Ninyo & Moore was retained by John Wayne Airport to provide as-requested (on-call) geotechnical engineering, materials testing, and special (deputy) inspection services for various Airport improvement projects. The terms of the contract are for five years up to a cumulative $8,500,000 over the contract period. The largest of the task orders issued under this contract was for the construction of the new $100 million dollar Terminal C building. This building consisted of a new multi-level structure providing approximately 282,000 square feet of floor space, including six new commercial passenger gates, security screening checkpoints, food/beverage and news/gift concessions, three baggage carousels, and a Common Use Passenger Processing System (CUPPS). The project also included construction of new permanent commuter terminals at the south end of Terminal C and the north end of Terminal A, replacement of passenger boarding bridges at all 14 existing gates in Terminals A and B, as well as a new baggage handling system for all three terminals and other upgrades to Terminals A. To date, Ninyo & Moore has received 52 task orders under this contract.

Project Challenge: Due to the large size of the project, Ninyo & Moore provided up to 15 special inspectors on any given day for this project, including dayshift and nightshift work. We also provided inspection for out-of-State shop fabrication in Oklahoma City (Oklahoma), Little Rock (Arkansas), Greeley (Colorado), and Littleton (Colorado). Along with providing sufficient staffing, there was the associated review and submittal of daily inspection reports and laboratory test results. Another challenge was that the work took place while the airport was still in operation. This necessitated careful separation of construction areas versus public zones, as well as secured versus non-secured work areas. Ninyo & Moore's inspection staff were security badged under the Airport's and Transportation Security Administration's (TSA's) procedures.

Innovative Solution: In order to manage the volume of documents and processes associated with the Terminal C construction, the Airport utilized the project/document control system, Oracle Primavera Unifier. This system is currently used for all of the Airport's capital improvement projects. Unifier was used to submit task order requests, progress payments, review plans and specifications, evaluate Requests for Information (RFIs), respond to dispatch requests, and submit inspection reports and laboratory test results. For the Terminal C project, Ninyo & Moore responded to over 700 inspection requests, submitted over 4,800 inspection reports, and submitted over 500 laboratory test reports.

Services: Ninyo & Moore's services included special (deputy) inspection for pile fabrication, reinforced concrete construction, structural masonry construction, epoxy dowel installation, expansion anchor installation, structural steel and welding, non-destructive testing, and fireproofing. Ninyo & Moore also performed field sampling and batch plant inspection during concrete pours, pull testing of installed epoxy dowels, and torque testing of installed expansion anchors. We were requested to perform reinforcement bar tagging and sampling in Benecia (Bay Area), California, as well as masonry block tagging and sampling. Ninyo & Moore performed laboratory testing for steel reinforcement bend and tensile strength, concrete compressive strength and masonry material compressive strength, Proctor density, Atterberg limits, corrosivity, gradation, and CBR value.