SLAC National Laboratory Equipment Removal Sectors 0 to 10, Menlo Park, CA

Detailed coordination efforts allowed the equipment removal to be complete one month ahead of schedule, allowing SLAC to have co-occupancy with other contractors for construction of the new LCLS II accelerator.


Gilbane successfully completed 100% removal of equipment from the 1 km long LINAC accelerator at SLAC National Laboratory under a highly aggressive schedule with a required completion date of December 31, 2016.  Through specialized sequencing of construction crews, all equipment was removed from the first floor (Klystron Gallery) and the underground accelerator housing before November 30, 2016, allowing a required co-occupancy for construction of the LCLS II.

The transport of removed components out of the Accelerator Housing required a great deal of planning and coordination. Due to the lack of ventilation, only electric forklifts were feasible for use inside the housing. In addition, the maneuverability was restricted by the width of the tunnel. In order to remove the 40 foot long accelerator structures, custom girders (dollies) were fabricated, which allowed workers to roll the accelerator structures out of the tunnel without the use of heavy equipment. This safer approach increased the efficiency of the work flow and enhanced overall safety for the project.

Because of radiological hazards identified in the Accelerator Housing, field crews performed a portion of the scope under radiological controls and oversight. To ensure that all radiological wastes were identified prior to removal from the work area, Gilbane’s subcontractor performed radiological surveys for every component removed from the radiologically controlled areas within the Accelerator Housing.

Design-Build of the Medical Education Training Center (METC) Medical Instructional Facility Building 5 (METC5)

Gilbane provided design-build services for new construction of the Medical Education Training Center Building 5 (METC5) at Fort Sam Houston, Texas.

 This $16.9 million two-story, 47,406 sf facility is designed for general and applied academic medical instruction and provides a variety of automation-aided classroom spaces, as well as laboratory, administrative and storage spaces. In March 2012, the project received its LEED Silver certification from the USGBC. This project was performed as a task order (TO) under Gilbane’s Design-Build MATOC contract with the USACE Fort Worth District.

The METC-5 building was constructed on a sloped site, with the appearance of a one-story facility from the front/main entrance and of two stories from the side/rear views. Anti-terrorism and force protection (AT/FP) measures included blast-resistant windows, a mass notification system, privately owned vehicle (POV) parking located outside of the stand-off distance required for the building, and a mailroom with a separate HVAC system sealed from rest of the facility.

The building is designed to serve 225 students and 65 total faculty and staff, with six separate medical instructional areas. Special requirements in the building include medical-grade compressed air and vacuum supplied in each of the nine Respiratory Therapy Intensive Care Unit (ICU) Rooms at each ventilator station in the respiratory therapy 52-student and 31-student classrooms and in the respiratory therapy laboratories; direct exhaust to the exterior for the Anatomy/Physiology Laboratory; negative air pressure for the Saw Room in the Orthopedic Casting Laboratory; and acid waste disposal system serving the Cadaver Classroom.

Ion Beam Facility Decommissioning

Decommissioning radioactive, complex projects is one of Gilbane’s unique capabilities.

As part of the decommissioning of the Ion Beam Facility at Los Alamos National Laboratory (LANL), Gilbane performed the demolition and removal of radioactive piping and equipment. Project work included completion of a readiness review with LANL; mobilization and verification of safe configuration for demolition and removal of piping and other components; characterization of contaminants of concern; equipment dismantling, demolition, and sectioning; lifting and rigging and waste storage and disposal.

During removal work activities, Gilbane removed radioactively contaminated piping, vacuum pumps, ventilation systems, and equipment. Where necessary, piping was drained of free mercury and cut or crimped into manageable lengths. Piping contained reactive cesium metal and had to be carefully removed and disposed of as a hazardous waste. Solder joints were cut and swiped for tritium, and sampled for lead and total mercury. Lead wastes were packaged for encapsulation to meet EPA regulatory requirements prior shipment for disposal.

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.

Fire Detection and Suppression System Modifications at Grissom Air Reserve Base

Gilbane’s federal team upgrades fire detection and suppression systems for five U.S. Air Force hangars.

Gilbane modified fire alarm detection and fire suppression systems in four hangars and constructed completely new systems in a fifth hanger. The modifications required re-piping water lines to pressurize the high-expansion foam (HEF) bladder tank, adding/modifying tamper switches connected to the fire alarm panel, reprogramming fire alarm panels, replacing software programs to support hardware changes, relocating HEF generators to meet new time requirements, replacing floor-monitor nozzles and stands, rebuilding valves, replacing a 12-inch fire main lead-in, and replacing sprinklers.

For the new fire protection systems in the fifth hangar, Gilbane installed an underground 12-inch main to the hangar, constructed a riser room, and provided complete new systems. These included a conventional wet-pipe system and an HEF system with a storage tank, ceiling-mounted HEF generators, all valves, piping, and controls, signage, fire alarm panels, and control panels. The systems included transmitting antennae and panels that relayed system status to the Base Fire Department.

Various Fuel Offloading and Hydrant Facilities Repairs

Gilbane made multi-site repairs and met both budget and schedule requirements.

Gilbane coordinated this  design-build project to repair various fuels loading and offloading facilities throughout Nellis AFB, Tolicha Peak, and Tonopah, Nevada.  A challenge during task order execution was meeting the differing security requirements across multiple locations.

At Nellis, Gilbane designed and replaced an existing diesel truck loading system, installed new E-stop station at facility exit, and performed associated repairs. This project required replacement of the loading arm, valves, piping, monitoring and overfill protection. Repairs at four other Nevada facilities included demolishing a concrete island and installing dispenser pans; installing isolation pads at 163 locations; constructing a canopy with lightning protection over a ground fuels equipment pad; and removing and replacing bollards, plus repairing the damaged column of an existing canopy.

Repair Hangar 250 Electrical Distribution System

Gilbane upgrades electrical distribution system for Air Force hanger.

Gilbane performed underground and directional drilling and excavation based on utility type and location after performing a site survey using electronic locating equipment to verify underground utility locations.

The team installed two 1,500 kilovolt ampere (kVA) transformers (and new concrete pads), 416 volt (V) control panels, installed 416 V to 208 V 150kVA transformers, and a 2,000 ampere non-segregated duct. Because cutting the power to Hangar 250 affected multiple buildings, Gilbane ensured that electrical service cut-over minimally affected Little Rock AFB and the facility’s mission. .

Repair Substation N, Bldg 536

Gilbane repairs electrical substation to support mission critical space launch missions.

Gilbane completely demolished and rebuilt the South Structure and subsequently re-energized it in less than 60 days while maintaining the North Structure at all times. In support of mission critical operations at Vandenberg AFB, Gilbane completed the removal and replacement of the existing Substation N including replacement of the subgrade concrete piles/piers and the replacement of the existing galvanized structural steel substation structures with new stainless steel structures.  The team installed 69kV Group Operated Air Break Switches, Lightning Arresters and 115kV Station Post Insulators. The existing 10 MVA transformers and existing primary circuit breakers remained in place.

Substation N is comprised of two separate structures and electrical components (North Structure and South Structure) that can operate either in parallel or independently.  They serve to support mission critical space launch missions.  As such it is of paramount importance to maintain one of the structures in a fully operational condition at all times.

MEC Removal Action/Construction Support

Gilbane brings a strong, diverse background and extensive knowledge involving munitions and explosives of concern (MEC) and (UXO) management for executing this performance-based remediation project at the Pohakuloa Army Training Area (PTA) in Hilo, Hawaii.

Gilbane supplies superior technical capabilities, an outstanding safety program, and solid management expertise to accomplish MMRP projects for the Department of Defense. This MEC project involves removal action under the Military Munitions Response Program (MMRP) to clear MEC and material potentially presenting an explosive hazard (MPPEH), including munitions debris and range related debris from areas of the construction footprint.

Our team is also providing construction support to the range contractor in high risk areas during intrusive activities in the construction of the PTA Infantry Platoon Battle Course (IPBC).

Our experience spans across all sites and geographies, including both active military installations and formerly-used defense sites (FUDS), and from small arms ranges to large bombing ranges to theater sites, working at both CONUS and OCONUS locations.