NC0037508_Upgrade&Expansion_20120316

OENR--FRO
ArA ___ MAR 2 0 2012
NCDENR OWO
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Charles Wakild, PE Dee Freeman
Govemor Director Secretary
March 16, 2012
Mr. Cary McSwain, County Manager
County of Moore
PO Box 905, 1 Courthouse Circle
Carthage, North Carolina 28327
Subject: Interim Inspection
Moore County Water Pollution Control Facility
Upgrade & Expansion
Project No. CS 370 496-02
Dear Mr. McSwain:
The Construction Inspection Group (CIG) of the Infrastructure Finance Section (formerly
Construction Grants & Loans Section) performed an interim inspection for the state and federally
funded portion of subject project Tuesday March 13, 2012. This interim inspection was conducted
in conjunction with the monthly progress meetings which are conducted on the 2nd Tuesday each
month at 10:00 am, generally preceded by a field inspection at 9:00 am. Location of the Progress
meeting is in the conference room at Wharton Smith's construction trailer. The next scheduled
progress meeting and interim inspection is April 10, 2012.
You should review this report, take actions or provide responses as indicated, and then file with
your project records. If you have any questions, please contact the undersigned at [phone]
or via e-mail at [e-mail].
Gerald W. Horton, PE
Environmental Engineer
Construction Inspection Group
cc: Randy Gould, PE, Public Works Director, Moore County
Adam Kiker, PE, Hobbs Upchurch & Assocs., Southern Pines office
Jason Caviness, Hobbs Upchurch & Assocs., 1094 Addor Rd., Aberdeen, NC 28315
Belinda Henson,]Fayetteville Regional DWQ Office
CIG - Mark Hubbard, PE, Gerald Horton
SRF
. attachment: Davis Bacon records summary
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Infrastructure Finance Section
1633 Mail Service Center, Raleigh, North Carolina 27699.1633
• Location: 8th Floor Archdale Building, 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone [phone]\FAX:[phone]
Internet: www.ncwaterquality.org
An Equal Opportunity/Affirmative Action Employer
NorthCarolina
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Moore County
WPCF Upgrade & Expansion
CS 370 496-02
Interim Inspection of
March 13, 2012
Page 2 of 4
GENERAL CONCERNS / RECOMMENDATIONS / ACTION ITEMS —Please note UPDATES
on Comments and Concerns noted from previous progress meetings are italicized for reference.
9. Mar. update: Jason Caviness subsequently provide updated subcontractor's list via 3/13 email.
[Dec.]- subcontractors list was provided to CG&L at December meeting. Please indicate which
are D,M, or W BEs? [Nov.] - CG&L requested list of all subcontractors presently utilized as
well as those anticipated to be used on project. Those of Disadvantaged , Minority, or
Women's Business Enterprise status should be so designated on the list. The subcontractors
list will be used to check for Davis Bacon compliance, hence Owner is advised to provide this
list immediately. Further, the list will be used at CG&L's final inspection to determine how
close project comes to achieving goals.
11. This was discussed in January meeting. Please keep this matter on monthly agenda. [Dec.]-
CG&L requested Owner put a discussion of "phasing and maintaining operations" during
construction on the monthly agenda. [ Nov.] - CG&L reminded all present that proper un-
interrupted conveyance and treatment of Owner's wastewater during construction is an
NPDES permit requirement and a loan assurance by Owner.
18. March update: these change orders discussed in January are all still pending. All parties are
advised to be on guard against delays in change order administration causing delays in
construction authorizations. [Jan.] -Owner stated that all changes in contract must go to the
County Commissioners for approval. The process may take 4+ weeks. Changes must go to
county's legal counsel and [then] to Commission's 3rd Tuesday preliminary agenda and
meeting. Commission meets on the 4th Tuesday each month.
20. March update: Owner's representative Rich Smith, stated his concern regarding slow pace
of review and approval of electrical submittals. IMPORTANT - IFS is likewise concerned
about the length of time it is taking to obtain review and approval of submittals as well as
responses to Requests for Information (RFIs), particularly electrical and control submittals.
Some of these items, in addition to having long review/approval times, may take
considerable time to fabricate and deliver. Owner is advised the loan payback date will not
be extended to accommodate unwarranted project delays. Jason Caviness, inspector, after
today's meeting called Hobbs Upchurch office to explain these concerns. [Jan.] -IFS
recommends Owner discuss and provide plan for more expeditious review and handling of
the submittals. At each meeting any critical submittals and their status should be discussed.
21. For the record IFS did not attend the February 14 meeting.
22. IMPORTANT -Today it was noticed that sheet E-2 in IFS's approval set was different than
the sheet E-2s being used at the site by contractor and Engineer. IFS hereby requests Owner
and/or Engineer explain discrepancy and provide list of drawings different from the
Approved set. IFS may request an entire updated set of half sized drawings if the sets do
not match. Owner and Engineer are advised if there are significant changes in the plans, a
permit modification may be required.
23. Engineer noted concern about quality of materials and workmanship regarding the
fabricated steel elements of the digester roof and support system. Specifically, there is mill,
scale and "fingernail" seams on some of the structural members. Please be prepared to
discuss resolution of this matter at next progress meeting.
24. IFS hereby acknowledges and appreciates WS providing one page summary construction
schedule in addition to the detailed 9 page project schedule and the 30 day 2 page schedule.
In January IFS had requested a 1 page schedule be provided at next meeting, similar to the
one posted on wall in meeting room.

Moore County
WPCF Upgrade & Expansion
CS 370 496-02
Interim Inspection of
March 13, 2012
Page 3 of 4
PROJECT & LOAN BUDGET
Project budget: COST
Wharton -Smith Inc. $21,572,000
Contingency $ 1,079,000
Technical Services $ 2,740,000
Legal, Testing, etc. $ 129,000
Total Expenditures $24,943,000
Moore County requested that the total loan amount be reduced to $ 20,000,000. Closing costs
are 2% of the eligible loan amount, thus $ 400,000. The loan maximum amount is
$20,000,000 for maximum 20 years at interest rate of 2.220 % per annum. •
CONTRACT: Wharton Smith, Inc., (WS) PO Box 471028, Monroe, FL 32747
tele: 704 525-5695 Unlimited -Building, Public Utilities (Water Lines & Sewer Lines) PU
(Water Pur. & Sewage Disp.) Lic # 38755,
Proj. Mgr. - Brian Klauka,
Project Supt. - Dave Gaztambide replaced Forrest Anderson who returned to Florida in February
CONSTRUCTION INSPECTION
Observations of WS construction and progress since January meeting:
o Jan. -Mar. - completed concrete wall placement on primary digester, began concrete
finishing and steel for roof has arrived and the steel is being sandblasted and painted; also
regarding problem, refer to comment 23) above
o placing/completing footings on aeration basin and clarifiers and continuing with concrete
wall pours
o continuing with electrical and conduit installation, also refer to comment 22) above
o cut into brick to place access to old DAF building and removed old DAF equipment
o began setting footings at sludge storage area at sludge drying beds
CHANGE ORDERs — none yet received at IFS, refer to comment 18) above
Request for Information, RFIs Status - according to WS handout "Request and Answer Log" at
March meeting there were 6 of 43 RFIs outstanding, oldest (sludge flow meter 1-1.-B2) is now 154
days old, 2 others over 115 days old. Age of RFIs is not acceptable. Refer to comment 20) above.
Project Schedule -- W-S indicates they are on generally on schedule, however, according to
March 9 correspondence to HUA, WS contends they may be 76 days behind in project completion
because of delays in the solids handling portion which goes through the critical path.
SUBMITTAL Status- at the December meeting several submittals (-16) had been under review
for a very long time. IFS subsequently recommended Owner discuss and provide plan for more
expeditious review and handling of the submittals. This issue is now becoming critical and Owner
is advised to take necessary measures to cause more expeditious reviews of this vitally important
aspect of the construction effort.
Project Signs and Postings - it appears all necessary signs are posted

Moore County
WPCF Upgrade & Expansion
CS 370 496-02
Interim Inspection of
March 13, 2012
Page 4 of 4
Inspectors logs/Work Orders - inspection logs were reviewed at March's meeting and deemed
adequate. IFS is on record asking that inspection logs and all test reports be available for review at
all meetings
Testing - concrete tests were reviewed, breaks and air entrainments are testing satisfactorily.
As-builts or Record Drawings red lines were reviewed at March's meeting and deemed adequate.
Davis Bacon records - refer to attachment
Progress Meeting List of Attendees (only those who signed roster, there were 15 in attendance):
Rich Smith
David Laurita
George Yankay
Jason Caviness
Steve Breedlove
Philip Daggerhart
Brian Klauka
Dave Gaztambide
Kris Trouteaud
Kate Datten
John Roberts
Wayne Dery
Gerald W. Horton, PE
Moore County Construction Manager
[e-mail]
Moore County
ORC, Moore County WPCF
[e-mail]
Hobbs Upchurch Assoc, inspector
jcaviness @hobbsupchurch.com
Hobbs Upchurch Assoc
[e-mail]
Hobbs Upchurch Assoc, coatings inspection
[e-mail]
Wharton -Smith Inc., Project Manager
[e-mail]
Wharton -Smith Inc., new Supt.
Wharton -Smith Inc.
[e-mail]
Wharton -Smith Inc., Schedule assistant
[e-mail]
Wharton -Smith Inc., Sr. Scheduling Engr.
[e-mail]
Graydaze, coatings subcontractor
NC Infrastructure Finance Section of DWQ
910 315-6055 c
910 215-7079-c
910 789-2658 c
910 639-7718 c
910 692-5616 ofc
910 692-5616 ofc
704 674-4679 c
704 525-5695 ofc
704 557-5225 c
704 525-5695 ofc
407 402-9654 c
404 388-3486 c
919 707-9185 ofc

Davis Bacon compliance AS OF March.13, 2012
records below compiled from information and conversations with Jason Caviness, HUA and Wharton
Wharton -Smith & subcontractors
-
Firm Name
Scope
City, State
Contact
HUB
Designation
DB interviews
performed
Certified
Payrolls
Compared to
Wage Rate
Determination
Wharton Smith
Prime contractor
Florida
2
2
yes, OK
AWS Services
Erosion Control
Columbia SC
Summers Duffie
Bilbrey Construction Services
(dba )
concrete sawing and cutting
W
1
need Cert
payroll(s)
Brooks Grading & Hauling
Erosion Control / select demo •
Pinebluff NC
Chris Brooks
Custom Overhead Doors LLC
Overhead coiling doors
Raleigh
Michael Ladrie
W
Dover Installation
{ipe insulation
Marion, NC
Melanie Dover
W
Dorsett Technologies
SCADA system
Yadkinville NC
David Hutchins
ECS
independent testing
Fayetteville NC
Mike Santiago
Graydaze Contracting Inc.
paints & coatings
Alpharaetta GA
Gary Gray
1
need Cert
payroll(s)
Guilford Bulding Systems LLC
PEMB
Greensboro NC
Doug Reaynolds
Heat Wave
demo, battered demo of DAF for
exempt
JR Steel
Rebar installation
Charleston SC
Jamal Magwood
B, SE
1
need Cert
payroll(s)
Kirby Construction Group
operations bldg CM
Southern Pines NC
Stephen Kirby
Quality Labor Management
labor temporary placement
Clayton NC
2
need Cert
payroll(s).
Stewart Mechanical
HVAC
Goldsboro NC
Joseph Stewart
SVG Concrete Services
concrete placement
Cary NC
Serg Verasteglui
HA, W
1
need Cert
payroll(s)
Sinns & ThonlaS -in Jan replaced by United
Signs & Signals
Electrical
2
need Cert
payroll(s)
United Signs & Signals
Electrical
Lake Worth FL
2
need Cert
payroll(s)
Wall Masters
concrete finishers
Crosshill SC
1
need Cert
payroll(s)
Sum -->
13
2
Davis Bacon Status
MOORE County WPCF
Wharton Smith