and flashing
around windows and other openings are dried and cracked. These conditions allow water to
penetrate the building.
4. Repair Paving, Upper West Parking Lot........................................... 600,000
The project will remove and replace approximately 12,000 square meters of asphalt paving on the
upper west parking lot including a portion of Explorer Road and parking areas adjacent to it from
Gyro Road on the west to the intersection of Pioneer Road on the east. The pavement will be
removed and the area will be regraded. A new 150mm aggregate base and 75 mm asphalt paving will
be placed. Included will be a new concrete surface drainage system. The pavement is 30 years
old and is severely deteriorated. Slurry coating is not justifiable as the sub-base is unstable
and would not hold up under constant traffic. In addition, approximately 50 more parking spaces
will be created by restoring the lot with 2.5 meter stalls.
E. Johnson Space Center (JSC)...........................................................2,750,000
1. Repair Access Road, White Sands Test Facility.................................... 900,000
This project provides for repair of the main access road to the White Sands Test Facility (WSTF).
The work consists of repairing the approximately 9.7 kilometer long by 7.3 meters wide road. The
repair will include crack sealing of approximately 76,100 square meters of existing pavement and
laying a 51 millimeter thick hot mix overlay. In addition, the shoulders will be raised to match
the new surface, settling basins will be dug at locations on the upstream side, and the
downstream shoulders will be engineered to prevent undercutting. The access road has not had a
major repair since it was constructed in 1963. Normal wear and tear over the last 31 years, plus
additional heavy construction traffic in the last 15 years, have made the replacement of the
surface necessary. Without major repair and a new surface, continued degradation of the road
will result in major damage to the road base necessitating a considerably more expensive repair.
2. Repair Aircraft Operations Facilities, Various Buildings Ellington Field........ 500,000
This project provides for selective repair and/or replacement of architectural, structural,
mechanical, and electrical systems in various buildings at Ellington Field. The work includes
replacement of interior and exterior building and roofing components, access modifications, air
conditioning and condensing units, electrical panels, transformers, lightning protection, wiring,
and lights. The facilities are over 40 years old and many of the buildingsÕ components and
systems have exceeded their life expectancy. These repairs will bring the buildings up to
current life safety standards.
3. Repair Avionics Systems Laboratory Mechanical Systems (16)...................... 900,000
This project provides for repair of heating, ventilating, and air conditioning (HVAC) equipment
in the Avionics Systems Laboratory. Also included is the installation of an automatic sprinkler
system. Work includes the repair/replacement of air-handler casing and structures, valves, and
fan scroll assemblies. The existing outdated HVAC control systems will be replaced with energy
efficient controls. This project will replace primary HVAC equipment that is over 30 years old
and beyond its useful life. The new HVAC system will provide efficient, reliable, and economical
service to the facility.
4. Repair Roads, Various Locations................................................ 450,000
This project provides for major repairs of roads at the center. The work includes five district
locations along First, Second, Fourth, and Fifth Streets. The work will include the replacement
of base material, replacement of worn surface material, and striping/marking for identification
and traffic control. The centerÕs roads are at the end of their service life and have received
only minimal surface maintenance since construction in 1962.
F. Kennedy Space Center (KSC)........................................................$3,750,000
1. Replace Roof, Vertical Processing Facility.................................... 480,000
This project replaces approximately 2,200 squares meters of deteriorated built-up roofing on the
Vertical Processing Facility. The roof has failed to the extent that maintenance and repair
actions can no longer provide watertight integrity. Work includes removal and replacement of
roofing, insulation, gutters, downspouts, and lightning protection.
2. Repair Wharf Slip at Hangar AF............................................... 800,000
This project repairs approximately 200 meters of failing seawall at the Hangar AF Wharf Slip.
The seawall has had recent interim repairs in an attempt to slow structural degradation until
this permanent repair can be accomplished. Sheet piling will be sealed, backfill replaced, with
adjacent concrete slabs stabilized and/or replaced, as appropriate.
3. Replace Utility Annex Pumps and Controls..................................... 700,000
This project replaces three deteriorated firex pumps for which spare parts are no longer
available. The project will also provide for a new recirculation/test line at the utility annex.
Internal inspections have revealed severe deterioration and erosion.
4. Remove/Install Bridge Expansion Joints, Banana and Indian River Bridges...... 600,000
This project replaces approximately 1,500 meters of bridge deck expansion joints on the Banana
and Indian River bridges. Deterioration of existing joints is jeopardizing the structural
integrity of the two bridges.
5. Repair Roads and Paved Areas, Various Locations.............................. 600,000
This project repairs approximately 60,000 square meters of paving throughout the Kennedy Space
Center. Surface courses will be sealed or replaced as appropriate, base courses repaired or
replaced as necessary, and restriping accomplished. Surface water runoff control will also be
provided as required by environmental regulations.
6. Repair Flame Deflection Systems.............................................. 570,000
This project repairs deteriorated flame deflectors which are part of Space Shuttle Launch Complex
Pads A and B. Launch vibrations have caused large sections to separate during vehicle lift off.
Flame retardant concrete and steel coatings will be replaced, as well as corroded structural
steel components. The project will also evaluate alternate positions for the deflector units in
an effort to reduce the corrosive effect of launch activity.
G. Langley Research Center (LaRC).................................................. $4,270,000
1. Repairs to Central Heating and Steam Generating Facility (1215)............. 900,000
This project provides for the replacement of the existing control systems for the boilers, air
compressors, and the central alarm system at the Central Heating and Steam Generation Facility
which serves LaRCÕs West Area. The new central control station will be environmentally enclosed
and controlled. The project will include an approximately 93 square meter addition to the
facility to offset the space required by the replacement control station. The existing control
panel is over 45 years old and requires replacement to assure continued safe operation, reduce
maintenance, and increase reliability and efficiency.
2. Replace Liquid Rheostat Serving Unitary Wind Tunnel (1251)................. 920,000
This project provides for the replacement of the existing liquid rheostat which provides control
of the electrical power to a pair of synchronous main drive motors for the Unitary Wind Tunnel.
The work to be accomplished includes the removal of the existing liquid rheostat, modifications
to piping and wiring to provide for the installation of the new equipment, and the installation
of a new liquid rheostat and associated mechanical and control components. The liquid rheostat
was installed in the mid 1950Õs and replacement parts are difficult to locate. Failure to
replace the liquid rheostat as scheduled will result in increased losses of tunnel operating time
and possible shutdown of the facility if a catastrophic failure occurs.
3. Repairs to High Pressure Systems, Various Facilities...................... 700,000
This project provides for the repairs to the high pressure systems at various facilities. The
work to be done under this project includes the replacement of defective piping, valves, and
fittings; radiographic inspection of welds; and repair of defective welds. The systems to be
repaired include piping systems and pressure vessels at the West Area Steam Generating Facility
(1215), the Steam Distribution System, the Jet Exit Test Facility, the East Area Compressor
Station (646), and the Unitary Wind Tunnel (1251). These systems are being analyzed and spot
inspected under Langley Research CenterÕs ongoing Recertification Program. Completion of this
project is essential to ensure the safe and efficient operation of these facilities.
4. Replacement of Substations, Various Locations............................ 900,000
This project provides for the replacement of 208 volt substation "LF-100," 480 volt substation
ÒPF-100,Ó and 480 volt Substation Number 5. The project will include replacement of the air
switch, secondary switchgear, and drawout circuit breakers for each of the substations. The
switchgear, breakers, and primary air switch for each substation are obsolete and replacement
parts are difficult to obtain. Substations "LF-100" and "PF-100" are over 40 years old. The
replacement of these substations will reduce maintenance, reduce downtime, and improve system
reliability and safety for the five facilities served.
5. Replace Roof, Engineering Building (1209)............................... 850,000
This project provides for replacement of approximately 4,830 square meters of existing built-up
roofing on the Engineering Building (1209). The new roof will consist of tapered rigid roof
insulation to provide a 2.08 centimeter per meter slope covered by a 4-ply built-up roof system.
The new roof will be complete with roof drains and associated plumbing, flashing, fascia, pitch
pockets, cant strips, gravel stops, and new expansion joints as required. Water which has become
trapped between layers of the 17 year old built-up roofing causes the roof to expand due to
temperature changes, causing further damage. The roof replacement is necessary to ensure the
integrity of this facility and to prevent damage to critical engineering and planning files,
original drawings, and computer systems.
H. Lewis Research Center (LeRC)............................................... $3,550,000
1. Repair Central Water System, Walcott and S. Taylor Roads............... 900,000
This project provides for the repair of the central water distribution system. The work includes
the replacement or cleaning/relining of corroded and clogged water mains and replacement of all
shutoff valves and fire hydrants located along Walcott and S. Taylor Roads. This project will
increase water pressure and improve water quality for the various buildings being serviced from
the water mains. Mineral deposits on the inside of the water mains have caused a general
reduction in water flow and water pressure throughout the Center. This project is part of a
multi-year program to increase water pressure and improve water quality for the various buildings
served.
2. Repair Steam Trenches, Outlying Areas II.............................. 900,000
This project provides for the repair and replacement of piping and valves at locations near
Buildings 24, 34, 107, 45, 87, and 88 in the central steam distribution system. The locations
will also require road excavation, trench cover replacement, drainage and manhole repairs, piping
and valve reinsulation, trench water level sensor installation, roadway resurfacing, and site
restoration. Existing conditions include collapsed sections of trench and roadway; severe
concrete deterioration due to road salts and freeze-thaw cycling; advanced corrosion of
condensate piping and pipe supports due to the trench environment; and poor condition of steam
line insulation, valves, and expansion joints. This project will provide safe, reliable steam
service to critical research buildings and administrative functions.
3. Replace Research Analysis Center Roof (142)........................... 450,000
This project provides for the installation of a new roof on the low and high roof areas of the
existing building. The work includes a new built-up roof membrane, insulation, and flashing.
The existing roof membrane has separated in various locations and has caused roof leaks into the
operations center below. The new roof system will prevent possible damage to sensitive computer
equipment in the operations center.
4. Repair 2400 Volt Switchgear, Substation G............................. 900,000
This project provides for the rehabilitation of the 2.4 kV switchgear in Substation G (43). It
will replace the existing 2.4 kV outdoor metal-clad switchgear with modern switchgear, replace
the associated 34.5 kV-2.4 kV transformer with a new voltage regulating transformer, and
redistribute feeder cable to balance substation loading. This project will improve reliability
and reduce the high level of maintenance needed to keep the system operational for the
institutional and critical research loads.
5. Repair Guerin Road.................................................... 400,000
This project provides for the repair and replacement of the water mains, hydrants, gas lines, and
pavement of Guerin Road. The existing hydrants and transite water main will be removed and
replace to repair the water system. Full depth asphaltic pavement will be utilized to repair the
road surfaces and the high pressure natural gas line will be repaired and replaced to provide low
pressure gas service. Repair and replacement of the underground utilities is required to meet
code requirements and to increase system reliability and safety.
I. Marshall Space Flight Center (MSFC)........................................ $4,300,000
1. Repairs to East Test Area Industrial Water Pump House (4567).......... 800,000
This project provides for the installation of a new 26,000 liters-per-minute diesel-driven pump
with associated piping and controls to replace three non-operating units in the East Test Area
Industrial Water Pump House. The three non-operating units with their associated piping and
obsolete controls will be removed and cannibalized to maintain four similar units which remain
operational. The pumps being replaced are out of production and parts are no longer available.
This project will reduce the potential for outages during testing activities.
2. Repairs to High Pressure Piping System............................... 900,000
This project provides for the replacement of approximately 3,500 meters of high pressure gas
piping and associated components throughout the Center. This piping is part of the high pressure
distribution system for hydrogen, helium, nitrogen, and high purity air. This system provides
critical support to major test programs. It is very old, deteriorated, and continued piecemeal
repairs are costly and disruptive to testing activities.
3. Repair Roads and Paved Areas, Various Locations..................... 800,000
This project provides for the repair and resurfacing of approximately 70,000 square meters of
deteriorated roads, parking areas, and hardstands. Scope includes repair of damaged base course,
application of tack coats, overlaying with asphaltic paving and/or seal coat, and painting of
parking stripes and road markings. Deteriorated concrete pavements will be repaired by
replacement of damaged slabs and joint sealing materials. These road surfaces and hardstands
provide primary access to key test, development, and production facilities.
4. Repair Interior of Power Systems Laboratory (4475).................. 900,000
This project provides for repairs to the interior of Building 4475. Scope includes the
replacement of the heating, ventilation, and air conditioning system; and restoration of the
electrical distribution and fire alarm systems. Also included is the restoration of the interior
surfaces, restrooms, interior lighting, emergency exit signs, etc. Building 4475 is a 1,200
square meter high bay facility. It is 30 years old and maintenance intensive. Restoration of
this facility will bring it into compliance with applicable codes, reduce operating costs, and
significantly improve its functionality.
5. Repair Roof of Developmental Processes Laboratory (4711)............ 900,000
This project provides for repairs to the roof on Building 4711. Work includes installation of an
R-30 roof insulation system; a 6,400 square meter sloped standing-seam metal roof; new gutters,
downspouts, and interior drains; replacement of flashing; and removal of unnecessary expansion
joints and vents. The existing roof has already exceeded its life expectancy and is very
deteriorated. Repair of this roof will preserve the integrity of the facility, reduce
maintenance costs, and provide energy cost savings.
J. Michoud Assembly Facility (MAF)......................................... $1,350,000
1. Repair Component Ablator Thermal Oxidizers (318)................... 850,000
This project provides for the repair of two thermal oxidizers in the Component Ablator Facility,
Building 318. The thermal oxidizers are suffering from metal fatigue, premature chamber buckling
and distortions, inadequate ductwork, and a poorly configured exhaust system for the current
layout and use of the facility. Scope includes repair or replacement, as necessary, of all the
major components of the thermal oxidizer system, including the refractory lining, the flow
control valves, the inlet and exhaust valves, and the repair and painting of all rusted metal
components. These repairs are required to ensure the mechanical integrity and reliability of the
two thermal oxidizers which support External Tank production critical operations.
2. Repair Roads and Paved Areas, Various Locations.................... 500,000
This project provides for the repair and resurfacing of approximately 40,000 square meters of
deteriorated roads. Scope includes repair of damaged base course, application of tack coats,
overlaying with asphaltic paving and/or seal coat, and painting of road markings. Deteriorated
concrete pavements will be repaired by replacement of damaged slabs and joint sealing materials.
The majority of the work is on Saturn Blvd. which is the route used to transport the External
Tank from the Manufacturing Building to the barge dock for shipment to Kennedy Space Center.
K. Stennis Space Center (SSC).............................................. $1,850,000
1. Replace Motor Control Centers...................................... 700,000
This project provides for replacement of motor control centers (MCCs) and power distribution
panels in various facilities. Most of the units are over 25 years old and spare parts are no
longer available. Many of the MCCÕs require modifications to meet code requirements. Several of
the facilities have outgrown their original MCCs and power distribution panels. This project
will improve reliability, maintainability, and provide safe electrical systems for various
site/test, maintenance, warehouse, engineering, logistics, and laboratory operations on the
Center.
2. Repair Bascule Bridge Controls..................................... 650,000
This project provides for the replacement of electrical and hydraulic controls and related
electrical wiring for the bascule bridge. The bridge is a critical element in the transportation
system at SSC. The bridge controls and associated wiring require replacement to eliminate
operational difficulties and delays in the bridge operations.
3. Repair Saturn Drive and Shuttle Parkway Pavement................... 500,000
This project provides for repairs to Saturn Drive and Shuttle Parkway. The work includes
repairing cracks, fixing pavement failures, and repainting pavement markings. The pavement is
severely deteriorated with ruts and cracks. These repairs are required to prevent further
breakdown of the pavement structure and provide safe access at SSC.
L. Wallops Flight Facility (WFF)........................................... $2,500,000
1. Repair Secondary Electrical Systems, Various Locations............. 900,000
This project provides for the upgrade and replacement of power panels, wiring, distribution,
substations, and switchgear. Included are modifications to electrical vaults and the 480 volt
services to facilities A-41, D-1, EÐ2, E-104-108, F-7, F-8, F-10, W-65, and W-100. These
secondary distribution systems are 40 years old and beyond their serviceable life expectancy.
Upgrading the systems will allow Wallops Flight Facility to meet current industry standards for
power distribution and enhance reliability. It will avoid the piece-meal replacement of a worn
out system, reducing maintenance and downtime.
2. Repair Main Base Storm Drainage System............................. 700,000
This project provides for the repair of various sections of 15 centimeters to 135 centimeters
diameter storm drainage system piping, inlets, and manholes on the Main Base. The work will
include the installation of new underground drains, swales and culverts, and all related street
repairs due to storm drainage damage. This work is required to repair deteriorated storm drains
and correct drainage deficiencies due to facility changes over the past 40 years. Also, the
storm drainage system is a source of erosion problems due to the pipe separations. The work must
be accomplished at this time to prevent additional system deterioration which could lead to the
undermining of roads and structures.
3. Repair of Seawall................................................. 900,000
This project provides for the repair of the Wallops Island seawall on the north end of Island.
The construction will be seaward of the existing seawall and include all necessary toe
protection. This work is necessary to prevent or minimize storm damage, which is becoming
increasingly common due to beach erosion and deterioration of the existing protection system.
M. Miscellaneous Projects Not In Excess of $250,000 Each.................. 410,000
Total............................................................. $35,000,000
FUTURE ESTIMATED CONSTRUCTION FUNDING REQUIRED:
Approximately $40-$50 million per year will be required for continuing repair needs.
CF-3.2