Waterproofing Archives - Concrete CPR

Landmark at Hillsboro

Overview

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Location: Hillsboro Beach, FL

Engineer: Bunker Engineering & Construction Services, Inc.

Owner: Landmark at Hillsboro Condominium Association, Inc.

Problem:

Landmark at Hillsboro Condominium was first built in the mid-1980s with an elevated pool deck above a parking garage. The parking garage had major water leaks due to the wear and tear of the existing waterproofing throughout the years. In June 2018, CP&R was contracted to strategically re-waterproof a portion of the pool deck to repair all the leaks. In the process, all necessary concrete structural repairs were made. The pool deck was also fully renovated with new pool finishes, a new fountain, a new handicap ramp, pavers and a new BBQ area.

Solution:

Remove all existing pavers, topping slab, and old waterproofing
Repair all damaged existing concrete
Re-waterproof pool deck with Carlisle Membrane System
Remove and replace fountain
Build new BBQ area
Remove and replace pool finishes
Build new handicap ramp

Aberdeen Arms

Overview

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Location: Highland Beach, FL

Project Size: $1,245,000.00

Owner: Aberdeen Arms Association, Inc.

Engineer: Karin’s Engineering Group, Inc.

Aberdeen Arms is a mid-rise condominium building built in 1971, located in-between the Intracoastal Waterway and the Atlantic Ocean on the West side of A1A in Highland Beach, Florida. The structure is comprised of conventionally reinforced concrete slabs supported by beams, columns, and concrete masonry walls. The tower rises 10 floors and has approximately 117 units. A ramp along the property’s southern boundary leads to the elevated deck which supports both pedestrian and vehicular use. Concrete masonry walls separate the owner patios from the parking deck. On the north side, there are fenced-in patios outside the individual units and a walkable courtyard leading to stairs and dock access.

Global expansion joint failures and various waterproofing breaches that required remediation were observed on the building at the elevated decks and courtyard above the garage. Active water intrusion was occurring at the expansion joints of the structure, jeopardizing the integrity of the concrete and causing water to intrude into the parking garage below. Concrete spalls and rusted rebar were observed on the soffit, beams and columns of the structure.

The scope of work included removing the existing sand set pavers, failed waterproofing, drain replacement, new drain installations, concrete repair, new expansion joints, hot-applied waterproofing and sand set pavers. Upon removal of the sand set pavers on the north side, the fence dividing the individual units was found to be deteriorated and in poor condition. As a result, it was chosen to be removed and replaced with new kynar coated aluminum rails. New planter walls were built along the south patios, providing the residents with increased privacy. The failed cementitious coating at the entrance ramp was removed and replaced with a urethane coating and moisture barrier.

AVA Ballston

Overview

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Location: Arlington, VA

Owner: Avalon Bay Properties

Engineer: Smislova, Kehnemui & Associates

Project Duration: 11 months

The AVA Ballston Apartment building is a 10-story high-rise, post tensioned building with approximately 344 units constructed in 1989. Visible signs of structural distress in the forms of spalling and delamination had occurred on the balcony slabs due to their embedded railings. Water infiltration was present along the building façade due to lack of proper flashing details. Additionally, damaged mortar joints and façade masonry in conjunction with deteriorated sealants were aiding water infiltration affecting the long-term integrity of the building.

Work-scope repairs included installation of new surface mounted railings, repairing all damaged concrete and post-tension components, removal and replacement of all sealants, and installation of pedestrian traffic coatings on all balcony slabs to ensure concrete repair longevity. Along the entire façade through wall flashings were installed, damaged facade masonry and joints were repaired, and all sealants and vertical expansion joints were replaced.

TechWorld

Overview

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Location: Washington DC

Project Size: $7,194,157.60

Owner: TechWorld Owner’s Association

Engineer: Construction Insight DC LLC

Project Duration: 2 years

The TechWorld campus is located in downtown Washington DC right next to Chinatown and two blocks from the Capital One Arena. 4 different addresses span the city block that sits overtop of the 500,000 square foot garage. Repairs at this jobsite required coordination with the Renaissance Hotel, the DEA, several restaurants, a labor union, a post office, and a building undergoing a complete top to bottom renovation. Two years were spent working inside these spaces as well as the loading dock and large parking garage below. Water leaking from a large paver plaza above and heavy traffic inside the garage contributed to the deteriorating condition of the concrete surfaces on the property. In addition to water entering from above, water was also making its way into the garage from below the mat slab and through the foundation walls. Thousands of feet of horizontal and vertical grout injection were carefully performed and monitored over several months to ensure sub-terranean water was being directed elsewhere. While the source of the water infiltration was being addressed, hydro demolition was performed on the concrete surfaces to repair the large scale of delaminations. Once structural repairs were complete, expansion joints and waterproofing were installed to ensure the new slabs were protected from future movement and moisture.

Notable project work scope items included:

· 75,750 square feet of partial depth hydro demolition and install of new concrete slab

· 10,000 square feet of mat slab repair

· 500,000 square feet of corrosion inhibitor treatment and urethane traffic membrane install

· Over 5,000 linear feet of grout injection at wall and deck cracks

· Over 20,000 linear feet of new rebar

· 5,365 linear feet of expansion joint removal and replacement

· 600,000 sf of new paint on soffit, walls, and columns

· New Elevator Lobby slip joints

· 390 linear feet of heavy-duty expansion joint and steel cover plate replacement at the properties loading dock

· New trench drains and concrete islands at garage entrances

Tysons Tower

Overview

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Overview: Tysons Tower and VITA Garages Repairs

Location: McLean, VA

Owner: Tysons Corner Office I, LLC c/o Hines

Engineer: Smislova, Kehnemui & Associates, P.A. (SK&A)

Project Duration: 5 months

Tysons Tower and VITA Garages Repairs included installation of a urethane traffic membrane to over 568,000 square-feet of garage slab. Full system coating thickness averages 56 dry mills exclusive of aggregate. Severe spider cracking around the columns were allowing water infiltration into the slab. 90,000 linear feet or cracks were routed & sealed prior to the waterproofing membrane application. Sealed cracks were detailed with liquid flashing a minimum of 2” on each side of the crack. A #3 flint aggregate was used for a heavy duty and durable application in a busy commercial and residential parking garage. All levels were line-striped before reopening to traffic.

The Continuum on South Beach

Overview

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Location: Miami, FL

Owner: The Continuum on South Beach Master Association, Inc.

Engineer: Willcott Engineering, Inc.

Project Duration: 2 Years

The Continuum front entrance and plaza deck sits on an elevated slab above the parking garage. The parking garage was experiencing water intrusion through multiple locations due to the failed waterproofing system located at the structural slab. The repair protocol called for complete demolition of the existing overburden down to the structural slab, removal of existing waterproofing, installation of new waterproofing system, and then complete build back of plaza deck. The main reason for this project was to stop any leaks that occurred in the parking garage and to protect the structure for many years to come.

National Capital Bank

Overview

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Location: Washington, DC

Owner: The National Capital Bank of Washington

Engineer: Tadjer Cohen Edelson Associates

Project Duration:

National Capital Bank is a full-service community bank headquartered on Capitol Hill in Washington DC. Founded and built in 1889, it is Washington DC’s oldest bank. Offering walk in and drive through service, NCB is well positioned to assist its surrounding community.

This project addressed various structural and waterproofing repairs across the property. Exterior brick and lintels showed wearing from exposure to the elements. The existing surface lot consisting of a PT slab with asphalt overlay showed visual signs of deterioration from years of heavy traffic. As a result, active leaking was experienced inside the bank’s operating office space. Inside, the subgrade garage exhibited drastic spalling of the concrete structure spanning from the deck, to columns, beams, etc. To address these issues, the scope of the project consisted of the following:

25,000 sf of wall-to-wall partial depth hydro demolition and install of new concrete slab
6,000 sf of full depth concrete repair
8,000 sf of asphalt removal
1,000 sf of topping slab R&R and hot apply install
800 sf of new bonded overlay at teller window drive through
Post-Tension cable repairs
300 lf of brick R&R to facilitate new flashing
New ADA ramp installation inside garage
200 lf of new Aluminum Cap over Coping Stones
500 lf of Mortar Joint Tuckpointing
Exterior Foundation Wall Waterproofing
1,400 sf of penetrating brick sealer
125 lf of expansion joint replacement
100 lf of hydrophilic foam injection
16,000 sf of SOG corrosion inhibitor treatment
33,200 sf of new urethane traffic bearing membrane in the garage and on the surface lot

3 Bethesda Metro Center

Overview

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Location: Washington, D.C.

Project Size: $7,053,075

Owner: Brookfield Properties

Engineer: Smislova, Kehnemui & Associates (SK&A)

Project Duration: 2.5 years

3 Bethesda Metro Center is a 368,000 square foot office building located in the heart of Bethesda, Maryland. The 16-story building has balconies on the upper floors, a large brick plaza, and many great amenities including a fitness center and lounge. Located on the 7th Street retail corridor, 3 Bethesda Metro Center is within walking distance of restaurants, retail stores, museums, and more. Perhaps most notable is its proximity to the Bethesda metro station on the Red Line, which services over 9,000 passengers daily.

This project addressed repairs in the building’s expansive garage, Metro bus terminal, various stairwells, air shafts, and ramps. The garage exhibited visual spalling to the extent that prompted wall-to wall hydro on the entire 1st two levels of the garage. Once complete, all concrete surface in the garage were coated with a vehicular, urethane coating membrane. Concrete and waterproofing repairs on the Metro Bus loop were coordinated with WMATA to ensure the regularly scheduled bus routes were unaffected as work progressed over a 6-month period. All loading docks and ramps had complete removal and replacement of their concrete topping slabs and hot applied waterproofing.

This two and half year long project consisted of 164 different work items including the following notable repairs:

121,000 square feet of wall-to-wall partial depth hydro demolition and install of new concrete slab
39,000 square feet of full depth hydro demo
22,000 square feet of hydro demo patch repair
9,000 square feet of waffle slab repair
356,000 square feet of urethane traffic coating system
178,000 square feet of corrosion inhibitor application
60 new drain install locations and 2,400 linear feet of new piping
1,000 linear feet of new pipe rail fencing
2,500 linear feet of expansion joint removal and re-installation
12,000 square feet hot applied waterproofing
Over 500,000 square feet of new soffit, wall, and column paint with color banding

Poff Federal Building

Overview

Poff Federal Building Garage Rehabilitation

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Location: Roanoke, VA

Owner: U.S. General Services Administration

General Contractor: Hoar Construction

Engineer: McMullan & Associates, Inc.

Project Duration: 14 months

Project Value: $2,114,682

The Poff Federal Building in Roanoke, Virginia, a 14-story high-rise, serves as a key government facility housing 400 to 500 federal employees, including offices for the General Services Administration (GSA) and the Circuit Court. Over 40 years of weathering had significantly deteriorated the adjacent parking garage, raising concerns about its structural integrity and long-term durability.

To address these issues, Concrete Protection & Restoration, Inc. (CPR) executed a comprehensive structural restoration, ensuring long-term stability, improved safety, and enhanced durability for the facility.

Scope of Work

The project required extensive structural rehabilitation, focusing on deteriorated concrete repair and reinforcement. Major restoration elements included:

Hydro-Demolition

Performed by Prepcon
Removed 32,000 square feet of deteriorated concrete via hydro-demolition.

Concrete Overlay

Installed a new concrete overlay to strengthen the structure and improve durability

Full-Depth Concrete Repairs

Performed 5,000 square feet of full-depth repairs to restore heavily damaged sections.

Structural Beam & Column Replacement

Replaced compromised beams and columns to reinforce the structural framework.

Vertical & Overhead Corrosion Protection

Applied a corrosion inhibitor treatment to prevent further steel reinforcement degradation.

New Stair Installation

Constructed new concrete stairs to enhance safety and accessibility.

Expansion Joint Replacement & Crack Repair

Replaced failed expansion joints to improve structural movement and prevent water intrusion.
Utilized chemical grout injection for crack repairs, ensuring long-term durability.

Traffic-Bearing Membrane Installation

Applied a protective membrane on the top deck to safeguard against moisture infiltration and extend surface life.

Project Impact & Results

The restoration of the Poff Federal Building parking structure significantly improved the structural integrity, longevity, and safety of the facility. By integrating advanced hydro-demolition techniques, high-performance concrete overlays, and protective treatments, CPR successfully extended the service life of the garage while minimizing future maintenance costs.

This project reinforces CPR’s commitment to preserving critical infrastructure, delivering solutions that enhance durability and protect structural investments for decades to come.

*Concrete Protection & Restoration, Inc. provides expert concrete restoration services throughout Florida, Maryland, Virginia, Pennsylvania, Washington D.C., and beyond.

Tyson’s Corner Marriott

Overview

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Location: Vienna, VA

Owner: MTC Hotel TRS LLC

Engineer: Construction Insights Inc.

Project Duration:

The Tyson’s Corner Marriott property consists of a 15-story high hotel situated on five acres off Leesburg Pike in Virginia. Built in 1979, this hotel has 396 rooms, almost 10,000 square feet of meeting & event space, and a recreational pool. There a two-level parking garage which offers on-site parking. The first level of the garage is open air with a portion directly under the hotel’s meeting space. A ramp takes you down to the enclosed, on grade second level. The base contract consisted of the following repair items:

5000 SF of Partial and Full Depth Hydro Demolition Patch Repairs
Full Depth Laundry Room Repairs
Overhead, Vertical, SOG concrete repairs
Expansion Joint Installation
20,000 SF of coating removal and full system install
30,000 SF of Re-coat

As the project progressed additional repairs were added to the scope due to the deteriorating conditions around the property:

Full Depth Kitchen Closet Repairs and new Epoxy Flooring
2,000 SF of topping slab removal and replacement at hotel sidewalk
2,000 SF of hot apply installation at sidewalk with WP turndown at foundation wall
Partial and Full depth repairs at Loading Dock
New Traffic Membrane at Loading Dock
Remove existing parging in Vent Shaft and apply new elastomeric coating on CMU walls

MacArthur Boulevard

Overview

MacArthur Boulevard Garage and Structural Steel Repairs

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Location: Bethesda, MD

Engineer: Tate, Shahbaz & Associates P.C.

Project Duration: 4 months

6106 MacArthur Blvd is a 2-story office building with a half-level below used for parking. Located in Bethesda, MD less than a mile from the DC line, the building sits on a steep hill with the east corner of the building on-grade and the parking garage on west side of the structure being cast-in-place concrete slab supported by structural steel framing on the hill. After years of rain/weather exposure combined with poor drainage and lack of a protective coating on the steel members, the steel beams along the west side of the building showed signs of corrosion and there was evidence of settlement within the brick façade. A structural engineer was contacted to perform an inspection of the structure, and it was determined that work needed to be done to reinforce the steel beams and protect them from further damage. A repair scope was developed which included:

Demo and remove brick parapet walls and column jackets supported by the slab edge
Demo existing concrete slab edge to expose top side of structural steel beams
Sandblast to remove all corrosion rust on steel beams and columns
Install/weld supplemental steel plates and angles to reinforce steel framing
Paint all structural steel with protective epoxy coating
Re-build concrete slab edge and brick parapet walls/columns
Perform partial and full depth concrete repairs to elevated garage slab
Apply Corrosion Inhibitor Treatment to elevated slab
Install polyurethane vehicular waterproof membrane & repaint parking lines

Dolphin Tower Restoration

Overview

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Location: Sarasota, FL

Engineer: Morabito Consultants

Karins Engineering Group

Project Duration: 13 months

Problem

In late June 2010, the Dolphin Tower was evacuated after the 4th floor transfer slab, which supports 117 residential units in the tower above, suffered major shear cracking. Immediately, emergency shoring was installed to carry the loads of the tower columns directly down to the building foundation in order to supplement and relieve the damaged transfer slab. In April 2014, after three years of investigation, design, and contract negotiation, a building permit was issued and CP&R crews were able to start the required structural repairs. The structural repair portion of the project was completed on schedule and under budget.

Solution

Structural reinforcement of the Dolphin Tower’s foundation
Column enlargements and shear wall installations
Shoring and repair of the fourth-floor transfer slab
Removal and replacement of exterior CMU walls with poured in place reinforced concrete shear walls
Reinforcement of carbon fiber & addition of post-tension beams
Repairs on the upper levels of the tower to relieve some overstressed slab locations and increase the wind load capacity based on the new building codes.

Awards/Acknowledgements:

ICRI National Project of the Year – Finalist
2017 PTI Award of Excellence
Featured of ACI Guide to the Code for Assessment, Repair, and Rehabilitation of Concrete Buildings, a Companion to ACI 562-16

City of Williamsburg Water Treatment Plant

Overview

Roof Replacement for 1 Million Gallon Tank at the City of Williamsburg Water Treatment Plant

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Location: Williamsburg, VA

Owner: Mount Carmel Municipal Authority

Engineer: TAM Consultants

Project Duration: 5 months

Daily, people use water without thinking twice about the infrastructure needed to provide the clean water supply that flows from their faucets. The City of Williamsburg, Virginia operates and maintains its own water and sewer system, providing water and sewer service to the entire City of Williamsburg as well as water service to parts of York and James City Counties.

The Williamsburg Filtration Plant is part of the City of Williamsburg’s water system infrastructure. The Filtration Plant is located north of the City in a wooded area off Waller Mill Road (Rt. 713). The Waller Mill Reservoir, a park enjoyed by many for recreation and fishing, is located nearby.

Originally constructed in 1982, the tank is a rectangular poured in placed, reinforced concrete structure approximately 104 feet x 114 feet x 15 feet tall, with a precast pre-stressed concrete double tee roof. Approximately 10 to 12 feet of the tank is below grade. There is a concrete bearing wall down the center of the tank, giving two spans approximately 51 feet long. The wall is discontinuous at each end to provide for water flow. Along the length of the tank are 14 double tees, each 8 feet wide by 25 inches high.

The tank was taken out of service in December 2014 due to failure of the roof membrane as well as deterioration of the original precast concrete roof structure, particularly severe cracking of the double tees along the stems. On a number of the tees, the bottom pre-stressing strands were corroded to the point that they were broken and draped down. Pieces of the concrete stems and debris were lying on the floor at the bottom of the tank. Deterioration of the roof membrane and resulting damage to the concrete roof resulted in a system that could no longer provide potable water to the community.

Since this tank was taken out of service, the City had been using an adjacent water tank to meet their needs. However, due to an increase in water demand, there was a need to put the 1 million gallon tank back into service. City of Williamsburg staff working with a local consulting firm developed a project scope that addressed the repairs needed to place this tank back into operation.

The project scope included the following:

Installation of a temporary service road and crane pad that would allow crews and equipment to access the tank.
Removing and replacing the existing double tee roof structure (110’ x 114’ roof).
Installation of a coating membrane on the new double tee stems.
Installation of new baffle walls inside the tank.
Installation of all roof hatches, access ladders and vents.
Installation of parapet walls on two sides of the roof to facilitate roof drainage.
Removing and replacing the roofing membrane with a new heat-weldable, PVC thermoplastic membrane.
Clean and sanitize the interior of the tank.

Awards/Acknowledgements:

ICRI National Project of the Year Award of Merit in 2017
ICRI Baltimore/Washington Chapter Project of the Year Award Runner Up

Mount Carmel Wastewater Treatment Plant

Overview

Mount Carmel Municipal Authority Wastewater Treatment Plant SBR Tank#1 Repair

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Location: Mount Carmel, PA

Engineer: Thornton Thomasetti, Inc.

Project Duration: ???

The Mount Carmel (Pa.) Municipal Authority (MCMA) Wastewater Treatment Plant serves Mount Carmel Borough, parts of Mount Carmel Township, and Cunningham Township in Columbia County. The plant was built in 1975 and consisted of a secondary contact stabilization designed for 1.5 mgd average daily flow and organic capacity of 2,500 pounds per day.

Critical plant upgrades and construction of the new SBR tanks were performed using stimulus funds and were completed in August 2010. In October 2012, the devastation of Hurricane Sandy took its toll on the newly constructed SBR tanks. The hurricane severely damaged the treatment plant SBR #1 tank. Overall resulting damage included: slab buckling, foundation movements, foundation wall displacement, walkway displacement, and column structural damage.

Repair Challenges

The tank structure consisted of 3 SBR tanks, 3 Pre-react tanks, 3 digester tanks and a gravity thickener tank. The tank was constructed with pre-cast concrete wall panels and bridge sections installed on a cast-in-place and post tensioned foundation slab/footing. The precast sections were set in place into receiving keyways and temporary bracing was installed. The precast sections have 1″ conduit through each panel and 0.60 post tensioning strands are threaded through the wall and bridge components. Partial tension is applied to the tendons, followed by grouting of the joints and full tensioning of the tendons. When performing repairs to this type of structure the stress on the tendons has to be maintained or temporary restraint measures have to be provided. The contractor elected to perform repairs to the damaged bridge structure using a phased repair approach that maintained the stress on the tendons at all times.

Heavy structural steel bracing was installed to prevent further displacement of the tank wall and consequential damage that could render the wall “un-repairable”. The shoring was constructed of vertical W18x86 compression struts spanning the width of the tank and horizontal W24x117# whalers that transferred the load from the “intact” interior wall to the “displaced” exterior wall. This temporary shoring structure was utilized to return the displaced wall and footing to its original position as follows:

Structural tube steel “jacking brackets” were installed on both sides of each compression strut, approximately 6’ from the displaced wall.
50 ton hydraulic jacks were installed between the “jacking brackets” and the W24 whalers.
The w24 whaler was unbolted from the compression strut.
A hydraulic pump and manifold system was utilized to provide evenly distributed forces, to return the wall and foundation to the original plumb position.

The extensive temporary shoring was then removed from the tank so that the post tensioned slab could be reconstructed and re-tensioned.

The re-positioning of the displaced wall required the removal and temporary stock piling of the soil adjacent to the wall. This task was complicated by the close proximity of the wall to the property line which dictated that the soil would have to excavated, hauled off-site and brought back after the repairs were completed. A further complication was presented by two large aeration lines that had to remain in service and were at an unknown location adjacent to the wall that was to be repaired. The contractor located the lines and designed a unique method to temporarily support the aeration lines, restrain the soil and provide a safe working condition for the repairs.

Other highlighted challenges during construction include the following:

Active plant, which was required to remain open and operational for the duration of the construction.
Topography of the site due to previous mining operations.
Access and conveying of material and equipment, everything had to be hoisted in and out of a below grade tank.
Safety concern with working in a confined area as well as adjacent to active tanks filled with hundred of thousand gallons of wastewater.
A distinguished critical path schedule dictated by a step by step process making the substantial completion date difficult to maintain when unforeseen conditions were encountered.

Conclusions

Through communication, innovation and strategic planning the project was a success from the beginning to the end. It was the commitment of the Contracting, Manufacturing, and Engineering team to provide accurate solutions to complex restoration problems by providing the highest technical support offered by a repair team. Dynamic design details and innovation demanded that CPR deliver a level of service and technical assistance that far exceeds industry standards.

Awards/Acknowledgements:

ICRI Baltimore/Washington Chapter Project of the Year Award – 1st Place, 2014

Landmark at Hillsboro

Overview

Aberdeen Arms

Overview

AVA Ballston

Overview

TechWorld

Overview

Tysons Tower

Overview

The Continuum on South Beach

Overview

National Capital Bank

Overview

3 Bethesda Metro Center

Overview

Poff Federal Building

Overview

Scope of Work

Project Impact & Results

Tyson’s Corner Marriott

Overview

MacArthur Boulevard

Overview

Dolphin Tower Restoration

Overview

City of Williamsburg Water Treatment Plant

Overview

Mount Carmel Wastewater Treatment Plant

Overview

CPR Mid-Atlantic

CPR Southeast

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