San Juan Construction, Inc.

Consolidated Construction Projects at U.S. Navy Support Facility, (DG2), Diego Garcia, B.I.O.T.

Contract Specifics:  It is mandated that federal contracts at Diego Garcia be a Joint Venture between a U.S. contractor and a British firm, with the U.S. partner holding the majority position and providing senior management.  San Juan Construction, Inc. was the managing partner of the San Juan Construction, Inc./John Laing International, LLC Joint Venture.  SJC executed all work to include scheduling, procurement, logistics, shipping, construction, quality control and safety oversight. 

Scope of Work:  This four-year construction project required the establishment and maintenance of temporary construction facilities of over 100 housing units and four commercial dining facilities to serve over 200 construction personnel.  Grounds maintenance, janitorial and laundry services, and facility maintenance crews were established to respond to operations and maintenance requirements, and to also support all construction sites and facilities.  Preventative maintenance schedules were established for construction-related facilities and equipment.  In addition, SJC established a call center for warranty maintenance and repairs for completed projects turned over to the Government.

As the General Contractor for this long-term construction project on a remote island, San Juan Construction has established and maintained logistics and materials management practices which allowed for the timely completion of multiple construction projects spanning 20 miles across the island.  Approximately 236,000 cubic meters of materials were scheduled, shipped, received and inventoried each month to ensure schedules were adhered to.  These materials included hazardous materials requiring unique handling and storage to comply with DoD requirements.  All projects were completed on or ahead of schedule.  In addition, SJC implemented and managed related environmental protection, quality control and safety programs ensuring compliance with the Island’s unique regulations.  Specific projects are described below.

Special Project RC20-96, BOQ 5 Rehab/Modern
Modernized a two-story barracks which included new doors, windows, flooring, paint and plumbing fixtures; set up base and wall cabinets and dressers; installed government-furnished microwave ovens and under-counter refrigerators; upgraded air conditioning and ventilation systems; and improved fire protection/fire alarm and electrical systems.  Work also included replacement of duct work; and an upgrade of the existing sprinkler systems and plumbing.  All systems installed were fully tested and warranted.  Exterior work consisted of touch-up painting and upgrades of the water distribution system.

Special Project RCM1-96, BEQ 1 Rehab/Modern
Modernized a one-story barracks which included new doors, aluminum windows, base and wall cabinets and dressers, solid polymer shower panels, roofing and incidental exterior repair work; installed gutters and downspouts and rigid roof insulation; did architectural finishes which included painting of all the exterior and interior; put in government-furnished microwave ovens; and improved the air conditioning, ventilation and electrical systems.  Work also focused on the replacement of the duct work, and an upgrade of the existing sprinkler, alarm and plumbing systems to include testing and warranty response corrective action/maintenance.

Special Project RCM3-96, BEQ 3 Rehab/Modern
Modernized a one-story barracks which included new doors, new base and wall cabinets and dressers, installation of government-furnished microwave ovens, aluminum windows, built up roofing, gutters and downspouts, rigid wall insulation and solid polymer shower panels; architectural finishes included ceramic tile fixtures, and exterior and interior wall painting, and other incidental exterior repair work and building specialties.  Work also consisted of replacement of duct work, upgrade of existing sprinkler systems, fire protection, fire alarm, electrical and plumbing systems which included testing and warranty response corrective action/maintenance.

Special Project RCM4-96, BEQ 4 Rehab/Modern
Modernized a one story barracks which included new doors, aluminum windows, base and wall cabinets and dressers, solid polymer shower panels, roofing and incidental exterior repair work; installed gutters and downspouts and rigid roof insulation; architectural finishes included exterior and interior wall painting; put in government-furnished microwave ovens; improved the air conditioning, ventilation and electrical systems.  Work also focused on the replacement of the duct work, and an upgrade of the existing sprinkler, alarm and plumbing systems to include testing and warranty response corrective action/maintenance.

Upgrade Gas Station, POL Causeway
The demolition work consisted of removal of the existing wooden shed, existing concrete foundations, and on-site fuel dispensers.  Construction work included a reinforced concrete building with concrete floor and roof along with an air conditioning and ventilation system, and installation of a plumbing system and septic tank.  Improvements to the existing gas station facilities included concrete fuel dispensers, piping, and a leak monitoring system, alarm system and related electrical work.  Significant safety and environmental protection controls were also included in the upgrades.

Install Oil and Water Separator, POL Tank Farm
This work included extensive site work excavations; installation of a new oil-water separator, above ground waste oil recovery tank, above and below ground piping, pipe supports, structural foundations and a concrete sump pit; electrical work and other support work.  Significant safety and environmental protection controls were also included in the upgrades.

FY03 MCON Project P-141, Physical Readiness Center
This was construction of a new, single-story gymnasium with reinforced concrete footings and concrete masonry walls.  The structural roof was built with modified bituminous sheet roofing on rigid roof insulation.  Included was EFIS exterior wall finishes, steel girder trusses, metal decking with concrete topping, and flashing and sheet metal.  Work also included extensive site preparation; installation of windows, mirrors and doors; architectural finishes within the facility; setting up of wet pipe sprinkler, air conditioning, ventilation, fire protection and alarm systems; plumbing, electrical and other incidental work.  Exterior site work included landscaping, ground maintenance, utility connections, and sidewalks.

FY03 MCON Project P-871, Waterfront Operations Facility
The project consisted of constructing a new single-story concrete masonry administrative building.  The building was founded on concrete footings and constructed with concrete masonry units, steel girder trusses, metal decking with concrete roof, modified bituminous sheet roofing on rigid roof insulation, and EIFS exterior wall finish.  In addition, the wet pipe sprinkler system, fire protection and alarm system, air conditioning and ventilation system, and low pressure compressed air system were all put into operation.  Work also included site preparation, all architectural finishes, and mechanical and electrical work.  Exterior site work included demolition of existing seahuts; asphalt concrete pavement, landscaping, ground maintenance, utility connections, and sidewalks.

Air Force FY03 MILCON Project B-2 Aprons
This project consisted of constructing four Portland cement concrete (PCC) aprons, each approximately 32,000 sq. ft. to support the erection of four prefabricated B2 bomber shelter systems (B-2SS) which were installed under a separate contract.  Each apron is approximately 40m by 76m with a pavement structure consisting of 520mm of non-reinforced PCC and 300mm of base course.  Each apron is surrounded by a PCC shoulder that has a pavement structure consisting of 150mm of non-reinforced PCC and 150mm of base course.  In addition, the project included the relocation of existing utilities; water lines, fire hydrants, electrical ducts, drainage swales and incidental related work.

FY03 Erect B-2 Shelters
The project consisted of the disassembly of two existing government-furnished prefabricated B2 bomber shelter systems on the existing parking apron and re-erection of the two B2 shelters on the new parking apron.  In addition, the project included erection of two additional government-furnished prefabricated B2 bomber shelters and incidental related work. Work included disassembly and relocation of plumbing, electrical, HVAC and switchgear equipment and systems.  In lieu of drawings and specifications, a technical manual of work packages for shelter parts, special tools, equipment, shelter assembly and erection, site interface information, illustrations, etc. was provided.

POL Pier Repairs
The work included repair of spall found on the concrete deck of the main pier, replacement of several timber members on the fender system, demolition and replacement of 49 underwater anodes and anode supports.  Also included were new anode cables in PVC conduits.  Reactivation of the cathodic protection system, surveying, and adjustment for proper operation followed the construction work.

Ordnance Separation and Unstuffing/Stuffing Pad
This was a design/build project for the construction of a 24” thick concrete munitions hardstand including lightning protection, operations building, restroom, security lighting, roads, communications and all necessary site improvements and utilities.  Extensive clearing and grubbing work was required with the added complexities of protecting endangered species in the area.

R11-99 (R2) Reconstruct North Ramp Sections
The work included reconstruction of North Ramp Sections NPA/002 and TWC/002, and incidental related work.  Foreign Object Damage (FOD) barriers were also constructed.

FGDA 00-1003 Replace Halon System
Work included the removal of existing halon systems, providing a fire protection sprinkler system for the entire facility, replacing the ceiling system, replacing the fire alarm system, replacing all the light fixtures, and minor construction such as walls and soffits.  SJC developed and implemented Value Engineering efforts which resulted in reduced costs and a reduced schedule for the HVAC and fire protection systems.

Repair HVAC System
The work included the replacement of existing mechanical equipment and control systems associated with Buildings 631 and 632 with new equipment.  The types of equipment to be replaced included chillers, air cooled condensers, refrigerant piping, air handlers and cooling coils.  This was a modified design/build project which provided for the construction of a 357 square meter communications remote switch facility.  Included were entry roads, fencing, underground utilities, and fiber optic lines from the new facility for site communications, and concrete foundations for communication satellite dishes and antennas.  Energy efficiency, low maintenance, durability, sustainability or “green” architecture and functionality were among the considerations.

Repairs the Alterations to BOSC Galley
This project replaced substandard and unsanitary components of the BOSC Galley (Facility 740) to a new building.  Work consisted of metal roof and frames, interior plywood paneling, floor and wall finishes, wooden posts, acoustic and gypsum board ceiling on metal frames, doors and windows, insulation, power supply, lightning and grounding system, air conditioning with insulated air duct system, freezer’s shed, and exhaust and ventilation system.  Also included were utilities trenching and tapping, cutting and disposal of coconut trees, hot and cold water system, steam piping, sanitary sewer system, wet pipe system, water storage tank and related mechanical and electrical work.  The construction portion included installation of a boiler complete with piping system; new pump house, fuel tank berm, toilet, utilities enclosures and concrete pads, concrete walk, expansion of existing toilet, boiler room, dry storage and scullery areas, new utilities and connections, and all related mechanical, fire protection and electrical work.  Due to the extreme rusted conditions of the existing facility, unique environmental issues arose and were managed by SJC by way of convincing the Government that this was a repair-by-replacement project.  In addition, SJC conducted value engineering analyses to reduce the impact on users, reduce costs and extend the service life of the facility.

Repair Runway Pavement
The work included diamond grinding texturing of the runway, spall repair, crack repair, joint sealant repair, runway pavement markings and incidental related work.

Test, Operate & Maintain Tub Grinder
The work consisted of testing, operating and maintaining a Tub Grinder Model 867TG in accordance with the manufacturer’s manual six days per week.  Shredded materials were loaded from the stock pile yard to the dump truck which was then transported to the landfill area for disposal and /or other required purposes six days per week.  Maintained the tub grinder in good operational mechanical and electrical status, and checked for any unusual noise and malfunction once every week of its operation.

Repair Runway Approach Lighting
Repaired, replaced and relocated approach lighting at the North end of the runway including demolition and removal of existing soil erosion control, concrete columns, lights and platform.  New work also included restoration of soil erosion control, installation of new concrete pedestal, platform and lighting.

Demolish Seahuts
The work included demolition of nine seahuts: Facility Nos. 462, 732, 2133, 2142, 2143, 2144, 2145, 2169 and 4019.

Quality of Life Improvement, BOQ 4 & 5
This project consisted of the construction of a picnic shelter complete with concrete pad, concrete counter-top, wooden posts, roof, baluster, and lighting system.

Alterations and Repairs to Ship Store and Demolition of Coral Reef Market
Work included the removal of existing racks, counters and office furniture, interior CMU walls, restrooms, doors, floor and ceiling tiles and removal of flooring containing asbestos. Alteration work included new offices, additional sale’s floor area, new rest rooms, doors, floor and ceiling tiles, new wall partitions, interior painting, additional outside security fence, roof ladder, installation of government-furnished interior display freezer/chiller equipment, installation of outside condensing units and pads at roof top area, plumbing system, air conditioning system, electrical outlets, lighting fixtures, fire protection system, and incidental related work as specified in the approved floor plans.  This job also included the complete demolition and removal of Building Nos. 146 and 147 which housed the Coral Reef Market.

Install Window A/C units, Bldg. #2304, 2305, 2306, and 2307
Thirty-five existing window-type air conditioning units were removed along with 14 exhaust fans located in each building.  Then new window-type air conditioning units were installed with stainless steel rain hoods.  Also, this project replaced existing jalousie windows at the living quarters with new fixed glass windows; restored CMU walls/sills; painted wood surfaces, exposed conduits, new CMU and all disturbed surfaces.  The electrical power supply in the buildings was upgraded.

Replace Glazed Railings, Control Tower, and Facility 913
This project included removal of deteriorated safety railings at the air control tower, including the ½” thick tempered glass panels on existing railings, corroded steel ladders and safety cages of steel ladders and landing.  Removed and saved grounding wires attached to steel channels support.  New fabricated steel channel supports were installed for the new glazed railings.  Restored disturbed concrete deck sections and applied an agent on the surface of the existing concrete to be in contact with fresh concrete.  Primed and painted new fabricated access ladders, manhole cover, posts and channel support.  Assembled, installed and sealed new galvanized railings and glass panels, and fully welded vertical frames of railings on exposed channel supports.

Upgrade / Replace Fire Suppression System, Officer’s Club Facility 100.
The work included the installation of a wet-pipe sprinkler system, alteration to existing fire alarm system, replacement of existing kitchen dry chemical fire suppression system with a new wet chemical fire suppression system, and incidental related work.

Alterations to Base Gym, Facility 132
This work included removal of existing exercise equipment, doors, windows, big size mirrors, audio speakers and televisions along with removal of floor tiles, rubber matting, and flooring materials containing asbestos.  Alteration work included new office walls, doors, floor and ceiling tiles, interior paintings, air conditioning system, electrical outlets, lighting fixtures, fire protection system, and incidental related work.

Remove/ Replace Airfield Lighting Control System
The work included removal and replacement of existing AN/FSN-7 Airfield Lighting Control System (AFLCS) including all controls and monitoring equipment, cabling and accessories.  It also consisted of installation, testing, commissioning and certification of the new SIEMENS-designed AFLCS, complete and ready for use.

Demolition of Various Facilities
This project included demolition and removal of 12 structures including securing, cutting, plugging and abandoning underground utilities and then restoring them to the surface.