Carolina Civilworks was contracted by New Atlantic to perform the water & sewer work on the new Seaforth High School project for the Chatham County Board of Education. Being that no City or County sewer was available, the biggest aspect of this project was the sanitary sewer system which not only treated & stored wastewater on-site, but also re-used some for irrigation of the athletic fields. Other features included a 7AC spray field and off-site water line work to connect to an existing main on US-64.
CCI was selected as the site utility contractor for Clancy & Theys on both the Block A and Block C projects at the Seaboard Station shopping center. Our scope of work included extensive water, sewer & storm drain upgrades in and around the 2 new multi-family buildings and hotel. Also included were underground detention / sand filter structures at both Blocks. The Block A utility work also involved painstaking upgrades in the middle of Peace Street & several intersections. Detailed planning, communication & close coordination were instrumental in making this project a success!
In February of 2020, RAM Realty contracted Carolina Civilworks for the Elliot Storage Design a.k.a. Booker Creek Expansion & Greenway project. This job included complete site erosion control, earthwork, a constructed wetland, retaining walls, deep foundations, a pedestrian bridge and new greenway extension for the Town of Chapel Hill. Also included were various storm drain improvements, CIP concrete work and landscaping.
CCI was low bidder and awarded the improvements project for Sludge Thickener No. 4 at the City of Raleigh’s E.M. Johnson Water Treatment Plant. Besides construction of the brand new 50’ diameter cast-in-place concrete tank, this project also included replacement of transfer pumps & MCC, upgrades to the existing SCADA system, yard piping modifications, high performance coatings and renovation of an existing storage building into a break room for plant operations staff.
CCI was low bidder & awarded Bid Package 11 on the Neuse River Resource Recovery Facility’s Bioenergy project for the construction of the Alum Facility. This included upwards of 6,000 LF of chemical distribution piping, 2 ea. 22,000 gallon FRP tanks for aluminum sulfate storage, 4 ea. metering pumps, 1 transfer pump and associated electrical upgrades. Added via change order was approx. 1,500 LF of concrete encased medium voltage duct bank including hand holes & vaults.
CCI was contracted by Clancy & Theys to perform the site utility work on this multi-family project for Kane Realty. That scope of work included water & sewer main replacements in West Cabarrus Street, Dupont Circle & Rosengarten Alley as well as domestic & fire services for the new development. The primary feature of this project however was the ~825 LF of new 10×6’ & 12×5’ precast box culvert that was required to relocate existing storm drain infrastructure out of the footprint of the new apartments & parking deck. This included several cast-in-place components as well as engineered shoring systems due to excavation widths and depths.
In May 2018, CCI was awarded this project to replace approx. 5,000 LF of existing force main with a new 16” PVC line. The majority of the alignment was through downtown streets occupied by businesses and single family homes. Traffic control, communication and phasing of the work were key to reducing impacts to CFPUA’s customers. Also included on this job were a horizontal directional drill and various storm drain improvements throughout the project corridor.
CCI was awarded the contract from the City of Raleigh to handle several upgrades to one of the largest sewer pump stations in its system. The bulk of the new 24” piping, electrical and SCADA improvements were associated with the addition of a 4th 150 HP dry pit vertical solids handling pump to the existing triplex station. In order to complete this work, we were responsible for installing a permanent bypass assembly on the 36” discharge force main and completely bypassing the station which was designed to handle flows up to 21 MGD. In addition to the pump-related work, HVAC modifications, roof repairs, door replacement, structural repairs to the aluminum stairwell and cleaning of the wet well were also included. Key subcontractors on this project were Bitting Electric and Shumate Mechanical.
This was a fast tracked repair project for the City of Raleigh Stormwater Management Department that ultimately replaced a failing 70 year-old CMP culvert under Clark Avenue. The old 72” corrugated metal arch culvert was replaced with approx. 110 LF of parallel 60” reinforced concrete pipes. In addition to the new piped system, a large custom masonry junction box and precast concrete headwalls were included to help stabilize upstream and downstream ends of the culvert.
UNC Chapel Hill’s Central Campus Athletics Project was designed to provide additional practice fields to their football team – primarily an indoor facility – as well as a renovation to their soccer stadium. As part of this construction, CCI was awarded a contract to replace and relocate underground chilled water lines and a steam tunnel to avoid the footprint of the new building and concourse. The chilled water work consisted of approx. 350 LF of parallel 18” RJDIP, butterfly valves, thrust block and multiple tie-ins to existing lines. Steam work included not only the demolition and abatement of existing tunnel, but the up-sizing of approx. 100 LF of new, larger tunnel with CIP base and precast tops. The majority of CCI’s work took place in a 30’ corridor between 2 occupied dorms and in one of the campus’ busiest roadways which required extensive planning, coordination and safety measures. Key subcontractors on this project included Aggregate Group, EHG, Raleigh Paving, Certified Concrete and Waterproofing Specialties.
CCI’s first project with H2GO Brunswick Regional Water & Sewer consisted of the construction of a large, regional pump station and associated force main in Leland, NC. A new gravity sewer system that fed into this station was constructed under separate contract. The 1,260 GPM pump station consisted of duplex 70hp pumps set in a 12’ diameter wet well nearly 35’ deep, valve vault, a 12” electromagnetic flowmeter & MH, sampling MH and complete electrical system including an emergency generator. The roughly 11,000 LF of 12” force main required to tie into the existing WWTP included 289 LF of jack & bores and approx. 3,500 LF of horizontal directional drills. Key subcontractors on this project included Sandy’s Hauling & Backhoe, Razorback Boring, Pitt Electric and Dun-Right Services.
In late May of 2018, a severe thunderstorm dropped nearly 4” of rain on Raleigh in less than 2 hours. On Newton Road in North Raleigh, the flash flooding caused not only the failure of a twin 72” CMP culvert, but also an active 12” water main. CCI crews responded on an emergency call from the City to repair the water main and once complete, consulted with Raleigh’s Stormwater Department on the best course of action moving forward. Utilizing a Design-Build approach, we were able to expedite the design process and begin construction on the pipe replacement within 3 days from the original failure. The outdated corrugated metal pipes were replaced with a 9×6’ precast concrete box culvert that utilized Stone Strong block retaining walls at both upstream and downstream inverts. Material selection was critical on this project as lead time, installation and cost were all crucial factors. CCI was able to have Newton Road paved and re-opened to regular traffic in 63 days, over a month sooner than projected. Key subcontractors and suppliers included Summit Coastal, Marvel Engineering, Puryear Transport, Fences Unlimited, Patriot Concrete, Raleigh Paving and Carolina Guardrail. In addition to those contractors, this project could not have been a success without the assistance and cooperation of the City of Raleigh Public Utilities & Stormwater Departments, HDR Engineering, Froehling & Robertson and CH Engineering.
This project for Cape Fear Public Utility Authority involved replacing sewer air release valves on some of the largest force mains in and around downtown Wilmington. Under this contract, we replaced a total of 18 ARVs on force mains ranging in size from 8” to 24”. The majority of the replacements were on 20” & 24” PCCP and involved installation of new 6’ dia. manholes to house the new valve assemblies. Night work and the use of several line stops were necessary in order to isolate our work areas and facilitate ARV installation without interrupting sewer service. Most of the work was done on or near high volume City of Wilmington and NCDOT roadways which required extensive traffic control measures in addition to coordination with local agencies, include the NC Port Authority. Key subcontractors on this project included Dun-right Services and Team Industrial.
National home builder KB Home and their consultant – TerraTech Engineers – awarded CCI this project in the summer of 2017. We were tasked with repairing slopes in multiple locations of the Phillips Place neighborhood in Cary. The designated method of repair was the installation of several gabion walls to help prevent any future erosion concerns around the already occupied homes. The scope of work in our contract included misc. erosion control measures, grading, installation of 6 separate rip-rap gabion walls as well as replacement of homeowner’s sod & landscaping. Key subcontractors on this project included Southeastern Erosion Control & Southern Garden.
At CCI, we pride ourselves on our relationships with customers and believe that is evidenced by the amount of repeat business we are fortunate enough to see. This job at the University of North Carolina was no exception. We were contracted to deliver a complete site package to the owner for 2 new practice fields and associated structures to be utilized by the soccer and field hockey teams. Work included erosion control measures, clearing & grubbing, grading, domestic and irrigation water services, fencing, CIP concrete, landscaping and electrical. Also included were a masonry kick wall, elevated steel coaching platforms and a wood framed shelter. Key subcontractors on this project were Boone Masonry, Frye Fencing, Summit Coastal, Phase III Electric, Quate Industrial and Southeastern Erosion Control.
After struggling with efficiency loss and increased cycle times at 3 of their wastewater pump stations, the Town of Cary contracted with CCI to undergo their first ever force main cleaning project. Before cleaning could commence, we had to install bypass connections at each station. These assemblies actually doubled as “pigging stations” which were required for the cleaning. The Progressive Pigging method was utilized to flush more than 15,000 LF of 6” & 8” force mains and combat the significant build-up in the lines. At one station alone, flow rates improved from 91 GPM before the cleaning to over 200 GPM after. Key subcontractors on this project were Montauk and Dun-Right Services.
This high profile project consisted of improvements to a storm drain trunkline running beneath Kenan Stadium at the University of North Carolina – Chapel Hill. The existing 42” RCP line was decades old and in need of an upsize and replacement. The 376’ of old pipe which ran from endzone to endzone at depths of 12 to 20’ was replaced with new 60” RCP with water-tight gasketed joints. A blind junction box was also added on the upstream end of the pipe alignment. The many challenges of the project included extremely tight construction access with limited laydown, the requirement to keep the stadium open to student traffic, construction occurring during one of the worst winters in the past 10+ years as well as a condensed schedule to ensure spring commencement could go on as planned. Even with the full field sod replacement added to the scope of work midway through construction, the project finished 2 weeks ahead of schedule. Key subcontractors included Southeastern Erosion Control, Carolina Green Corporation, Summit Coastal, Fortress Fencing and Puryear Trucking.
616 Oberlin is a new project in Raleigh that when complete, will provide 207 residential units on prime real estate within walking distance of Cameron Village. CCI was selected as the site contractor for the project and is responsible for all erosion control, earthwork, site utilities, asphalt paving, curb & gutter, concrete sidewalks and paving, striping, signage and traffic control, including a multi-phased pedestrian control plan. Due to the site constraints and the amount of cast-in-place foundation walls splitting footprint of the building, the grading on this project had to be performed in multiple phases. An initial mass excavation produced approximately 20,000 CY of material – half of which was exported, while the other half was stockpiled onsite to eliminate import costs. The stockpile material will serve as backfill for the large foundation walls once complete. In order to provide a safe excavation for the concrete foundations to be installed, approximately 1400 SF of temporary shoring via a driven bar system was utilized on the northern boundary of the site. The water and sewer utilities serving the project required a total of 3 taps in Oberlin Road and another 3 in Daniels Street. Also associated with this project is an offsite sewer replacement on Smallwood Drive which will require both traffic control and by-pass pumping operations. Key subcontractors include Certified Concrete Construction, Gelder & Associates, Southeastern Erosion Control, Sides Seeding, Puryear Transport, Morrison Engineers and Boone Masonry.
While results are always important, safety is paramount and that was certainly the case on this repair for the City of Raleigh. CCI was awarded the contract to replace missing and/or damaged flights & shrouds on several large screw pumps at the City’s Crabtree Creek Lift Station. Confined space, ventilation and access / egress were all issues that had to be addressed and constantly monitored to ensure worker safety. With the station on full sewer bypass, repairs were able to be made on four of the five 70 foot long screws in just 7 days. Pump station capacity was increased from 28MGD to 33MGD after work was complete.
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