New Project Announcement : JP-5 Fuel Tank Closures, Base Coronado, CA

Gilbane Building Company awarded a $41.2 million fuels pipeline

Shell Technology Center

When completed, these renovation projects were transformed to Class A status

Renovations to 13 buildings at this 33 year old campus

This expansion and renovation is for the Shell Technology Center, previously called the Westhollow Technology Campus. The 33 year old facility has 43 buildings and the project included renovating 13 of the buildings. Renovations included conversion to modern laboratories, conference rooms and cafeteria center, office and administrative space. The projects included extensive MEP upgrades including:

  • Utilities – comprised of a new electrical duct bank
  • Command Center – to house fiber and recording instruments for observation and monitoring
  • A four-story research laboratory, a new multi-purpose building annex to an existing building, a new building replacement and a new shipping and receiving facility are also components of the scope of the project.
  • All new switchgears, new roof and air handling units
  • Installation of miles of fiber loop (with interduct fiber) for the entire campus
    • This included the underground infrastructure of trenches 6 to 10 ft deep with concrete.

    When completed, the renovation projects were transformed to Class A status. Additionally, these projects targeted LEED EB Silver certification. For instance, at 30% completion, we were able to achieve 93% recycling of debris and construction materials. Due to the campus size and the fact that much of the campus is occupied, our logistics plan included the coordination of the transport of more than 400 construction workers from a central parking location to their respective buildings for work.  As with all our projects, safety is priority and this project had no lost time incidents.

Fuel Pump House Repairs | Incirlik Air Base in Turkey

Gilbane is providing valuable support and construction for clients throughout Europe, the Middle East and Africa.

The U.S. Air Force Civil Engineering Center (AFCEC) awarded Gilbane this project to repair various systems at Pump House 1A at Incirlik Air Base in Turkey. These repairs will provide a complete, serviceable and operating facility.

Work  includes replacement of two fuel pump motors, one backpressure control valve, a fuel isolation valve R4, a solenoid valve associated with the emergency shut-off valve, eight refueling pit equipment sets, 66 pantograph swivel connections, and six pantograph single-point refueling nozzles. Work also includes removal and burial off-base of two valves and two filters from the branch-off pit, and replacement with elbows.

Key challenges include navigating the language differences between American and Turkish subcontractors, which requires multilingual staffing and translation of reports and work materials, and delivery of materials from the US or Europe.

Gilbane has multiple projects in Turkey totaling more than $6 million.

Miscellaneous Pipeline Repairs at Naval Station Rota

Gilbane Inspects and Fixes Deficiencies to Multiple Fuel Pipelines at NAS Rota, Spain

Naval Facilities Engineering Command (NAVFAC) Engineering and Expeditionary Warfare Center (EXWC) awarded Gilbane a project to conduct API 570 inspections and repairs to multiple fuel system pipelines and ancillary support structures at Naval Air Station Rota, Spain. The project requires excavation and inspection of underground pipelines for corrosion and other deficiencies.

Gilbane’s general repair tasks include replacing all pipeline areas with anomalies, sealing the water intrusion around the pipes at several valve pits, installing pipe supports, and removing and recoating, or else spot repair coating, the pipelines. All of the valve pits require excavation to a depth below the pipes. New rolling lids must be fabricated and installed on the larger valve pits. Other tasks include removing calking sealant, chipping or cutting away concrete walls, installing new pipe sleeves, and retrofitting piping with mechanical pipe seals. Logistic challenges include repairs to the pipe bridge that crosses over the Rio Salado waterway. Gilbane found this segment of pipelines to have severe corrosion.

This project is especially unique in that there is not only a distance (time zone) challenge but also a language barrier in dealing with the local sub-contractors.

Repair Tank 4 | Incirlik Air Base in Turkey

Gilbane Awarded Repairs to Return Concrete Fuel Tank to Service at Incirlik Air Base, Turkey

The U.S. Air Force Civil Engineering Center (AFCEC) awarded Gilbane a project to repair extensive deficiencies to Tank 4 at Incirlik Air Base. The tank has uncommon features not typical to most fuel tanks. It is made of concrete and not steel.

Gilbane’s repairs include installing a new reinforced concrete tank shell with a polyester resin liner to prevent fuel from seeping into the concrete. Gilbane is developing the concrete design to ensure that proper water-to-cement ratios exist in the mix for proper strength, strain profiles, and ability to retain varying fluid loads. Other major repairs involve patching holes in the tank’s roof, providing scaffolding supports in the concrete shell, removing and replacing tank coating, executing other upgrades to the tank to meet tolerances and standards, and performing a final inspection to verify the tank is suitable for service.

This project, valued at over $2million, follows two previous awards in Turkey. Gilbane’s wins in Turkey continue to expand our competitive and quality project execution for clients throughout Europe, the Middle East, and Africa.

With three ongoing projects totaling more than $6 million at Incirlik Air Base, this win and our other projects in Turkey represent a strong strategic position due to its contiguity with the Middle East and proximity to Africa.

Pipeline, Refueling, System Controls, and Other Repairs | Incirlik Air Base in Turkey

Gilbane Executes Various Pump House Repairs at Incirlik Air Base, Turkey

Gilbane was awarded a fuel system repair project at Incirlik Air Base by the Air Force Civil Engineering Center (AFCEC). This project valued at over $3.5 million, is one of multiple Gilbane projects at Incirlik.

The project involves numerous tasks that include repairing refueling truck parking (lighting and extra-thick concrete pavement with custom curbs), valves and control equipment repairs (computer logic programing, facility upgrades, hardware interface, and pump installation), and installing 100 meters of fuel pipeline. Other tasks include assessing facilities for lead paint abatement requirements, and survey, removal, and disposal of any contaminated soil in the refueler parking lot that requires demolition.

Key challenges include navigating the language differences between American and Turkish subcontractors, which requires multilingual staffing and translation of reports and work materials. This win and our other projects in Turkey represent a strong strategic position due to its contiguity with the Middle East and proximity to Africa.

Executing Work at Joint Base Pearl Harbor-Hickam

Gilbane has been serving DoD clients at Joint Base Pearl Harbor-Hickam for more than 10 years.

Gilbane has completed 16 projects at Joint Base Pearl Harbor-Hickam totaling over $70 million since 2002. Projects include environmental assessments and remediation, fuels facilities, new construction, and renovation and abatement work of existing facilities.

From managing environmental assessments and remediation work, to building large, multi-million facilities from the ground up, Gilbane has been serving DoD clients at Joint Base Pearl Harbor-Hickam for more than 10 years.

Clean, Inspect, Repair Tanks | Kunsan, Suwon, and K-16 Air Bases

Gilbane identified deficiencies and recommended additional repairs in the tank inspection reports.

Gilbane cleaned, inspected and repaired 13 storage tanks at three US Air Bases in Korea: Kunsan, Suwon, and K-16. The various-sized tanks included cut-and-cover, aboveground storage tanks (ASTs), and underground storage tanks.

The tank inspections, which were executed per API 653 and API 650 standards, identified numerous mechanical repairs and necessary upgrades needed to return each tank to compliance. Gilbane also performed tank tightness testing.

Overall mechanical repairs and necessary upgrades included repairs to patch plates, valves, piping, and containment; lead-based paint (LBP) abatement; stilling well installation; seal welding and pitting repairs; and vacuum vent and manual gauge hatch repairs. Gilbane inspected all welds via magnetic particle or dye penetrant testing. Gilbane also resealed/recoated deteriorated metal components including vents, access hatches, piping, electrical components, pits and tank interiors.

After repairing each tank, Gilbane calibrated the tank and had a licensed tank inspector certify all repairs were completed per applicable codes and API standards.

Fuel Pier Cathodic Protection Inspection and Upgrade

Gilbane completes D-B repairs to base-wide cathodic protection system in Portugal.

Gilbane completed mission critical JP-8 jet fueling system repairs at an operational airfield at Lajes Field, which is located in the Azores. Lajes is a Portuguese archipelago in the Atlantic Ocean that is subject to erratic weather, including heavy rain, sleet and winds. Because the project site was on an active runway, the team had coordination with the airfield tower. Also, all equipment and materials had to be imported by sea from the U.S. and Europe.

Design-build repairs to the base-wide cathodic protection (CP) system included new rectifiers, CP test stations, and new anodes on underground fuel pipelines. While validating the conceptual design, many existing CP system components were discovered to be non-functional or non-reliable. Also, the CP system at the South Pier Tank Farm needed repair. Gilbane performed these repairs and evaluated mechanical deficiencies and identified required repairs at the tank farm and pier.

Gilbane excavated and constructed an underground, cast-in-place concrete vault east of the existing south tank farm entry guard house to contain the flange joints on the underground fuel lines and enable future inspections. Gilbane also wired cabling to the flange joints on the fuel lines to provide better monitoring of CP performance. The team performed design-build replacement of a fuels receipt piping system manifold for unloading fuel tankers; inspected welding and pipe coatings; and performed start-up and testing.