Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 1 of 31 PageID# 33 IN THE UNITED STATES DISTRICT COURT FOR THE EASTERN DISTRICT OF VIRGINIA ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) UNITED STATES OF AMERICA, EX REL. [UNDER SEAL] v. [UNDER SEAL] DEFENDANTS Case No.16 CV 316 AMENDED COMPLAINT FOR VIOLATIONS OF THE FALSE CLAIMS ACT 31 U.S.C. §§ 3729 et seq., AND THE VIRGINIA FRAUD AGAINST TAXPAYERS ACT, Va. Code§ 8.01-216.3 et seq. NDAA Section 828,41 U.S.C § 4712 COMMON LAW WRONGFUL TERMINATION FPYD MAILROOM [~2-~?~~J CLERK, U.S. D!STHlGT COURT ALEXANDRlA VIRGINIA 1 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 2 of 31 PageID# 34 IN THE UNITED STATES DISTRICT COURT FOR THE EASTERN DISTRICT OF VIRGINIA UNITED STATES OF AMERICA AND THE STATE OF VIRGINIA, ex rei. NATHAN DAVIDHEISER Plaintiff, v. UNIVERSAL CONCRETE PRODUCTS CORPORATION 400 Old Reading Pike Suite 100 Stowe, PA 19464 CAPITAL RAIL CONSTRUCTORS 196 Van Buren Street, Suite 200 Herndon, VA 20170 ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) Case No. 16 CV 316 AMENDED COMPLAINT FOR VIOLATIONS OF THE FALSE CLAIMS ACT, 31 U.S.C. §§ 3729, et seq. AND THE VIRGINIA FRAUD AGAINST TAXPAYERS ACT, Va. Code § 8.01-216.3 et seq. NDAA Section 828,41 U.S.C § 4712 COMMON LAW WRONGFUL TERMINATION FILED IN CAMERA AND UNDER SEAL ). DONALD FAUST ) ) ) ) ) ) ) ) ) ) ) ) ) 400 Old Reading Pike Suite 100 Stowe, P A 19464 ANDREW NOLAN 400 Old Reading Pike Suite 100 Stowe, PA 19464 Defendants. 2 JURY TRIAL DEMANDED Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 3 of 31 PageID# 35 INTRODUCTION 1. Qui tam relator Nathan Davidheiser ("Davidheiser" or "Relator"), by his attorneys, on behalf of the United States of America and the State of Virginia, files this amended complaint against Universal Concrete Products Corporation, ("UCP") and Capital Rail Constructors., ("Capital Rail," collectively "Defendants") to recover damages, penalties, and attorneys' fees for violations of the federal False Claims Act, 31 U.S.C. §§ 3729 et seq. ("FCA") and the Virginia Fraud Against Taxpayers Act, Va. Code Ann. § 8.01-216.3 ("V AFTA") committed by the Defendants. 2. In May 2013, Capital Rail Constructors ("Capital Rail") contracted with the Washington Metropolitan Airports Authority ("MWAA") to build Phase II of the Metrorail Silver Line project ("Dulles Project"). This phase of the project will extend the Silver Line metro to Dulles Airport and the surrounding area. 3. The value of the contract is $1,777,777,000 and is funded through a mix of funds from the federal government, Loudon and Fairfax Counties, VA 4. The MW AA is providing the majority of the funding for this project and is overseeing its construction. 5. The Washington Metropolitan Airports Authority ("MWAA") is providing the majority of the funding for this project and is overseeing its construction. 6. Defendants are violating the False Claims Act in at least two ways. First, Defendants are intentionally producing and shipping concrete that does not meet contract specifications for, among other things, air entrainment and viscosity and are using unapproved stone. Each of these failures by Defendants will result in significant degradation to the Dulles Project. 3 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 4 of 31 PageID# 36 7. Second, Defendants are either not performing the required quality assurance tests or, in cases where the tests are actually performed, are falsifying test data in an effort to hide the fact that their concrete is deficient. Defendants are then providing these false records to the government to support their claims for payment. 8. Defendants' fraudulent conduct is ongoing through the present. Jurisdiction and Venue 9. This Court has jurisdiction over this action under 28 U.S.C. §§ I 33 I and 3 I U.S.C. § 3732. Davidheiser's federal cause of action for retaliatory discharge is authorized by the False Claims Act, 3 I U.S.C. § 3730(h). IO. Venue is proper in this District pursuant to 28 U.S.C. § I39I(c) because Defendants contractor Capital Rail Constructors and subcontractor Universal Concrete Corporation transact business within this judicial district, and committed the false and fraudulent acts alleged in this complaint within this judicial District. Parties I I. Relator Nathan Davidheiser is a citizen of the United States and resident of Pennsylvania. I 2. Davidheiser graduated from Mansfield University in May 2013 with degrees in Biology and Fisheries Management. I3. Prior to joining UCP, Davidheiser worked in the gas industry and as a purchasing manager for Stony Run Masonry Supply. I4. Davidheiser was an employee ofUCP from July 20I5 until February 2016 as a lab technician in UCP's quality control division. 4 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 5 of 31 PageID# 37 15. Among other duties, Davidheiser was assigned to work on the Dulles Project and was responsible for testing concrete before it was poured into pre-cast molds and ensuring that it met contract specifications. 16. Capital Rail Constructors is a joint venture of Clark Construction Group, LLC ("Clark"), and Kiewit Infrastructure South Co. ("Kiewit") that was formed for the purpose of bidding on the Dulles Project. 17. Universal Concrete Products Corporation is a subcontractor to Capital Rail on the Dulles Project. 18. UCP is headquartered in Stowe, Pennsylvania and specializes in the manufacturing of pre-cast concrete. 19. UCP's annual revenues are approximately $15,000,000. 20. Donald Faust is the President and owner ofUCP. 21. Andrew Nolan is a Quality Control Manager at UCP. Factual Allegations AboutDefundan~ L 22. Founded in 2013 in order to bid on the Dulles Project, Capital Rail is a Joint Venture of Clark Construction Group, LLC and Kiewit Infrastructure South Company. 23. Capital Rail Constructors contracted with the MWAA to build the Dulles Metrorail Project Silver Line Phase 2. 24. UCP was founded in 1967 by Donald Faust who is also the current owner and President. 25. UCP is based in Stowe, Pennsylvania. 5 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 6 of 31 PageID# 38 26. Capital Rail subcontracted with UCP to produce pre-cast concrete for the Dulles 27. UCP began supplying pre-cast concrete for the Dulles project in or around August 28. Smith-Midland, another pre-cast provider for the Dulles Project, contracted with project. 2015. Capital Rail for $4,000,000. Smith-Midland is providing 15,000 tons of concrete for the Dulles Project. 29. In terms of dollar value, UCP's contract with Capital Rail is comparable to or likely to exceed that of Smith-Midland. II. About the Dulles Corridor Metrorail Project 30. The Dulles Corridor Metrorail Project ("The Dulles Project") consists of a 23 mile extension that branches off the existing DC Metrorail System orange line after the East Falls Church metro station. 31. The Dulles Project is being built in two phases. Phase I of the project opened on July 2014. 32. Preliminary construction of Phase 2 began in 2014. 33. Phase 2 will extend the Silver Line metro from Reston to Washington Dulles International Airport and to Ashburn in Loudoun County. III. The Contract Incorporates PCI Specification Requirements 34. On February 6, 2013 MWAA issued an amendment to its request for proposals (the "Amendment," http://www.mwaa.com/sites/default/files/archive/mwaa.com/file/8-13COO 1-RFP Amend4.pdf). 35. Capital Rail submitted its bid acknowledging the Amendment. 6 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 7 of 31 PageID# 39 36. Section 03450 of the Amendment requires that pre-cast contractors comply with Precast Concrete Institute ("PC I'') Manual I I 6 and PCI Manual I I 7. 37. PCI Manuals I I6 and I I 7 define the technical specifications that will govern the manufacturing of pre-cast concrete slabs. 38. Section 4.2. I of PCI Manual I I 6 and the Contract require concrete with air content at 6% (+-I .5%). Table 4.2.1. Total Air Content for Normal Weight Concrete Total air content, Nominal maximum percent, bl volume 1 size of aggregate, Severe Moderate in. (mm) Exposure Exposure less than 3/8 (9 3/8 (9 1/2 13 3/4 19 1 25 1-1/2 38 9 7-1/2 7 6 6 5-1/2 7 6 5-1/2 5 5 4-112 1. Air content tolerance is ::1: 112 percent. 39. This 6% requirement is also reflected in the concrete mix design documents used by the company. 7 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 8 of 31 PageID# 40 IV. Proper Testing Procedures 40. Precast concrete is concrete that is produced by casting concrete in a reusable form or mold which is then cured in a controlled environment, transported to the construction site and lifted into place. 41. The process for manufacturing a pre-cast slab begins with Bill Hydock, a manager at UCP, preparing a document called a "mix design" document. 42. This mix design identifies all of the technical specifications that a concrete must meet, including, among other things, the air content (or air entrainment) and "slump." 43. Air content is the percentage of air voids within a particular batch of concrete. 8 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 9 of 31 PageID# 41 44. Concrete with the appropriate level of air content is able to expand and contract during freezes and thaws. 45. If the air content is too low, the concrete will not be able to expand and contract with temperature changes. 46. When a slab of concrete is unable to expand and contract with temperature changes, it is more likely that the structure will crack. · 4 7. Cracks in concrete reduce overall structural integrity allowing penetration of water that will reach the rebar causing oxidation of the rebar. 48. "Slump" measures the viscosity of a batch of concrete. 49. To test slump, testers fill a cone with concrete and then lift the cone off of the concrete. 50. As the form around the concrete is removed, the concrete will drop as it lacks the support to remain completely erect. 51. The tester then measures the change in height of the concrete and this number is referred to as the "slump." 52. Concrete with a high slump number means that there is either too much water or admixtures present, resulting in weak, brittle concrete. As identified in the "mix design," slump is to be 5 inches. 53. Before large-scale production commences, UCP provides to its customer a sample of the resulting concrete batch. 54. UCP does not test this sample prior to shipping it to the customer. 55. The customer will examine the color and texture of the concrete sample and either approve or deny the mix. 9 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 10 of 31 PageID# 42 56. If approved, UCP will then work from that mix design when it ramps up to large- scale manufacturing. 57. If denied, UCP will introduce a number of different aggregates in order to meet the previously identified air entrainment and slump requirements. 58. In layman's terms, admixtures are chemical additives used when making concrete to get it to the right specifications and properties on a mix design. Once the sample has been approved, UCP's engineers have a set of design 59. specifications from which to work that should, theoretically, result in concrete that meets specifications. 60. When concrete is being mixed and the admixtures are being introduced, UCP takes a small representative sample to its quality control labs for testing. 61. This additional quality control testing is necessary primarily because of deviations in the environment in which the concrete is being produced. 62. As temperatures fluctuate and weather changes, the resulting concrete may have different qualities or characteristics even if the same mix-design is followed. 63. Davidheiser was a technician in the quality control lab and performed much of the quality control testing relating to air entrainment and slump. 64. The purpose of this testing was to ensure that concrete met specification. 65. If the concrete does not meet specification, that batch of concrete should be discarded and a new batch created and tested. V. UCP Knowingly Produces and Delivers Concrete that does not Meet Specifications 66. UCP provides deficient concrete in two ways. First, its concrete fails to meet contract specifications relating to air entrainment and slump. Second, the stone being used as the 10 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 11 of 31 PageID# 43 aggregate is from an unapproved quarry that fails to meet other industry standard testing requirements, including alkali-silica reaction ("ASR") testing. 67. PCI manuals 116 and 117 are incorporated by reference into the Contract and specify that the air content for precast concrete should be tested periodically during daily operations. 68. Davidheiser was responsible for quality control testing the representative samples for each batch of concrete used by UCP in its pre-cast slabs. 69. When Davidheiser rejected a representative sample as failing to meet requirements, that rejection should have led to UCP's engineers discarding that batch of concrete and beginning anew. 70. Instead, when Davidheiser discovered that a particular batch failed to meet specifications, Nolan instructed Davidheiser to "bump the next batch up an ounce," referring to the admixtures used to make the concrete. 71. Nolan further instructed Davidheiser to let the engineers pour- and, ultimately, put to use on the Dulles Project- the non-conforming batch of concrete regardless of the failed test results. 72. Davidheiser received instructions from Nolan and project manager Dave Kuzowa to record false test data that would mask the deficiencies in UCP's concrete. 73. By November 21, 2015, Davidheiser had completed coursework in concrete testing and more fully understood the ramifications of employing deficient concrete on the Dulles Project. 74. Davidheiser began keeping accurate records of instances in which the concrete failed to meet the required 4.5% to 7% air entrainment requirement. 11 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 12 of 31 PageID# 44 a. On November 11, the air content was as low as 3.8%. ----, 1 ~~·Chlltt..lill\. Property Test ' ·,-.= .i b. On November 12,2015, the air content dropped to 2.9%. tJOitt·· II} JL.j 15 Property Test c. On November 19, 2015 the air content is 4.1 %. 75. Despite the fact that none of these batches met contract specification, UCP incorporated all of them into pre-cast slabs that were put to use on the Dulles Project. 12 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 13 of 31 PageID# 45 76. These same test records also establish that, on numerous occasions, the "slump" for the concrete far exceeded that which was specified in the mix design documents. VI. UCP Sources Stone from an Unapproved Quarry that Cannot Meet Industry Standard Testing 77. All concrete is subject to an alkali-silica reaction ("ASR"). This reaction is a byproduct of the interactions among the various materials found within concrete and is present to some degree in all concrete. This reaction will inevitably result in some degradation and cracking of the concrete. 78. One way to mitigate the effects of ASR is to test the aggregate to ensure that it is less susceptible to the effects of ASR as various types of stone will react differently within the concrete 79. When UCP originally entered into its contract with Capital Rail, it did so by stating that it was going to source its stone from a quarry operated by Eastern Stone in Oley, Pennsylvania. 80. In late December 20 I 5, Davidheiser received an e-mail from Martin Limestone, a quarry in Denver, Pennsylvania, stating that the aggregate did not pass the ASR test and that it was to be considered as "potentially deleterious" or words to that effect. 81. In early January 20 I 6, Davidheiser took this e-mail to Hydock and Mark Davis, Vice President, who were clearly panicked that Davidheiser had uncovered this problem. 82. Hydock told Davidheiser that the company "is not even supposed to be using that aggregate [from Martin Limestone]. It's not in the contract for Dulles," or words to that effect. 83. Hydock went on to explain that UCP was supposed to be using aggregate from a quarry operated by Eastern Stone in Oley, Pennsylvania but that the quarry had closed down two years ago. I3 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 14 of 31 PageID# 46 84. Davidheiser pressed the issue, asking why UCP could not source stone that was within specification for ASR. 85. Hydock replied that there is "No local quarry with stone that fits the petrographic analysis in the contract," or words to that effect. VII. 86. The Combined Effects of the Non-Compliant Concrete and the Improperly Sourced Stone Could be Catastrophic Defendants' failure to utilize appropriate aggregate coupled with the deficiencies associated with the concrete's air entrainment and slump is a confluence of problems that will lead to significant degradation if utilized on the Dulles Project. 87. During a freeze and thaw cycle, the concrete will need to expand and contract. 88. This will necessarily result in the scaling of the concrete and, given these deficiencies, cracks will form that will allow water to penetrate the concrete. 89. Once this happens, the ASR will occur more rapidly, ultimately resulting in exposure of the rebar (reinforcement) to oxidation and the compromising of structural integrity. VIII. Nolan Instructs Davidheiser to Generate and Submit False Testing Data 90. While Davidheiser was employed at UCP, Nolan instructed him and one of his co-workers at the concrete plant, George Gill, to input false data into its books. 91. By November 2015, UCP had completed nearly all of its first delivery under the contract. 92. On or about November 19, 2015, PCI inspectors came on site to perform an audit ofUCP's facility. 93. In anticipation of this audit, UCP, through Nolan, began a rushed campaign to get the out-of-specification concrete up to specification. 14 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 15 of 31 PageID# 47 94. During the audit, PCI concluded that UCP's quality control testing was deficient in some areas and identified numerous batches of concrete as being noncompliant with PCI standards. 95. Following the audit, Kuzowa, project manager, told Davidheiser that "If you have concrete out of spec in that data book, you need to change it before you submit it to Dulles or they'll reject it." 96. Concerned by these instructions, Davidheiser texted Nolan who was on vacation in Florida at the time. 97. In this text message, Davidheiser informed Nolan that the "air [entrainment] is below 2% or more," well outside of the contract specifications. 98. Nolan responds in the text by stating, "We cannot give them [customers of the Dulles project] sheets with any testing data out of specs. They will reject those panels. We have to change the data." 99. Nolan then instructed Davidheiser on what he should say if confronted by anyone regarding the seemingly deficient quality control reports. 15 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 16 of 31 PageID# 48 ( Messages Andrew Nolan Details The lab has the break data. We cannot give them sheets with any testing data out of specs. They will reject these panels. We have to change the data. And adjust our mix to achieve the specffiecl condHlons. Talk to Brian befora you give them any data Just say concrete was poured before qc finished testing or something (If anyone asks) and that's why we have some bad data. But we have to change 1t. Ok do you hnvo i'l copy ol your summ,1ry th::t I can double check eve tllinq 0 I 00. Following this exchange, Davidheiser did as instructed and fabricated testing data to make it appear as though UCP's concrete was within specification. Kuzowa then sent this data to the customer. IX. Nolan Instructs George Gill to Falsify Testing Data I 0 I. Nolan also instructed one of Davidheiser' s co-workers, George Gill, to falsify test I 02. Nolan routinely provided Gill with an empty book to log testing data and data. instructed him to enter into the books results for tests that Gill had not performed and about which Gill had no knowledge. I 03. When Gill questioned Nolan about how he should log test results for tests that he had never performed, Nolan told Gill, "Make something up, and make sure it's a good number," or words to that effect. I6 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 17 of 31 PageID# 49 104. By "good number," Nolan meant for Gill to fabricate test results which fell within the bounds required by the contract. 105. In or about mid-September, Nolan instructed Gill to "do the books" for a series of tests that had not been performed. 106. Nolan explained to Gill that there was an upcoming inspection and that the books needed to be complete. 107. Nolan instructed Gill to take the books home and enter testing data for these tests that were never performed or for which data was lost. 108. Gill protested to Nolan and mentioned that it was illegal for UCP to record false test data. 109. Nolan responded by stating, "By the time this is built, the concrete will be hardened enough for construction purposes," or words to that effect. 110. Gill complied with Nolan's instructions to take the books home and falsify test 111. Upon returning to work, Gill shared his concerns with company Vice President results. Mark Davis. 112. The very next day, UCP demoted Gill, took him out of quality control, and forced him to work the night shift. 113. When Gill questioned why he was demoted, Davis told Gill that Gill was "not a good fit" for quality assurance. X. Management is Keenly Aware of and Directed the Fraud. 114. On various occasions, Davidheiser protested UCP's testing protocols and the instructions that he was receiving to falsify test data. 17 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 18 of 31 PageID# 50 115. After repeated attempts to get his supervisory chain to adhere to the correct testing protocols, Davidheiser began to ignore the instructions to enter false numbers into UCP's records, and instead began to enter the actual testing results. 116. On February 17,2016, Davidheiser sent an e-mail to Mark Davis, Vice President ofUCP, complaining about the falsification of testing records, and stating that he did not want to break any cylinders (i.e., perform strength testing on the concrete) because he was not qualified to do so. 117. Davis did not reply to Davidheiser's concerns regarding the falsification of records and instead focused on explaining to Davidheiser that he was qualified to perform strength testing. From: Nathan Dllvldhelser lmailto:da\idheiseml03@aolcom) Seat: Wednesday, February 17, 2016 9:48AM To: Marc Da\is Subjea: PCI non compliences Mark, I am writing to express my concern for the company's Integrity and safety or both Its d!ents and employees. Test such as gradations and overnight concrete temp graphs are being deliberately forged. Cylinders for the 821 job are being lntentlonally mislabeled In order to make up for days missed. Break data has been made up In the past If cylinders are missing. Concrete Is being poured out of specification. I am being asked to constantly falsify data that we send out to our dlents In order to appear that the concrete Is In specification. We are missing many aggregate certlflcatlons and test results. I am concerned that these actions will continue, and has seem to be the norm In the ac department for years. Issues such as the confusion for the Martin #8 being deemed deletenous. and not using the approved aggregate for the 821 job could have been avoided by following proper QC procedures. The 828 job has had many Issues with air that Is only being resolved now that 1am more expenenced with admixtures. These Issues have been brought up numerous times and are not being addressed. I feel that I am over burdened with work, and am frustrated when I see Andrew on the phone while we are behind on work. It Is even more frustrating when I am working non stop, he Is on his phone. a test Is not done In time for production, and I get blamed for holding back production. Cylinders are not being broken by the 28 day mark. Documents are being falsified for bo1h the audit and for our customers. I reel that these Issues are an easy fiX. and will take minimum effort to regain proper protocols. I do not reel comfortable doing things that are fraudulent 1will no longer comply with Changing numbers If asked. I will also not be breaking any cylinders until ACI certified. Nate, take a look at PO MNL-111-13 Chapter 1 sub-section 1.3.1 second paragraph down on page 1.4 & Chapter 6 sub-section 6.2.1 fourth paragraph down on page 6.3 and carries over to page 6.4. 1am more than willing to receive my certification and also prep tile cylinders for breaking. My lntentlons are for the best or company and Its customers, and the safety of our employees. Please handle this will care. as 1fear retaliation for co-workers. Thank you for your Ume and consideration. Nathan Davldheiser 118. The next day, Davidheiser refused to continue breaking cylinders. 119. Plant Manager Brian Brenzua sent Davidheiser home, and at this point Davidheiser believed he had been terminated. 120. On February 22, 2016, Davidheiser followed up with another e-mail to Davis again complaining about UCP's failure to adhere to the contract requirements. 18 Case 1:16-cv-00316-TSE-IDD Document 2 Filed 03/29/16 Page 19 of 31 PageID# 51 Ffom: Nathan Oavldhelsc!r [III2ilto:da\'idbeiseml03@aol.coml sent: Monday, February 22. 2016 7:59AM To: MDrc Dftls