This project was a design build of a two-stage, 10-foot high security/safety fencing and gates system to secure the Building 836 complex. The owner requested that the existing manually operated gate that provided access to B836 be replaced with an automatic rolling gate meeting the owner’s security requirements. The outer safety gate was upgraded with a gate that met the owner’s fencing safety standards. The safety fencing that connected the safety fence loop with the security fence loop was replaced. New fence posts were installed at the inner gate, with fencing aligned with the rolling gate track. A new motorized rolling gate was installed. Two safety loops were embedded within the asphalt paving, one inside and one outside the gate. A concrete pad for the gate motor and future owner equipment was formed and poured adjacent to the rolling gate. The existing asphalt driveway was trenched to accommodate conduit between the new housekeeping pad and the building to provide emergency power to the inner gate motor from the building’s emergency power panel. The trench was backfilled with slurry and finished with asphalt paving. The existing pedestrian gates on both the security and safety fence line were replaced with new crash gates
There was an operational need to increase storage and accessibility to the corporation yard area. Two new automatic sliding gates and a personnel swing gate were added, with modifications made to the existing slatted, chained link fencing to secure the yard material lay down area. An electrical equipment concrete pad, two gate operator concrete pads and concrete pavement for the gate tracks were installed. High density hand holes, electrical receptacles, conduits, conductors and grounding system were all installed both above and below grade to provide power for the new lighting, panel board, motorized gate operators, photoelectric beam sensors, radio receivers and loop detectors.
Four gate operating manual control switches were installed, one each at the two photo beam sensor posts at the interior of the yard, and one each at the exterior of both rolling gates inside TESA boxes. Perimeter fence grounding was installed, with connections at five posts by connection to the closest container pier ground wire and tent post ground.
Grounding was provided for a transformer and air injection skid at an adjacent building. The existing ground rod and associated conductor was demolished, and a new grounding system provided with new conduits and conductor from the panel to the skid.
Electrical modifications were made to a utility trailer box next to the corporation yard. Power was provided from an existing electrical panel to a client provided VFD, and from the panel to new convenience receptacles
Building 391 was constructed in 1973, and has one basement level and two levels above. The project location was on the basement floor which has vehicle and pedestrian access from the north side of the building. Below the basement floor is a 30-foot diameter concrete pit. The pit floor is approximately 37 feet below the basement floor. The basement floor itself is approximately five feet thick. There are two openings in the basement floor above the pit. A scaffold stair accessed the pit floor through one opening. The other opening is an eight-foot diameter hole. An existing gantry crane located at the top of the basement floor’s 40-foot high expanse was utilized to move construction materials in and out of the pit through this hole.
Cerrudo grouted an existing 15-foot diameter, 3” deep depression in the pit floor with self-leveling mortar. Scaffolding was constructed in the basement floor plenum to provide access to the existing fire riser connection. The fire protection piping was extended from this point down and around the basement wall, and through a small opening in the floor to the pit. Low conductivity supply and return piping, compressed air piping and electrical conduits were extended from the basement floor down into the pit. New electrical panels, disconnect switches and lighting were installed. A sump pump including holding tank, control panel, disconnect switch, float switch and associated piping was installed in the pit.
The existing scaffold stair was removed and a new metal spiral stair, furnished in four sections, was lowered through the stair opening into the pit with the gantry crane, and bolted together and to the concrete pit wall. Aluminum plates, 4 foot by 8 foot, were lowered to the pit floor and secured to the floor with flush anchors.
The existing autoclave in Building 361 required replacement due to age and unreliability. Cerrudo Services managed the removal of the existing autoclave, made architectural, mechanical and electrical modifications associated with preparation for a new autoclave installation, and managed installation and startup of the new autoclave.
The removal of the old autoclave and installation of the new autoclave was performed by Steris Corporation, who de-installed and removed the existing autoclave to the building loading dock, moved the new autoclave into place from the loading dock, installed and leveled the machine and provided manufacturer startup of the autoclave. Cerrudo was responsible for the utility disconnection of the existing autoclave and connection of the new autoclave. Lock Out Tag Out procedures were implemented in accordance with client requirements.
Architectural work was performed in and outside of the autoclave equipment room including installation of a new layer of gypsum board, painting, and application of new epoxy flooring with rubber base. Mechanical work, in addition to disconnection and connection of the autoclave, included new exhaust ductwork, domestic cold water to autoclave, steam piping and pressure testing, back flow preventer, pressure gauges and reducing valve, pipe insulation, and drain lines from the autoclave and an adjacent ice maker to a new funnel drain. Electrical work, in addition to disconnection and connection of the autoclave, included installation of the autoclave disconnect switch, conduit to the autoclave control unit, installation of an emergency light and relocation of existing lighting in the autoclave equipment room.
Lawrence Livermore Labs performed abatement services after the existing autoclave was removed and before modification work began, including removal and disposal of asbestos piping insulation, lead paint, loose gypsum board tape and joint compound, and floor mastic.
The second floor restrooms at Building 311 underwent a complete renovation. The existing tile contained lead and the gypsum board and taping mud contained asbestos. The demolition of the two restrooms was performed under containment. Gypsum board was installed on the walls and ceilings, and painted. Porcelain floor tile and wainscot with accent rows were mortared in place and epoxy grouted. Plastic laminate countertops with top mounted lavatories, under-mounted cabinets and mirrors were installed. The work included new toilet partitions and accessories. New plumbing fixtures and lighting were installed.
Due to high building security, all work was performed under Lab escort which required advanced scheduling of material deliveries and labor.
Building 235 was constructed in 1968, with two floors above ground and one basement floor. The building currently housed research laboratories. Room 1232 required reconfiguration to house new Tekna lab equipment. Existing utilities were demolished as needed to accommodate the new equipment and layout. New stainless steel and uncoated ductwork, and gas and water piping were installed. A new acoustical ceiling was installed with washable tiles. New air diffusers, LED lights, light switches, disconnect switches and power outlets were provided. The walls and doors were patched and painted. New vinyl sheet flooring was installed over existing tiles. The existing wall cabinets were cleaned and repaired, and new epoxy countertops installed, with under counter epoxy sink and fittings, including an eye wash station.
Cerrudo installed and connected Lab-supplied equipment including fume hood, furnace and chiller, glove box, HEPA filter and housing, gas bottle racks and gas regulators. The existing fume hood controls were upgraded.
The room was balanced for negative air pressure, and the HVAC system commissioned.
Cerrudo was awarded the design build contract to perform roof repairs at Buildings 50 and 78. Building 78 is a 5,675 SF single story structure built into the north side of a hill. The existing roof is a concrete deck with a fully adhered built up roof and gravel cover. There are four interior roof drains. The roof has an existing air handling unit on a curb. The roof repair for Building 78 was initially designed as a three-ply modified roof system based on the RFP requirements. The client requested a change of design to a PVC membrane roof system so that the existing built up roof could remain. The new design has been completed and is under client review. Once work commences, the existing loose gravel will be removed. Tapered insulation with diamond crickets will be adhered to the roof. DensDeck primed recovery board will be installed over the tapered insulation, then the Duro-Last PVC membrane roof system will be adhered to the recovery board. The perimeter parapets will be raised and new two-piece perimeter edge metal installed. The installation work is scheduled to begin April 2017.
The new Building 50 roof over the existing library, 2,208 SF, was designed with a fully-adhered PVC membrane system. Before work commenced, fall protection delineators and warning flags were set up six feet away from the open perimeter building edge. The existing horizontal lifeline cable attached to the building wall was used for securing each workers’ personal fall restraint devices.
The existing built-up roof membrane was tested and found to contain PCB’s. The membrane was removed by workers trained in PCB removal and containment. A DensDeck cover board was installed over the concrete and corrugated metal roof deck, and rigid thermal insulation adhered over the cover board. A 40 mil PVC single ply white fully adhered field membrane with water-based adhesive was installed over the insulation, heat welded at laps. New gutters, downspouts and roof ladder were installed.
The Lab required a new autoclave with enhanced safety and ergonomic features for processing laboratory animal caging systems. A new pit-mounted large steam autoclave was transported, placed, leveled and anchored. In preparation for the new autoclave installation, existing walls were removed and replaced with new to fit the dimensions of the new autoclave. A concrete pit with drain was constructed to accommodate the autoclave, and painted with epoxy. Mechanical ductwork, plumbing piping and electrical conduits and conductors were modified and added for the new sterilizer.
Cerrudo Services provided approximately 6,800 SF roof patching at failing areas of roof at Buildings 50 and 51. A pre-construction walkthrough was performed to identify existing patch locations noted in the RFP as well as any additional areas requiring repair. This site visit identified the material loading areas for each building, the material lay-down area and the debris box location.
The roof deck was be prepared by pressure washing the existing surface areas for repair at tie-in locations. The surface was allowed to dry thoroughly. Blister areas were cut out to expose the BUR roof membrane surface. The roof membrane remained in place. The repair areas were primed with silicone primer at a rate of 400-600 SF per gallon, per manufacturer’s specifications. The primer was allowed to dry thoroughly. Butter grade silicone roof sealer was applied at cut edges and reinforcement fabric embedded into sealer. Silicone coating was roller applied at patch areas at a rate of 2.5 gallons per square. The roof patching was warranted for five years.
The sunshades on the building were failing due to age and water damage. A 1″ x 1″ aluminum tube support spacer was installed by welding at the end of the new shade closest to the building to facilitate drainage away from the building. The new sunshades are solid 18 gauge sheet aluminum with a 90 degree bend. Mechanical fasteners were used to fasten the sunshades to the supports. A return lip was incorporated to the front valance portion of the new awnings to increase rigidity and to provide a solid anchor point for the attaching screws. The sunshades were painted prior to installation.