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Full text of "[Interim report, construction costs for the O'Hare revenue bond first stage development program]"

NAESS & MURPHY ■ ARCHITECTS ENGINEERS 



August 30, 1960 



Mr. George L. DeMent 
Commissioner of Public Works 
City Hall 
Chicago 2, Illinois 



Dear Commissioner DeMent: 



Chicago-O'Hare International Airport 
First Stage Development Program 
Interim Report 



In accordance with your recent request, we submit herewith a report analyzing 
construction costs for the O'Hare Revenue Bond First Stage Development Program. 
The report sets forth construction costs to date and projects fund requirements 
for the balance of the authorized program. 

Since March 1959, when revenue bond funds became available and final engineer- 
ing was authorized, twenty-four separate construction projects have been 
engineered for bidding. Twenty-three of these projects have been bid and 
nineteen are under construction. One more is currently in process of bidding. 

Construction contracts have been awarded for nineteen projects for an aggregate 
amount of $47,978,752. These divide as follows: 

General Construction Account $33,678,172. 

Hangar Construction Account 14,300,580. 

$47,978,752. 



224 SOUTH MICHIGAN AVENUE. CHICAGO A. ILLINOIS • HARRISON 7-3456 



From experience during the first half of the program it is certain that the 
original estimate of funds for the General Construction Account will be 
exceeded. Reasons for overrun in costs are detailed in Section li of this 
report. For the most part they are the result of working out detailed design 
problems in developing the engineering and construction phases of the work 
and did not arise from basic changes in the scope of the program. Costs 
were also increased over estimates because of conditions, impossible to anti- 
cipate, encountered as the work progressed; and in several cases early 
estimates proved to be inadequate due to the fact that preliminary drawings 
could not be developed in sufficient detail beforehand. 

We now estimate that approximately $35,000,000 will be needed to complete 
the first stage program. This includes a new contingency reserve of approxi- 
mately $3,000,000 on the first stage program, but does not take into account 
any deduction for interest reserves which are accruing on the proceeds of the 
initial bond issue. 

We believe that it is impossible to cut back the program since a lesser program 
will not fulfill the requirements. In fact, as traffic estimates for the airport 
are currently being exceeded, we believe that the initial program should be 
extended to include additional facilities which will be needed in the immediate 
future. In accordance with your recent request, we have listed in Section III 
of the report several new projects that are recommended for early construction. 



Our preliminary estimates indicate that $26,239,000 will be needed for this 
new construction. Due to the preliminary nature of these estimates a 10% 
contingency reserve has been allowed in this cost. 

If these projects are included in the first stage of construction a total of 
$60,889,000 additional funds will then be necessary to complete the program 



Yours very truly, 



NAESS & MURPHY 



fyjCfoc Al. Tt^w^^q 



INTERIM REPORT 



I Comparison of Actual Costs and Future 

Projections with Original Estimate 

II Analysis of Differences Between Original 

Estimates and Present Projections 

III Additional Projects Recommended for 
Construction 

IV Contract Awards to Date 
V Contract Schedules 

VI Value of Revenue Bond Contracts 



August, 1960 



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CHICAGO - O'HARE 



VALUE OF REVENUE BOND 



1959 



HANGAR 
GENERAL 
TOTAL 



1962 



(A 

Z 

o 



(0 

a. 

< 
-i 
_i 
o 

Q 





MAY 


JUN 


JUL 


AUG 


SEP 


a 

p 


EC 


JAN 


FEB 


MAR 


APR MAY JUN 


















130 






























120 
































110 






























100 
































90 
































80 
































70 
































60 
































ISO 






























40 






























30 












































20 














HB 7 




































10 


RB 4 


•■■ 1 ' ^— 








RB 1 


■■Jl 






















Prtllmin 
and RB- 

o 1 





































CHICAGO -CyH ARE INTERNATIONAL AIRPORT 

VALUE OF REVENUE BOND CONTRACTS 



key: 



HANGAR 
GENERAL 
TOTAL 



1959 I960 1961 1962 

MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN 



















































































130 






I 

■ 








1?0 
















































■ ■■■ 
■ ■ 
■ 






























110 










































■ ■■ 


■ 












































































■ ■■ 

■ 

■ 












































■ ■■■■ 


Q 


■ 


51 


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100 






S 


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90 




































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80 


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■ 
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70 
































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1 AUTHORIZED EXTENSION 

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1 


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CHICAGO - O'HARE, 










CONTRACT SCHEDULES 






■■!■■ •'■•:•■■■ 






i 1 




CONTRACT 


61 


1962 


JUL 


AUG 


SEP 


OCT 


NOV 


DEC 


JAN 


FEB 


MAR 


APR 


MAY 


RB 1 SITE GRADING 






















RB 2 


AMERICAN AIRLINES HA 




















RB 3 


PAVING, GRADING, arv 








1 






RB 4 


TERMINAL AREA BUILDIN 










| 












RB 5 


FUEL STORAGE TANKS 





















RB 6 


FOUNDATIONS FOR FUE 










' 1 ' 1 




RB 7 


EXTENSION TO RUNWAY 


















1 ■ 




RB 8 


WATER MAIN & SANITARY 














1 1 




RB 9 


UNITED AIRLINES HANG/ 








' 1 


1 


1 






RB 10 


GENERAL FACILITIES TAN 






















RB 11 


EASTERN AIR LINES HANC 
























RB 12 


REFRIGERATION MACHIN 
























RB 13 


HIGH TEMPERATURE WATE 
























RB 14 


TERMINAL BUILDING BAS 
























RB 15 


DELTA AIR LINES HANGA 






































RB 16 


CONCOURSE BUILDINGS 
























RB 17 


NORTH CENTRAL AIRLINE 


























— — 


RB 18 


POTABLE WATER & FIRE PR 






1 


















RB 19 


TWA HANGAR 
























RB20 


ENTRANCE ROAD & SITE 1 
























RB 21 


CARGO BUILDINGS 


















1 

I 








1 






RB 22 


MAINTENANCE BUILDINC 












1 


I I 

! I 




RB 23 


BALANCE OF FUELING SY 




1 






1 1 








RB 24 


UNDERGROUND ELECTRIC 






















RB 25 


WATER SUPPLY RIVER CRO 
















i | 


RB 26 


WATER MAIN EXTENSION 














i 


RB 27 


UTILITIES, PHASE 1 


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1 


RB 28 


TERMINAL BUILDINGS 






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RB 29 


INTERIM PAVING & ROAD 
















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! i 


RB 30 


NORTHWEST-BRANIFF HAI* 


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RB 31 


RESTAURANT BASEMENT & 


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RB 32 


FIRE STATION 




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UTILITIES, PHASE II 


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ELEVATED ROADWAY 


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FLYING TIGERS CARGO F 


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CHICAGO -O'H ARE INTERNATIONAL AIRPORT 

CONTRACT SCHEDULES 



key: 



SCHEDULED ENGINEERING 
AUTHORIZED EXTENSION 

SCHEDULED CONSTRUCTION 
ACTUAL PERFORMANCE 



r 


CONTRAHT 


1959 


I960 


1961 


1962 




APR 


MAI 


JUN 


JUL 


AUC 


SEP 


OCT 


NOV 


DEC 


JAN 


FEB 


MAR 


APR 


MAV 


JUN 


JUL 


AUG SEP 


OCT 


NOV 


DEC 


JAN 


FEB 


MAR 


APR 


MAY 


JUN 


JUL AUG 


SEP 


OCT 


NOV 


DEC 


JAN 


FEB 


MAR 


APR 


MAY 


RB 1 


SITE GRADING 




[U 








































































RB 2 


AMERICAN AIRLINES HANGAR 
























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RB 4 


PAVING, GRADING, and UTILITIES 
TERMINAL AREA BUILDING SUBSTRUCTURES 


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1 ~ 






BEEBSSSBBES 


























| 












1 

i 
| 




RB 5 


FUEL STORAGE TANKS 


■ 






























■ — 












































RB 6 


FOUNDATIONS FOR FUEL TANKS 







































































1 1 




RB 7 
RB 8 


EXTENSION TO RUNWAY 14R-32L 
WATER MAIN & SANITARY SEWERS 






























■=■ 








































^— 




RB 9 
RB 10 
RB 1 1 


UNITED AIRLINES HANGAR 
GENERAL FACILITIES TANK FARM 
EASTERN AIR LINES HANGAR 











1 




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RB 12 


REFRIGERATION MACHINES 














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1 






























RB 13 


HIGH TEMPERATURE WATER GENERATORS 














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RB 14 
RB 15 


TERMINAL BUILDING BASEMENTS 
DELTA AIR LINES HANGAR 












■ 


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. 




^ 
































RB 16 
RB 17 

PR 1ft 


CONCOURSE BUILDINGS 

NORTH CENTRAL AIRLINES HANGAR 

POTABI F WATFP fL FIPF PR<"">TFrTI<"lM WITFM 












































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, 






m 




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RB 19 


TWA HANGAR 


































i — - 








^" 1 




— 












1 


















RB20 


ENTRANCE ROAD & SITE IMPROVEMENTS 






























-T- 






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RB 21 


CARGO BUILDINGS 
































m 




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1 — 






















RB 22 
RB 23 


MAINTENANCE BUILDING 
BALANCE OF FUELING SYSTEM 






























z 




mi 




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t 


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MB 



























RB 24 
RB 25 


UNDERGROUND ELECTRIC MANHOLE & DUCTS 
WATER SUPPLY RIVER CROSSING 






























— 








■,,„: 








































RB 26 


WATER MAIN EXTENSION 








































































i 




RB 27 


UTILITIES, PHASE 1 








































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i m 






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1 




RB 28 


TERMINAL BUILDINGS 






































— -i 




1 


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RB 29 


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RB 32 


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CONTRACT SCHEDULES 



SCHEDULED ENGINEERING 
SCHEDULED CONSTRUCTION 



wmmmm®. authorized extension 









ACTUAL PERFORMANCE 




CONTRACT [ 




61 


1962 




JUL 


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OCT 


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DEC 


JAN 


FEB 


MAR 


APR MAY 


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OZARK HANGAR , 

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HEATING AND REFRIGEfc 

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CHICAGO -O'H ARE INTERNATIONAL AIRPORT 

CONTRACT SCHEDULES 



key: 



SCHEDULED ENGINEERING 
SCHEDULED CONSTRUCTION 



mtmmffli^ authorized extension 







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ACTUAL PERFORMANCE 






61 




D 
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CONTRACT 

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1959 


I960 


19 




1962 


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MAY 


JUN 


JUL 


AUG 


SEP 


OCT 


NOV 


DEC 


JAN 


FEB 


MAR 


APR 


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AUG 


SEP OCT 

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DEC 


JAN 


FEB 


MAR 


APR 


MAY 


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G 
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restaurant superstructure 
capital hangar 
apron paving, phase 1 





































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II. ANALYSIS OF DIFFERENCES BETWEEN ORIGINAL COST ESTIMATES AND 
CURRENT PROJECTIONS 



A. RUNWAYS AND TAXIWAYS 

1 . Taxiways Serving Cargo Area 

Original Estimate $ 986, 000 

Actual Cost to Date $ 139,000 

Estimated Balance of Costs 889, 000 1 , 028, 000 

Overage $ 42, 000 

The overage on this Item resulted from the addition of short turn-offs to the 
future parallel taxiway to 9R-27L. It was deemed necessary that these short 
turn-offs be added in the first stage program In order to prevent any interrup- 
tion of service to the Cargo Area when Runway 9R-27L and its parallel taxi- 
way are constructed later. 

2. Improvements to Runway 14R-32L 

Original Estimate $ 333,000 

Actual Cost to date 390, 000 

Overage $ 57, 000 

The overage on this item resulted from a change In final engineering design 
which required a large box culvert in lieu of a multiple pipe system as part 
of the program to eliminate the hazardous ditch at the end of the runway. 
Also very poor soil conditions were encountered in constructing the box 
culvert which necessitated increased yardages of suitable material. 

3. Taxiway to Hangar Area 

Original Estimate $1,492,000 

Actual Cost to Date $1 , 1 74, 000 

Estimated Balance of Costs 390, 000 1 , 564, 000 

Overage $ 72, 000 

An overage on this item is anticipated because of the addition of taxiway 
lighting to the property lines of each hangar lot. Although, the taxiway 
connections to each hangar lot are provided by the airlines under each 
hangar contract, the lighting for these connections must be part of the 
overall airport system. Prudent engineering design dictated that this 
lighting be added to the general construction program. 

4. Outer Circular Taxiway 

Original Estimate $1,467,000 

Actual Cost to Date $1, 328, 000 

Estimated Balance of Costs 408, 000 1,736,000 

Overage $ 269, 000 



There was some saving on this item because of federal participation on 
Contract RB-7, however, there is still a net overage above the original 
estimate. This overage resulted from the extension of the outer circular 
taxiway around Concourse Building "r. In the final engineering design 
It was deemed essential to add this taxiway, which is part of the ultimate 
master plan, In order to permit two-way aircraft traffic from this concourse 
in the same manner as is being provided for all other concourses. 

5. Taxiway Shoulder Stabilization 

Original Estimate $ 267, 000 

Estimated Balance of Costs 201,000 

Underage $ 66, 000 

The anticipated underage on this item resulted from a current forecast of 
lower unit prices for this work than originally estimated. 

6. Blast Fence 



Original Estimate $ 7,000 

Estimated Balance of Costs 7, 000 

No change in this estimate. 

B. UTILITIES 

1 . Water Main to Terminal Area 

Original Estimate $1,840,000 

Actual Cost to Date $ 433,000 

Estimated Balance of Costs 1 , 306, 000 1,739,000 

Underage J 101,000 

The anticipated savings on this item are due to a favorable construction 
arrangement with the City Water Department and to lower unit prices for 
materials than originally estimated. 

2. Water Main to Hangar Area 

Original Estimate $ 596, 000 

Actual Cost to Date $ 475, 000 

Estimated Balance of Costs 24, 000 499, 000 

Underage $ 97,000 

The savings now anticipated on this item are due to favorable prices actually 
received on Contract RB-8, These savings would have been even larger had 
not winter construction and Increased airport operations dictated tunnelling 
under several taxiways originally planned for open cutting. 



3. Terminal Area Water Reservoir 

Original Estimate $ 711,000 

Estimated Balance of Costs 660,000 

Underage $ 5 1 , 000 

The underage now anticipated on this item is due to later engineering design 
which contemplates a savings over the original estimate in pumping equip- 
ment and meters. 

4. Sanitary Sewer to Hangar Area 

Original Estimate $ 605, 000 

Actual Cost to Date $ 635, 000 

Estimated Balance of Costs 274, 000 909,000 

Overage $ 304, 000 

The overage on this item resulted from closer spacing of manholes requested by 
City Bureau of Sewers and unforeseen improvements necessary to the existing 
sewer in the Terminal Area. 

5. Airport Storm Drainage 

Original Estimate $ 942, 000 

Actual Cost to Date $1 , 636, 000 

Estimated Balance of Costs 1,738,000 3, 374, 000 

Overage $2, 432, 000 

There are several factors which have contributed to the large overage on this 
item. During the course of detailed engineering of the airport utility systems 
(gas, electricity, water sanitary and storm), it became evident that the high 
outfall elevation of the area drainage to the Des Plaines River would not per- 
mit the extensive use of open ditches for storm drainage in areas where it was 
necessary to cross the ditches with other utilities. To effect these crossovers 
it was essential to carry the storm drainage in pipe much more extensively 
than originally contemplated. 

Also the apparent imminence of construction of future runway 9R-27L made it 
advisable to extend the pipe system beyond the location of this runway at this 
time. 

Other factors which contributed to the original estimates being exceeded 
were City requirements to increase capacities and use less corrugated metal 
pipe and more concrete pipe than originally planned. 



Also final engineering design made it necessary to introduce two large lift 
stations to serve the underpass into the main parking lot and a depression 
created in the entrance roadway which will accommodate a future overpass 
for a taxiway connection between runways 27L and 27C. 

6. Cargo Area Utilities 

Original Estimate $ 208, 000 

Estimated Balance of Costs 195,000 

Underage $ 13,000 

A more finalized engineering design at this time indicates that the original 
estimate was more than adequate. 

7. New Heating and Refrigeration Plant 

Original Estimate $4,530,000 

Actual Cost to Date $ 929,000 

Estimated Balance of Costs 6, 586, 000 7,515,000 

Overage $2,985,000 

Later engineering design indicated that the heating and cooling distribution 
system, which is included under this item, should be greatly expanded over 
preliminary estimates. Pipe sizes were increased and, whereas originally a 
two pipe distribution system seemed adequate it later appeared essential to 
have a three pipe system for both chilled water and high temperature water 
in order to offer maintenance flexibility which will avoid shut downs of 
service to large areas of the Terminal Buildings during times of repair. In 
addition, we propose adding a centralized control system not originally 
contemplated. Although this is an added capital cost we believe that it 
will more than pay for itself in future operational and maintenance savings. 

In addition, air conditioning requirements are considerably greater than 

anticipated, particularly in the airline areas on the first floor of the 

concourses, 
v 

Not only have pipes been increased in number but also in size. This has 
required greatly expanding the underground tunnels at a considerable in- 
crease in cost. 

The heating and refrigeration building has also increased in size resulting in 
some increase over original estimates. 

On the other hand, contract prices for the high temperature hot water 
generators and the refrigeration compressors under Contracts RB-12 and 
RB-13 were considerably below original estimates. 



8. Fueling System 

Original Estimate $5,413,000 

Actual Cost to Date $2,403,000 

Estimated Balance of Costs 4, 893, 000 7, 296, 000 

Overage $1,883,000 

The large overage on this item has resulted from several factors. Among the 
most Important are the following: 

a* Airline request to increase the number of bulk storage tanks to 
permit greater supply flexibility. 

b. Airline need during interim period for temporary truck fill stands 
in the main tank farm to permit early use of storage facility. 

c. Insurance company requirement for more extensive fire protection 
system in the tank farm than was originally contemplated. 

d. Safety considerations dictated burying satellite tanks completely 
below grade rather than mounding as originally planned. 

e. A large parking apron for refueler trucks was added in the 
permanent truck fill stand area. 

f. Later engineering developments indicate that changes in aircraft 
and airline furnished ramp equipment require modification of the 
fueling system for compatibility, (i.e. pressure drop of hydrant 
carts and aircraft require increased pumping head in fueling system.) 

C. TERMINAL AREA 



1. New Terminal Buildings, Concourses and Restaurants 

Original Estimate $23,500,000 

Actual Cost to Date $13,585,000 

Estimated Balance of Costs 18,859,000 32,444,000 

Overage $ 8,944,000 

This large overage is In two major areas. The mechanical - electrical work in 
the buildings has increased by approximately $4,500,000 and the general work 
by approximately $4,400,000. Much of the increase in the mechanical - 
electrical work can be explained by later developments, wherein It was found 
that airline requirements were much greater than originally anticipated (i.e. 
more air conditioned areas on the apron level of the concourses and great 
increases in electric power requirements at aircraft parking positions.) This 
factor also contributed to increases in the general work. The concourse utility 
tunnel, for instance, was expanded to nearly three times the width originally 
proposed. Penthouses which enclose the mechanical equipment were expanded 
considerably. 



Efforts have been made during the course of design to effect economies wherever 
practical. The structure of the building was changed from steel to reinforced 
concrete at a substantial savings and the exterior walls on the lower level of 
the concourses were changed to concrete block. In other areas materials have 
generally remained as originally contemplated, but it is apparent that quantity 
take-offs from preliminary plans were inadequate and that unit prices estimated 
for some items were also inadequate. 

2. New Apron Paving 

Original Estimate $9, 1 4, 000 

Actual Cost to Date $1,245,000 

Estimated Balance of Costs 8, 644, 000 9,889,000 

Overage ~~ "$ 875, 000 

Later engineering analysis indicates that a large section of the existing apron 
in the area of Concourse *3 is at the wrong elevation for proper drainage. 
Other areas along this concourse must also be removed and replaced to permit 
installation of the underground fueling system. 

In addition, ground water conditions indicate that a sub-surface drainage 
system should be provided under all new aprons. 

3. Main Entrance Road 

Original Estimate $1 , 1 66, 000 

Actual Cost to Date $2, 008, 000 

Estimated Balance of Costs 4, 408, 000 6,416,000 

Overage $5, 250, 000 

The large overage on this item has resulted from several factors: 

a. Later planning and engineering considerations indicated that the 
volumes of automobile traffic anticipated demand a grade separation 
at the entrance into the parking lot. To design this separation 
without greatly reducing the area of the parking lot, it was ne- 
cessary to shift the parking lot entrance to the north. This In turn 
required construction of additional length of new roadway and 
abandoning more of the existing roadway than previously planned. 

b. The road materials were changed from asphalt to concrete to con- 
form with the connections to the Northwest Highway constructed 
by the County. 

c. The master plan for the future development of the airport calls for 
a taxiway connection between runways 9R-27L and 9C-27C on the 
east side of the terminal area. It is necessary for this taxiway to 
pass over the entrance road. In order to maintain access into the 



terminal area when the overpass is constructed in the future it was 
deemed advisable to depress the entrance roadway at this time. 

d. The unit price assigned to the elevated roadway structure in the 
original estimate was too low. Although the final design of this 
structure is an economical one, it will cost considerably in excess 
of the original estimated figure. 

e. Later design considerations indicate the use of more curbs and gutters 
than originally planned. 

4. Parking Lot 

Original Estimate $1,610,000 

Actual Cost to Date $ 733,000 

Estimated Balance of Costs 2, 246, 000 2,979,000 

Overage $1,369,000 

Later engineering considerations indicate that there can be no salvage of the 
existing pavement. New pavement with adequate base is now estimated at a 
considerably higher unit cost than in the original estimate. Later engineering 
considerations indicate that the original estimate for electric lighting is also 
inadequate. In addition, some sidewalks and canopies have been added. 

(At the time of this writing consideration is being given to double decking a 
portion of the parking lot (see Section III). This would probably change the 
paving materials to concrete under the deck). 

5. Landscaping 

Original Estimate $ 500,000 

Actual Cost to Date $ 18,000 

Estimated Balance of Costs 482, 000 500, 000 

There has been no change in the original plan to budget an arbitrary amount 
of $500,000 for landscaping. 

6. Apron Paving for Split Finger B 

Original Estimate $ 410,000 

Actual Cost to Date 501,000 

Overage $ 91,000 

The unit prices for this work exceeded those originally estimated. In 
addition an electrical grounding system was added to this project. 

7. Alterations to Terminal B 

Original Estimate $1,520,000 

Estimated Balance of Costs 5,550,000 

Overage $4, 030, 000 



Original planning was based on a skeleton program. Due to an increased 
demonstrated traffic growth, Landrum and Brown, our Airport Consultants now 
advise that this facility should be planned to handle approximately 800,000 
deplanned passengers annually, estimated between 1965 and 1970, with 
provision to extend the facility to handle potential ultimate traffic of approx- 
imately 1,500, 000 deplanned passengers. These capacities require extensive 
remodelling of the existing building and the addition of an expandable 
section to the front of the existing building. 

D. HANGAR AREA 



1. Railroad Connection 

Original Estimate $ 14,000 

Actual Cost to Date 19,000 

Overage $ 5,000 

The contract price for this work exceeded the original estimate. 

2. Overall Grading 

Original Estimate $ 554,000 

Actual Cost to Date 880,000 

Overage "$ 326,000 

Poor soil conditions encountered in actual grading operations required removal 
and replacement of larger earth quantities than foreseen. Unit prices also 
exceeded original estimates. 

3. Balance of Hangar Area Roads 

Original Estimate $ 372,000 

Actual Cost to Date $ 627,000 

Estimated Balance of Costs 1 00, 000 727, 000 

Overage $ 355, 000 

Grading preparatory to roads was greater than anticipated because of poor soil 
conditions. Unit prices were higher for pavement and base than anticipated. 
Also extensive sub-surface drainage was required because of poor soil conditions. 

E. CARGO AREA 

1 . Airplane Parking Apron 

Original Estimate $1,035,000 

Actual Cost to Date $ 224,000 

Estimated Balance of Costs 756, 000 980, 000 

Underage $ 55,000 

Although sub-surface drainage has been added in the later engineering designs, 
unit prices anticipated for the balance of the paving work are anticipated to 
result in a saving over the original estimate. 



2. Roads and Truck Parking 

Original Estimate $ 217,000 

Actual Cost to Date $ 75, 000 

Estimated Balance of Costs 468, 000 543,000 

Overage $ 326, 000 

Unit prices are now expected to exceed the original estimate. Poor soil 
conditions resulted in increased excavation and soil preparation and nec- 
essitated french drains. 

Extent of road has increased in service and in connection to Mannheim 
Road via Lawrence Avenue. (The County Highway Department has requested 
that there be no access to Mannheim Road between Lawrence Avenue and the 
airport Lead-in road). 

3. Cargo Warehouses 

Original Estimate $1,001,000 

Estimated Balance of Costs 1,528,000 

Overage $ 527, 000 

Original estimates were based on unit costs for existing cargo warehouse. New 
cargo warehouses, however, now must conform to Chicago Building Code which 
requires extensive mechanical ventilation which was not required at time 
original building was constructed in 1955. 

Airlines have recommended a sprinkling system to reduce insurance risks. This 
is also an added item. 

From study of operation of existing facility, it was found that additional toilets 
and an improved type heating system should be provided and that apron and 
truck parking lighting should be increased. 

F. SERVICE AREA 

1 . Fire Station 

Original Estimate $ 330,000 

Estimated Balance of Costs 513,000 

Overage $ 183,000 

Original estimate contemplated two-story fire station which proved unsuitable 
in final design analysis. Final plans contemplate single story unit which has 
been expanded somewhat in accordance with Fire Department requests. 



Site conditions require removal of large section of existing 15" concrete 
pavement. Both the removal of the existing concrete and the installation 
of new pavement was omitted from the original estimate. 

2. Airport Maintenance Building 

Original Estimate $ 353, 000 

Actual Cost to Date $ 19,000 

Estimated Balance of Costs 449, 000 468, 000 

Overage $ 115,000 

The overage on this item has resulted principally from increased mechanical 
and electrical requirements in the final engineering design. In addition, it 
is now anticipated that the unit cost for exterior paving will be substantially 
exceeded. Also because of soil conditions grading costs have been exceeded 
and french drains have had to be added to the pavement design. 

G. REQUIRED ADDITIONAL ITEMS 

1 . Additional Roadways 

Actual Cost to Date $ 164,000 

Estimated Balance of Costs 301,000 

$ 465, 000 

During the course of actual construction and later engineering design, it has 
been found essential to construct several temporary roads to facilitate con- 
struction and lessen interference with airport operations. One of these 
service roads has been designed to conform to a road master planned for future 
construction around the terminal area apron. It will thus remain as a part of 
the permanent roadway system. 

2. Temporary Taxiway 

Actual Cost $ 21,000 

ft was necessary to add this item as a temporary measure when existing access 
to the temporary maintenance area was removed to make way for construction 
of concourse "o. 

3. Overall Airport Grading 

Actual Cost to Date $2,377,000 

Later engineering design indicated that it was necessary to grade and shape 
more areas of the airport than originally planned. Soil conditions at O'Hare 
are much worse than were originally foreseen. It has been necessary to 
excavate and replace much more unsuitable material than was anticipated in 
order to obtain a proper base for any future work. 



4. Reshape Outfall Ditch 

Estimated Cost $ 145,000 

Present Indications are that it will be necessary to clean, deepen and re- 
shape existing outfall ditches serving the airport in order to accommodate 
future drainage requirements. 

5. Conversion of Existing Reservoir 

Estimated Cost $ 1 75, 000 

Insurance advisors and the Fire Prevention Bureau has requested conversion of 
existing reservoir for increased fire protection. This will require installation 
of new pumps, piping and electric wiring. 

6. Revision to Control Tower Heating System 

Estimated Cost $ 35,000 

ft is planned that the existing control tower will remain in the first stage of 
construction. The present steam heating system will require modification for 
operation for the new hot water system. 

7. Underground Electrical Manholes and Duct Distribution System 

Actual Cost to Date f\, 434, 000 

Original plans contemplated use of direct burial cables except under paved 
areas where ducts were planned. Later engineering indicated that a direct 
burial distribution system was inadvisable and would be more costly and 
troublesome in future airport operations than if electrical distribution cables 
were contained in ducts. Accidental cutting of existing direct burial cables 
has been a serious source of annoyance to airport operations during the con- 
struction program to date. 

8. Miscellaneous Other Electrical Work 

Estimated Costs $ 236, 000 

During the construction, it has been found that temporary power connections 
will be necessary to facilitate airport operations. 

Since preliminary estimates power requirements have greatly increased. To 
supply proper capacities to various facilities, it will be necessary to provide 
secondary switchgear equipment at the Commonwealth Edison's substation not 
originally contemplated. 



It is also planned to provide ducts for a fire alarm system in the terminal area 
requested by the Bureau of Fire Prevention. 

9. Relocation of Temporary International Building 

Cost to Date $ 164,000 

To allow construction of the new terminals, it was necessary to relocate the 
existing International Building. At the new location it was necessary to 
expand the aircraft apron and provide a temporary parking lot and roadway 
to allow efficient operation of this facility. 

10. Airport Construction Clean Up 

Estimated Balance of Cost $ 27,000 

Construction has required heavy equipment and trucks to travel on and across 
taxiways and runways, ft has been necessary to have special cleaning equip- 
ment "on call" at all times to remove the resultant debris which could cause 
great damage to jet aircraft. 

11 . Temporary Measures to Facili tate Airport Operations 

Cost to Date $ 16,000 
Estimated Balance of Costs 200, 000 

Total $ 216,000 

As airport operations have greatly increased it will be necessary to provide 
temporary utility and power connections to allow uninterrupted service during 
the interim until new facilities are completed. It is envisioned that barricades 
around Terminal Area construction will be necessary and that other temporary 
parking areas and walks will be necessary to properly handle increased numbers 
of airport users. 

12. Expanded Weather Station 

Estimated Balance of Costs $ 91,000 

To provide necessary weather information for the forecasted volumes of traffic, 
it has been found that present weather station must be expanded. 



Ill ADDITIONAL PROJECTS RECOMMENDED FOR CONSTRUCTION 

1 . Electronic System for Arrival and Departure Boards 

The original program contemplated the use of airline furnished, manually posted 
arrival and departure boards. We now believe that this is not the best solution to 
the problem. After an exhaustive study with the airlines and equipment manu- 
facturers, we recommend a system using four large electronically posted boards 
in each of the two domestic terminal buildings. A third system probably requiring 
fewer boards is recommended for the International Terminal . 

This system has been described and presented to you and the airlines in a previous 
report. 

Preliminary estimate of cost excluding International Building $ 1,400,000 

2. Elevated Parking Deck 

The original program contemplated only grade level parking in the first stage. 
As described to you in a recent brief report, we now feel that parking will be 
inadequate in 1965 and recommend the construction of approximately one half 
of a proposed future parking deck at this time. 

Preliminary Estimate of Cost $ 3,300,000 

3. Additional Air Cargo Facilities 

During the past year several airlines have indicated that their original forecasts 
for air cargo facilities were far short of their present predictions. United, 
American, NOR and Delta have already requested that means be found for pro- 
viding additional facilities. Several freight forwarders have also expressed an 
interest in obtaining facilities at O'Hare as have a few of the international 
carriers and U. S. Customs. 

This problem is currently being pursued by an Airlines Cargo Subcommitte and 
by the Department of Aviation. 

We estimate that approximately 150,000 square feet in additional cargo buildings 
with accompanying aprons, taxiways and roads will be required to provide the 
necessary facilities. 

Cargo warehouses %2 , 225 , 000 
Aircraft Apron 1,000,000 

Taxiways 500,000 

Truck Parking 350,000 

TOTAL $4,075,000 



4. Runway 9R-27L 

Construction of this runway was deleted from the first stage program in order to 
reduce initial capital expenditures. Expanding traffic at O'Hare indicates that 
this runway will be needed at the completion of the First Stage Program. 

Preliminary Cost Estimate $ 10,000,000 

5. New Control Tower 

The present control tower is too low to permit an unobstructed view of all run- 
ways and taxiways. A future higher and larger tower is master planned near the 
center of the terminal complex. It would provide greater space for FAA and 
City offices and would be constructed so as to provide support for the new Air 
Surface Detection Radar facility which the Federal Aviation Agency has already 
programmed for installation at O'Hare. 

$ 1,000,000 

6. Taxiway Over Entrance Road 

At present taxiway distances to the instrument runway, 14L 32R, and the present 
east-west runway do not allow efficient and economical aircraft movements. It 
is proposed to extend the outer circular taxiway around the terminal area over 
the Entrance Road to effectively reduce taxi distances to these very active runways 

$ 2,750,000 



IV 



CONTRACT AWARDS TO DATE 



The following is a list of construction contracts awarded to date of this report, 



Contract 
No. 

RB-1 
RB-2 
RB-3 
RB-4 
RB-5 
RB-6 
RB-7 



RB-8 
RB-9 
RB-10 
RB-11 
RB-1 2 
RB-1 3 
RB-1 4 
RB-16 
RB-1 8 
RB-20 

RB-24 

RB-29 



Description 

Site Grading, Phase 1 

American Airlines Hangar 

Paving, Grading & Utilities 

Terminal Building Substructures 

Sixteen Fuel Tanks 

Foundations for Fuel Tanks 

Second Extension to Runway 14R-32L and 

Portion of Outer Circular Taxiway (Revenue 

Bond Portion only) 

Water Main & Sanitary Sewers 

United Air Lines Hangar 

General Facilities Tank Farm 

Eastern Air Lines Hangar 

Refrigeration Equipment 

High Temperature Water Generators 

Terminal Building Basements 

Concourse Buildings Superstructure 

Hangar Reservoir (EAL, CAP, NWA-BNF) 

Site Grading Phase II and Entrance Road 

Paving 

Underground Electric Manholes and Ducts 

(Revenue Bond Portion only) 

Interim Paving and Alterations to Parking 

Lot 



Amount of Original 
Contract & Change Orders 

$ 2,442,589 

5, 387, 000 

4,071,388 

1,625,562 

474, 920 

88,570 



1,841,505 

1,256,213 

4,652,914 

1,645,000 

3, 794, 000 

283,477 

218,926 

818,690 

11,097,000 

466,666 

5, 986, 734 

1,792,637 

34,961 



Total Under Contract 



$47,978,752 



3 5556 038 786570 



3/15/2010 
WT 192570 1 52 00 



a. 

=3 



CO 



SAYUORD