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Home My WebLink AboutIA2016-1504 Page 1 of 120 June 22, 2016 TX FIRM #F-11847 Ms. Erica Lee Tower Engineering Professionals Crown Castle 326 Tryon Road 2055 Stearman Dr. Raleigh, NC 27603 Chandler, AZ 85286 (919) 661-6351 (office) (480) 734-2406 (office) (919) 661-6350 (fax) com Subject: Modification Inspection Report Crown Castle Customer Apps: AT&T App: 313011 Crown Castle Designation: Crown Castle BU Number: 843732 Crown Castle WO Number: 1221507 Crown Castle Site Name: Minters CHPL/ HWY114 Crown Castle JDE Job Number: 355713 Engineering Firm Designation: TEP Project Number: 59350-47941 Site Data: 1201 Minters Chapel Rd. Grapevine, Tarrant County, TX 76051 Latitude N 32° 55' 50.7”, Longitude W 97° 3' 50.9” 119.5± Foot – Monopole Tower Dear Ms. Lee, Tower Engineering Professionals is pleased to submit this “Modification Inspection Report” (MI Report) to Crown Castle for the modification/reinforcement to the subject structure. This Modification Inspection (MI) was performed in accordance with Crown Castle ENG-SOW-10007 Modification Inspection SOW, Contract Documents, and Crown Castle Purchase Order number 890840. The purpose of this MI is to confirm that the modification installation configuration and workmanship are in accordance with the contract document(s) listed in Table 2. The MI is not a review of the adequacy or effectiveness of the modification/reinforcement solution. Page 2 of 120 Table 1 – General Information Company Contact Dates on Site MI Inspector Tower Engineering Professionals Trenton H. Johnston, P.E., C.W.I. N/A MI Inspector Field Representative (if applicable) Tower Engineering Professionals Nate House and Jonathan Luna 6/1/16 Independent EOR Turnkey Modification Design EOR B + T Group John W. Kelly, III, P.E. N/A General Contractor B + T Group Bryan Edgmon Unknown Sub to the General Contractor N/A N/A N/A Field CWI for the General Contractor Lair Industries, LLC Eddie Lair, C.W.I. 5/31/16 – 6/1/16 Field NDE for the General Contractor Lair Industries, LLC Eddie Lair, C.W.I. 5/31/16 Table 2 – Documents Document(s) Remarks Source Modification Drawings Date: December 18, 2015 EOR: John W. Kelly, III, P.E. Project #: 96580.003.01 Creator of Drawings: B + T Group Project #: 96580.003.01 Date of Drawings: 12/18/15 CCIsites Drawing File: 6028919 Page 3 of 120 Based on our inspection, Tower Engineering Professionals, Inc. determines this project: X PASSING MI The configuration, materials and/or workmanship of the modifications are installed in accordance with the Contract Documents and no deficiencies were found. __ PASS AS NOTED MI The configuration, materials and/or workmanship of the modifications are accepted as noted (see detail below). __ FAILED MI The configuration, materials and/or workmanship of the modifications are NOT installed in accordance with the Contract Documents. The rejection is based on non- conformance in the following area(s): __ Materials (see detail below) __ Workmanship (see detail below) __ Configuration (see detail below) - The EOR approved changes to the layout of the modifications. See Section 6.2.6 GC AND TEP REDLINE DRAWINGS for more details. - Crown Castle waived the requirement of the Foundation Inspection. See Section 6.3.5 ENGINEER OF RECORD EMAIL for more details. Discrepancies were noted between field measurements and structural modification drawings. All items not verified and approved by the Engineer of Record have been corrected by the General Contractor to match the specifications of the original modification drawings. All discrepancies are redlined on the modification drawings. All observations were performed after the construction was complete. Tower Engineering Professionals, Inc. was not present during the construction phase. The onsite MI was performed by Nate House and Jonathan Luna of Tower Engineering Professionals, Inc., (919) 661-6351. We at Tower Engineering Professionals, Inc. appreciate the opportunity of providing our continuing professional services to you and Crown Castle. If you have any questions or need further assistance on this or any other projects please give us a call. Respectfully submitted, Trenton H. Johnston, P.E., C.W.I. Vice President TX FIRM # F-11847 Page 4 of 120 Table of Contents PAGE NO. PRE-CONSTRUCTION ................................................................................................................................. 5 6.1.1 MI CHECKLIST DRAWING .............................................................................................................. 6 6.1.2 EOR APPROVAL ............................................................................................................................. 7 6.1.3 FABRICATION INSPECTION .......................................................................................................... 9 6.1.4 FABRICATOR CERTIFIED WELD INSPECTION .......................................................................... 11 6.1.5 MATERIAL TEST REPORT (MTR) ................................................................................................ 32 6.1.6 NDE REPORT OF MONOPOLE BASE PLATE ............................................................................. 44 6.1.7 PACKING SLIPS ............................................................................................................................ 68 CONSTRUCTION ....................................................................................................................................... 70 6.2.1 CONSTRUCTION INSPECTIONS ................................................................................................. 71 6.2.2 FOUNDATION INSPECTIONS ...................................................................................................... 72 6.2.3 POST INSTALLED ANCHOR ROD VERIFICATION ..................................................................... 73 6.2.4 CONTRACTOR’S CERTIFIED WELD INSPECTION .................................................................... 75 6.2.5 ON SITE COLD GALVANIZING VERIFICATION .......................................................................... 76 6.2.6 GC AND TEP REDLINE DRAWINGS ............................................................................................ 78 POST-CONSTRUCTION ............................................................................................................................ 82 6.3.1 POST INSTALLED ANCHOR ROD PULL-OUT TESTING ............................................................ 83 6.3.2 EXECUTIVE SUMMARY ................................................................................................................ 89 6.3.3 PHOTOGRAPHS ............................................................................................................................ 92 6.3.4 GC PUNCH LIST PHOTOS ........................................................................................................... 94 6.3.5 ENGINEER OF RECORD EMAIL .................................................................................................. 96 Page 5 of 120 PRE-CONSTRUCTION Page 6 of 120 6.1.1 MI CHECKLIST DRAWING Page 7 of 120 6.1.2 EOR APPROVAL Page 8 of 120 Page 9 of 120 6.1.3 FABRICATION INSPECTION Page 10 of 120 Page 11 of 120 6.1.4 FABRICATOR CERTIFIED WELD INSPECTION Page 12 of 120 Page 13 of 120 Page 14 of 120 Page 15 of 120 Page 16 of 120 Page 17 of 120 Page 18 of 120 Page 19 of 120 Page 20 of 120 Page 21 of 120 Page 22 of 120 Page 23 of 120 Page 24 of 120 Page 25 of 120 Page 26 of 120 Page 27 of 120 Page 28 of 120 Page 29 of 120 Page 30 of 120 Page 31 of 120 Page 32 of 120 6.1.5 MATERIAL TEST REPORT (MTR) Page 33 of 120 Page 34 of 120 Page 35 of 120 Page 36 of 120 Page 37 of 120 Page 38 of 120 Page 39 of 120 Page 40 of 120 Page 41 of 120 Page 42 of 120 Page 43 of 120 Page 44 of 120 6.1.6 NDE REPORT OF MONOPOLE BASE PLATE Page 45 of 120 Page 46 of 120 Page 47 of 120 Page 48 of 120 Page 49 of 120 Page 50 of 120 Page 51 of 120 Page 52 of 120 Page 53 of 120 Page 54 of 120 Page 55 of 120 Page 56 of 120 Page 57 of 120 Page 58 of 120 Page 59 of 120 Page 60 of 120 Page 61 of 120 Page 62 of 120 Page 63 of 120 Page 64 of 120 Page 65 of 120 Page 66 of 120 Page 67 of 120 Page 68 of 120 6.1.7 PACKING SLIPS Page 69 of 120 Page 70 of 120 CONSTRUCTION Page 71 of 120 6.2.1 CONSTRUCTION INSPECTIONS Page 72 of 120 6.2.2 FOUNDATION INSPECTIONS The Foundation Inspections has been waived by Crown Castle (see Section 6.3.5 Engineer of Record Email for the waiver email). Page 73 of 120 6.2.3 POST INSTALLED ANCHOR ROD VERIFICATION Page 74 of 120 Page 75 of 120 6.2.4 CONTRACTOR’S CERTIFIED WELD INSPECTION See Section 6.1.6 NDE Report of Monopole Base Plate for the Contractor’s Certified Weld Inspection. Page 76 of 120 6.2.5 ON SITE COLD GALVANIZING VERIFICATION Page 77 of 120 Page 78 of 120 6.2.6 GC AND TEP REDLINE DRAWINGS TEP REDLINES June 22, 2016 Nate House and Jonathan Luna X Built As Drawn __ Contractor Red Line Verified __ Discrepancies Noted TEP REDLINES June 22, 2016 Nate House and Jonathan Luna X Built As Drawn __ Contractor Red Line Verified __ Discrepancies Noted Page 79 of 120 TEP REDLINES June 22, 2016 Nate House and Jonathan Luna X Built As Drawn __ Contractor Red Line Verified __ Discrepancies Noted TEP REDLINES June 22, 2016 Nate House and Jonathan Luna X Built As Drawn __ Contractor Red Line Verified __ Discrepancies Noted Page 80 of 120 The splice elevation measured to be 51’-3” as opposed to 50’ causing the plates to be installed from 51’- 4” – 66’-4”. The mount, hardware, and feedline was not removed at 104’ and 107’. TEP REDLINES June 22, 2016 Nate House and Jonathan Luna __ Built As Drawn ___ Contractor Red Line Verified _X_ Discrepancies Noted (See Section 6.3.2 Item #3) TEP REDLINES June 22, 2016 Nate House and Jonathan Luna __ Built As Drawn ___ Contractor Red Line Verified _X_ Discrepancies Noted (See Section 6.3.2 Item #2) Scorch marks were observed on the inside of the tower where the plates were welded. Page 81 of 120 The new anchor rods were installed on flats 3, 6, and 11, as opposed to 3, 8, and 11. The GC was not able to completely core out the existing anchor rod on flat 8. The new anchor rod holes were 3” diameter as opposed to 2.75” diameter. Hilti RE 500 used in flat 6 and is embedded to only 17’ as opposed to 20’. TEP REDLINES June 22, 2016 Nate House and Jonathan Luna X Built As Drawn __ Contractor Red Line Verified __ Discrepancies Noted TEP REDLINES June 22, 2016 Nate House and Jonathan Luna __ Built As Drawn ___ Contractor Red Line Verified _X_ Discrepancies Noted (See Section 6.3.2 Item #1) Page 82 of 120 POST-CONSTRUCTION Page 83 of 120 6.3.1 POST INSTALLED ANCHOR ROD PULL-OUT TESTING Page 84 of 120 Page 85 of 120 Page 86 of 120 Page 87 of 120 Page 88 of 120 Page 89 of 120 6.3.2 EXECUTIVE SUMMARY Photograph Observations and Recommendations Item 1 Observation: The replacement of the existing anchor rods with new anchor rods was not completed in accordance with the modification drawings provided by B + T Group, dated December 18, 2015. The new anchor rods were installed on flats 3, 6, and 11, as opposed to 3, 8, and 11. The new anchor rod holes were 3” diameter as opposed to 2.75” diameter. Hilti RE 500 used in flat 6 and is embedded to only 17’ as opposed to 20’. These items have been approved by the EOR (see Section 6.3.5 Engineer of Record Email for the approval email). Note: The cored out anchor rod hole on flat 8 was not plug welded. The hex nuts on the new anchor rods on flat 3 and 11 were not seated properly and were left untightened. The existing anchor rod on flat 9 was not tightened. The GC returned to tighten the hex nuts and plug weld the anchor rod hole. The GC also tightened the existing anchor rod on flat 9. The plug weld passed the CWI and has been approved by the EOR (see Section 6.3.4 GC Punch List Photos for the correction photos and 6.3.5 Engineer of Record Email for the approval email). Recommendation: No action is required. Page 90 of 120 Photograph Observations and Recommendations Item 2 Observation: The installation of the new flat plate reinforcements was not completed in accordance with the modification drawings provided by B + T Group, dated December 18, 2015. The splice elevation measured to be 51’-3” as opposed to 50’ causing the plates to be installed from 51’-4” – 66’-4”. These discrepancies have been approved by the EOR (see Section 6.3.5 Engineer of Record Email for the approval email). Note: Scorch marks were observed on the inside of the tower where the plates were welded. The GC was unable to properly cold galvanize the areas due to access restrictions. This discrepancy has been waived by Crown Castle (see Section 6.3.5 Engineer of Record Email for the wavier email). Recommendation: No action is required. Page 91 of 120 Photograph Observations and Recommendations Item 3 Observation: The removal of existing equipment, mount and transmission line from 104’, 107’ and 108’ was not completed in accordance with the modification drawings provided by B + T Group, dated December 18, 2015. The mount, hardware, and feedline was not removed at 104’ and 107’. These discrepancies have been approved by the EOR (see Section 6.3.5 Engineer of Record Email for the approval email). Recommendation: No action is required. Page 92 of 120 6.3.3 PHOTOGRAPHS Page 93 of 120 Page 94 of 120 6.3.4 GC PUNCH LIST PHOTOS BEFORE AFTER Page 95 of 120 Page 96 of 120 6.3.5 ENGINEER OF RECORD EMAIL Page 97 of 120 Page 98 of 120 Page 99 of 120 Page 100 of 120 Page 101 of 120 Page 102 of 120 Page 103 of 120 Page 104 of 120 Page 105 of 120 Page 106 of 120 Page 107 of 120 Page 108 of 120 Page 109 of 120 Page 110 of 120 Page 111 of 120 Page 112 of 120 Page 113 of 120 Page 114 of 120 Page 115 of 120 Page 116 of 120 Page 117 of 120 Page 118 of 120 Page 119 of 120 Page 120 of 120