CONSTRUCTION CONSTRUCTION OBSERVATION TIPSOBSERVATION TIPS

2009 NCRWA Conference2009 NCRWA Conference

May 14, 2009May 14, 2009

Kenny P. Keel, PEKenny P. Keel, PE

PROCESS FOR A SUCCESSFUL PROCESS FOR A SUCCESSFUL PROJECTPROJECT

► Construction Process ChecklistConstruction Process Checklist► Pre-Design/Preliminary Project MeetingPre-Design/Preliminary Project Meeting► PermitsPermits► Specifications & DetailsSpecifications & Details► Pre-Construction ConferencePre-Construction Conference► ConstructionConstruction► Final InspectionFinal Inspection► As-Built SubmittalsAs-Built Submittals

Construction Process Construction Process ChecklistChecklist

► Develop a checklist of Develop a checklist of steps in the construction steps in the construction processprocess

► Makes it easy for Makes it easy for developers, contractors, developers, contractors, staff, etc. to know what is staff, etc. to know what is required and whenrequired and when

► Keeps you from looking Keeps you from looking unfair when enforcing unfair when enforcing your typical processyour typical process

► Ensures that requirements Ensures that requirements are not overlookedare not overlooked

Sample Sewer Project Flow ChartSample Sewer Project Flow Chart(from Pierce County, WA)(from Pierce County, WA)

Pre-Design/Preliminary Project Pre-Design/Preliminary Project Meeting with Meeting with

Developer/Engineer Developer/Engineer ► Developer/Engineer should meet Developer/Engineer should meet

with Utilities Director, Town with Utilities Director, Town Engineer, etc. to informally discuss Engineer, etc. to informally discuss project to coordinate planned project to coordinate planned improvementsimprovements

► Water/Sewer Extension Contract Water/Sewer Extension Contract required?required?

► Unusual requirements of the Unusual requirements of the utility?utility?

► Who will review, and how many Who will review, and how many copies of submittals needed?copies of submittals needed?

PermitsPermits► Water (NCDEH-Public Water Supply Section)Water (NCDEH-Public Water Supply Section)► Sewer (NCDWQ)Sewer (NCDWQ)► Erosion Control (usually >1acre, but locally could be as little as 10,000 sf Erosion Control (usually >1acre, but locally could be as little as 10,000 sf

disturbed – DLQ or County)disturbed – DLQ or County)► Road right-of-way encroachment (NCDOT)Road right-of-way encroachment (NCDOT)► New driveway (NCDOT)New driveway (NCDOT)► Local building, plumbing, electrical permits (County or Town)Local building, plumbing, electrical permits (County or Town)► Site Plan Review, Zoning Permit, Conditional Use Permit, Stormwater Site Plan Review, Zoning Permit, Conditional Use Permit, Stormwater

Review (Town)Review (Town)► OTHER – OTHER – Lots of possibilitiesLots of possibilities, depending on project: Wetlands (Army , depending on project: Wetlands (Army

Corps of Engineers & State), US Fish & Wildlife, Surface Water Protection, Corps of Engineers & State), US Fish & Wildlife, Surface Water Protection, Air Quality, Aquifer Protection, Coastal Management (CAMA), Air Quality, Aquifer Protection, Coastal Management (CAMA), Hazardous/Solid Waste, Underground Storage TankHazardous/Solid Waste, Underground Storage Tank

► One-Stop Permit Coordination - One-Stop Permit Coordination - http://http://www.envhelp.orgwww.envhelp.org//

Specifications & DetailsSpecifications & Details► If you don’t have If you don’t have

any, you need any, you need themthem

► Can be simple & Can be simple & straightforward, straightforward, or very complex. or very complex. For example: For example: Hillsborough – 4 Hillsborough – 4

pages total pages total Specs plus about Specs plus about 15 details15 details

OWASA – Over OWASA – Over 200 pages plus 200 pages plus about 70 detailsabout 70 details

Pre-Construction ConferencePre-Construction Conference► Make sure the contractor has a copy of the Make sure the contractor has a copy of the

APPROVED plans & specsAPPROVED plans & specs Contractors are sometimes given early copies of the Contractors are sometimes given early copies of the

plans that get revised during the bidding processplans that get revised during the bidding process Engineering and/or Architectural firms sometimes Engineering and/or Architectural firms sometimes

move a project forward without waiting for all move a project forward without waiting for all approvals, even taking bids before all permits are in approvals, even taking bids before all permits are in placeplace

► Exchange contact info with all appropriate Exchange contact info with all appropriate partiesparties Contractor – Site Superintendent and Office SupportContractor – Site Superintendent and Office Support Other Inspectors – Town, County, State, etc.Other Inspectors – Town, County, State, etc. Owner/DeveloperOwner/Developer EngineerEngineer Private Testing Laboratory Rep and/or Geotechnical Private Testing Laboratory Rep and/or Geotechnical

EngineerEngineer

ConstructionConstruction► Road Projects - Drainage Structures, Sub-Grade, Gravel Base, Road Projects - Drainage Structures, Sub-Grade, Gravel Base,

Concrete Curb, Fine-Grade, Base-Course Asphalt, Shoulder Concrete Curb, Fine-Grade, Base-Course Asphalt, Shoulder Adjustments, Surface Course Asphalt, Storm-Water Management Adjustments, Surface Course Asphalt, Storm-Water Management Inspections, etc.Inspections, etc.

► Water/Sewer Projects – Alignment (horizontal & vertical), Erosion Water/Sewer Projects – Alignment (horizontal & vertical), Erosion Control, Cast-in-place Concrete, Trenching & Shoring, Pipe bedding, Control, Cast-in-place Concrete, Trenching & Shoring, Pipe bedding, Backfilling, Compaction, Seeding & Mulching, Clean-up, etc.Backfilling, Compaction, Seeding & Mulching, Clean-up, etc.

► All Projects – Follow the Approved Plans. If it will not work, follow All Projects – Follow the Approved Plans. If it will not work, follow procedures for changing the plans (Consult with Contractor, procedures for changing the plans (Consult with Contractor, Engineer/Architect, Owner, Permitting Officials.Engineer/Architect, Owner, Permitting Officials.

Final Inspection & As-Built Final Inspection & As-Built SubmittalSubmittal

► Inspections should occur often Inspections should occur often during construction periodduring construction period

► A final inspection should not A final inspection should not find any major issues, if find any major issues, if inspections were performed inspections were performed regularly and wellregularly and well

► A designated set of plans A designated set of plans should be marked throughout should be marked throughout construction to show construction to show deviations and adjustmentsdeviations and adjustments

► The record drawings must be The record drawings must be reviewed by the contractor, reviewed by the contractor, inspector, and engineer to inspector, and engineer to ensure that the actual ensure that the actual installed facilities are installed facilities are accurately shownaccurately shown

POTENTIAL ISSUESPOTENTIAL ISSUES► RelationshipsRelationships

Not a good thing when the Not a good thing when the contractor REALLY LIKES the contractor REALLY LIKES the InspectorInspector

Contractors have been Contractors have been known to “pay off” inspectors known to “pay off” inspectors with gifts, like liquor, food, with gifts, like liquor, food, etc.etc.

Need to Inspect your Need to Inspect your InspectorsInspectors

► One thing intentionally done One thing intentionally done wrong to make Inspector stop wrong to make Inspector stop looking for other issueslooking for other issues

► New contractors (or new to New contractors (or new to area) often scrutinized harder to area) often scrutinized harder to establish inspector’s establish inspector’s authority/credibilityauthority/credibility

► People do what you People do what you Inspect, not what you Inspect, not what you ExpectExpect Left Photo - Aerial sewer crossing Left Photo - Aerial sewer crossing

with deflection over riverwith deflection over river Right Photo – PVC water main Right Photo – PVC water main

laid 2” from sewer force mainlaid 2” from sewer force main

TESTS & CONTRACTOR TESTS & CONTRACTOR TRICKS/SHORTCUTSTRICKS/SHORTCUTS

► Contractor custom-built test rigs (typ. Contractor custom-built test rigs (typ. Pressure testing equipment)Pressure testing equipment)

► Pressure Testing (Water lines & Force Mains)Pressure Testing (Water lines & Force Mains)► Air Test (Gravity Sewers)Air Test (Gravity Sewers)► Vacuum Test (Manholes)Vacuum Test (Manholes)► Sewer TV InspectionSewer TV Inspection► Mandrel (Non-rigid piping)Mandrel (Non-rigid piping)► Super Chlorination (Water line disinfection)Super Chlorination (Water line disinfection)► Flushing New Water LinesFlushing New Water Lines► Compaction Testing (all piping)Compaction Testing (all piping)

Sewer Line Air Test & MandrelSewer Line Air Test & Mandrel

Vacuum Test & TV InspectionVacuum Test & TV Inspection

Water System Flushing IssuesWater System Flushing Issues

THINGS TO LOOK FORTHINGS TO LOOK FOR► Proper pipe beddingProper pipe bedding► Proper compactionProper compaction► SAFETYSAFETY

Utility/Owner could be held Utility/Owner could be held responsible by a jury if responsible by a jury if someone is injured or killed, if someone is injured or killed, if U/O was aware of safety issuesU/O was aware of safety issues

► DocumentationDocumentation Take lots of pictures, videos, Take lots of pictures, videos,

etc. If going through private etc. If going through private property, document its pre-property, document its pre-construction condition very construction condition very well. Private owners have well. Private owners have rose-colored glasses when rose-colored glasses when recollecting the prior condition recollecting the prior condition of their property.of their property.

PROBLEMS ENCOUNTEREDPROBLEMS ENCOUNTERED► Leaking Water Line ExtensionLeaking Water Line Extension► 12” DIP water line installed on 12” DIP water line installed on

bedrockbedrock► Service taps not backfilled well Service taps not backfilled well

with voids under corporation stopwith voids under corporation stop► Sewer Outfall Extension ProblemsSewer Outfall Extension Problems► Restrained Joint Pipe (saves the Restrained Joint Pipe (saves the

day)day)► Tree Protection AreaTree Protection Area► PS Bypass Blown ApartPS Bypass Blown Apart► Shallow Water Line and Valve in Shallow Water Line and Valve in

Parking LotParking Lot► Rusted Out PS Influent PipeRusted Out PS Influent Pipe► Shallow PVC under Drainage Shallow PVC under Drainage

DitchDitch► Eccentric Reducer placementEccentric Reducer placement► Gravity Pipe used for Force Main Gravity Pipe used for Force Main

repairrepair► Backflow DangerBackflow Danger► Don’t Leave Your Truck Don’t Leave Your Truck

Unattended at the Job SiteUnattended at the Job Site

Clogged sink problems??Clogged sink problems??

Leaking Water Line ExtensionLeaking Water Line Extension► Private Developer ProjectPrivate Developer Project► Originally PVC water line Originally PVC water line

extension approved, approx. extension approved, approx. 1,200 feet1,200 feet

► Found Sewer Force Main within Found Sewer Force Main within 10 feet of proposed water after 10 feet of proposed water after plans had been approved and plans had been approved and construction startedconstruction started

► Deal made for Town to exchange Deal made for Town to exchange Contractor’s C900 for our DIPContractor’s C900 for our DIP

► Manufacturing defect in one Manufacturing defect in one section of pipe caused failure of section of pipe caused failure of pressure test. Hairline crack pressure test. Hairline crack that could not be seen unless that could not be seen unless under pressure.under pressure.

► Took several days (and a Took several days (and a claimed $24K expense) of claimed $24K expense) of looking for leak, exploratory looking for leak, exploratory digging, and damage to traffic digging, and damage to traffic signal equipment before leak signal equipment before leak was foundwas found

► Since it was a manufacturing Since it was a manufacturing defect that could not be defect that could not be detected until under pressure, detected until under pressure, liability fell to manufacturer, and liability fell to manufacturer, and settlement offeredsettlement offered

12” DIP water line installed on 12” DIP water line installed on bedrockbedrock

► Compaction and later Compaction and later construction of a road construction of a road pressed water line down on pressed water line down on sharp edge of blasted sharp edge of blasted bedrockbedrock

► Punctured water line and Punctured water line and caused approximately 20 caused approximately 20 gpm leak for months.gpm leak for months.

► It is best to install some clean It is best to install some clean stone as a bedding under all stone as a bedding under all piping to ensure a consistent piping to ensure a consistent and flat base.and flat base.

Service taps not backfilled well Service taps not backfilled well with voids under corp stop & with voids under corp stop &

service lineservice line► Contractor did not Contractor did not

backfill soil well under backfill soil well under service tapsservice taps

► Polyethylene piping Polyethylene piping pulled out of the grip pulled out of the grip joint at the corp stop joint at the corp stop upon settlementupon settlement

► Settling caused Settling caused multiple leaks in a multiple leaks in a subdivision after subdivision after warranty had expired, warranty had expired, many requiring many requiring pavement cutspavement cuts

Sewer Outfall Extension Sewer Outfall Extension ProblemsProblems

► Unapproved Unapproved Subcontractor Subcontractor performing majority of performing majority of the workthe work

► Safety Procedures Safety Procedures IgnoredIgnored

► Lack of Compaction or Lack of Compaction or Compaction TestingCompaction Testing

► Silt Fencing Never Silt Fencing Never Removed from SiteRemoved from Site

► Construction Debris & Construction Debris & Mounds of Dirt Left Mounds of Dirt Left along Outfallalong Outfall

Sewer Outfall Extension Problems, Sewer Outfall Extension Problems, continuedcontinued

► Promises made & broken by Promises made & broken by sub-contractor negotiating sub-contractor negotiating directly with a property directly with a property owner for access through a owner for access through a residential propertyresidential property

► Sub did not hire surveyor to Sub did not hire surveyor to stake alignment, which stake alignment, which resulted in clearing beyond resulted in clearing beyond the limits of the easementsthe limits of the easements

► Drainage ditch constructed Drainage ditch constructed at end of project period at end of project period with vertical sides, dirt with vertical sides, dirt mounded beside ditch, and mounded beside ditch, and no erosion control no erosion control measuresmeasures

Restrained Joint Pipe (saves the Restrained Joint Pipe (saves the day)day)

► Hurricane Floyd Hurricane Floyd washed the road out, washed the road out, leaving a 70 foot leaving a 70 foot crevasse. At a height crevasse. At a height of 12 feet, the 12 inch of 12 feet, the 12 inch water main remained water main remained operational, under operational, under pressure the whole pressure the whole time due to the Romac time due to the Romac GripRings installed on GripRings installed on the pipe. It was the the pipe. It was the only water main only water main serving a town of serving a town of more than 11,000.more than 11,000.

► Good example of Good example of product working product working properly in extreme properly in extreme conditions.conditions.

Tree Protection AreaTree Protection Area

►Do you Do you see see anythinanything wrong g wrong with with this this picture?picture?

PS Bypass Blown ApartPS Bypass Blown Apart

► 30”-20” HDPE 30”-20” HDPE Pre-fab reducer Pre-fab reducer fitting failed while fitting failed while the line was the line was being pressurized being pressurized for a hydrostatic for a hydrostatic pressure testpressure test

► Importance of Importance of properly properly designing and designing and pressure testing pressure testing bypass linesbypass lines

Shallow Water Line and Valve in Shallow Water Line and Valve in Parking LotParking Lot

►6” GV nut 6” below 6” GV nut 6” below rim of the valve box rim of the valve box

►C-900 PVC pipe <3’ C-900 PVC pipe <3’ covercover

►Contractor trying to Contractor trying to conceal improper conceal improper cover by cutting cover by cutting the valve box off to the valve box off to get it to correct get it to correct elevation for paving elevation for paving

Rusted Out PS Influent PipeRusted Out PS Influent Pipe

► When tying into When tying into existing PS existing PS influent pipe, influent pipe, found it severely found it severely rusted awayrusted away

► Had to install a Had to install a liner in the liner in the influent pipe influent pipe (Change Order)(Change Order)

► Importance of Importance of verifying existing verifying existing conditionsconditions

Shallow PVC under Drainage Shallow PVC under Drainage DitchDitch

► C-900 PVC pipe had C-900 PVC pipe had <12” of cover in the <12” of cover in the bottom of the bottom of the drainage ditchdrainage ditch

► Installed bore with 3’ Installed bore with 3’ cover under road, cover under road, ignoring ditch coverignoring ditch cover

► Also installed PVC Also installed PVC pipe under the road pipe under the road through the casing through the casing (plans req’d DIP)(plans req’d DIP)

► Improper coverage, Improper coverage, sub-contractor work, sub-contractor work, periodic inspection periodic inspection

Eccentric Reducer placementEccentric Reducer placement

► Eccentric reducer Eccentric reducer on wet well on wet well suction linesuction line

► Flat side of Flat side of reducer should be reducer should be installed on top installed on top to avoid potential to avoid potential air pocket trapair pocket trap

► Trapped air in Trapped air in reducer can reducer can cause pump cause pump cavitation, or cavitation, or cause the pump cause the pump to not work to its to not work to its full potentialfull potential

Gravity Pipe used for Force Main Gravity Pipe used for Force Main repairrepair

► Project to replace an Air Project to replace an Air Release Valve & vault Release Valve & vault

► Force main pipe found Force main pipe found was actually for gravity was actually for gravity sewer onlysewer only

► Had to install Had to install approximately 400 feet of approximately 400 feet of new pipe (Change Order)new pipe (Change Order)

► Incorrect pipe was Incorrect pipe was installed previously to installed previously to replace corroded DIPreplace corroded DIP

► Project to solve one Project to solve one problem found anotherproblem found another

► Verify existing conditionsVerify existing conditions

Backflow DangerBackflow Danger

► Gray line (on right) goes Gray line (on right) goes to an eye wash. SS line to an eye wash. SS line goes to a Hydrogen goes to a Hydrogen Peroxide feed line.Peroxide feed line.

► Cheap SS check valve Cheap SS check valve screwed into tee was screwed into tee was only backflow only backflow prevention to eye wash.prevention to eye wash.

► Had to disconnect the Had to disconnect the chemical feed line and chemical feed line and cap the teecap the tee

► Check valve failure Check valve failure could result in eyes could result in eyes washed with Hydrogen washed with Hydrogen PeroxidePeroxide

Additional examplesAdditional examples

Additional examples, continuedAdditional examples, continued

Inspectors - Don’t Leave Your Inspectors - Don’t Leave Your Truck Unattended at the Job SiteTruck Unattended at the Job Site

► This Inspector’s truck This Inspector’s truck was left at the job site was left at the job site when the Inspector when the Inspector went to lunch with went to lunch with others others

Special Thanks to:Special Thanks to:

► Town of Hillsborough & Utilities Dept. Town of Hillsborough & Utilities Dept. EmployeesEmployees

► Highfill Infrastructure Engineering, PCHighfill Infrastructure Engineering, PC► Summit Consulting Engineers, Summit Consulting Engineers,

HillsboroughHillsborough► WK Dickson & Co., Inc.WK Dickson & Co., Inc.► Civil Consultants, DurhamCivil Consultants, Durham► Town of Cary Utilities Dept.Town of Cary Utilities Dept.► Charles R. Underwood, Inc.Charles R. Underwood, Inc.

THANK YOU!THANK YOU!

Kenny P. Keel, PEKenny P. Keel, PETown Engineer/Utilities Town Engineer/Utilities

DirectorDirectorTown of HillsboroughTown of Hillsborough919-732-1270 ext 75919-732-1270 ext 75Fax 919-644-2390Fax 919-644-2390kenny.keel@hillsboroughnc.orgkenny.keel@hillsboroughnc.orgwww.ci.hillsborough.nc.uswww.ci.hillsborough.nc.us