Project Type: Concrete Restoration, Precast Systems, and Waterproofing

The Vital Structure: 

Campus Cooling Tower Concrete Repairs, Pre-Cast Façade Repairs and Basin Waterproofing System Replacement

Issue

Vital Structures was hired to evaluate deterioration of the concrete frame structure supporting four (4) Cooling Towers as part of a University Campus Central Utility Plant. The waterproofed concrete roof slab (which serves as the ‘basin’ water collection slab below the cooling towers) and exposed concrete beams and columns exhibited severely corroded steel reinforcing, spalled concrete falling to the deck below, deteriorated pre-cast façade panels and steel support clips.

Spalled Concrete at Reinforced Concrete Column

Overhead Girder Spall Repair & Corroded Reinforcing Bars.

Heavily corroded steel reinforcing at spandrel beam

Formwork and supplemental reinforcing for overhead repair.

Heavily corroded steel reinforcing at spandrel beam

Polyurea hybrid detail coating transitions completed for placement of new wall panels.

Diagnosis

With the assistance of a qualified contractor, Vital Structures performed destructive test cuts and removed core samples for petrographic analysis of the existing concrete. The evaluation concluded that the existing waterproof coating system had far exceeded its serviceable lifespan, locations of the existing structure had areas of spalled, leached concrete and poor consolidation. Corrosion and spalling were also widely related to poor securement of the reinforcing steel during original construction, causing concrete cover to be as little as 1/8”. Precast façade panel steel clips and miscellaneous steel framing needed limited replacement and restoration at all four (4) cooling towers and the adjacent screen walls.

Our Solution

Vital Structures was contracted to provide the owner with a design for restoration of the existing reinforced concrete structure and miscellaneous steel supports. The design included concrete repair at areas where the existing concrete was found to be delaminated or poorly consolidated, replacement of pre-compressed foam expansion joint seals, and replacement of the concrete roof deck waterproofing coating system with a chemical resistant Polyurea hybrid coating system. Chemical analysis of the cooling tower water was performed to confirm compatibility of coating systems. Additionally, Vital Structures provided a design for replacement of the existing precast wall panel support brackets, as the existing were found to be severely corroded.

Coating installation at underside of the first-floor ribbed slab

Supplemental brackets for pre-cast concrete facade panels.

Result

The Owner required that the repair project be completed during the Winter season while the Cooling Towers were not operational. The project has been phased to accommodate Cooling Tower motor replacement, piping replacement and other mechanical upgrades in parallel with the structural/building envelope repairs. Transitional polyurea hybrid coating systems were placed at the rising walls in Phase 1 and 2 to allow tie-in of the balance of the basin slab without removing wall panels. Phases 1 and 2 (Winter 2021 and 2022, respectively) were completed on-time and within the owner’s budget.

Evaluate. Guide. Revitalize.

Let's Do Something Vital Together!

“An Objective Expert We Could Trust”

We retained Vital Structures after finding our builder unwilling to help identify and rectify obvious bowing and waving to our accessory building.  The information provided by Vital was impressive as it was detailed and specific calling out nonconformance to building codes, industry standard construction practices and manufacturer specifications.  The reports were written in a way that was observational, with pictures and evidence.  Had we not hired an objective expert we would have been faced with serious structural problems unknown to layman.  The professionalism, expectation setting and follow-through on Vital Structures part was the due diligence we needed to protect ourselves in this endeavor.  It is well worth the time and expense to correct the issues in advance of accepting subpar construction.

Jeanne Pagani

Homeowner

“Vital Structures Has My Highest Recommendation.”

As the trustee for the Lois J. Lewis Trust, I contracted Vital Structures to oversee a project to evaluate and repair the foundation pilings of an 1880s lakefront cabin on Spofford Lake. The cabin’s piling foundations had deteriorated due to hillside erosion, age, and lack of maintenance. By the time Vital Structures took on our project, the foundation was close to failure.

David Morand, who oversaw the project, was professional, meticulous, and flexible,- offering several well-considered solutions to our problem. He and his team were involved from start to finish, readily available for updates, and on site to address any issues that arose. David was also instrumental in connecting us with a contractor who could meet our unique needs, given the limited access and difficult site conditions.

I can’t say enough good things about the way Vital Structures conducted the project and their professionalism throughout the process. They were a pleasure to work with.

Kenneth Betts

Trustee, The Lois J. Lewis Trust

“Vital provided invaluable assistance and made our buildings healthy again!”

Our Association hired Vital Structures to inspect our decks. David, Richard, and the rest of their team are very professional, knowledgeable, and easy to work with. As our relationship formed, Vital Structures became our Engineers of choice to develop a new design to replace all the decks in the Association.  Vital provided us with invaluable assistance in obtaining Contracting Bids, so we had verifiable Construction Company choices.  Once renovation began, Vital oversaw the project, holding Contractors accountable, ensuring construction was completed to our new design specifications and that the job was done correctly.  Everyone loves the new look and our buildings are becoming healthy again!

Mike Labrecque

Trustee, The Colonial Village

“A huge value to our business!”

We are a waterfront business operating in Provincetown for over fifty years. Vital Structures has been our valued “go-to” partner whenever we address issues relative to our building or property. Their comprehensive knowledge and ability to assess issues and provide solutions across the board is truly a unique expertise and of huge value to businesses like ours. They are service-oriented, extremely responsive, and know their business – and ours. Five-star excellence in all regards!

 

Jill Botway

Managing Director, The Boat Slip LLC

“Highly Recommended! “

Vital Structures llc has proven to be a top notch engineering firm. Beginning with a comprehensive and thorough review of the job scope, to the completion of a project with no details missed. All personnel involved with each project we have found to be excellent to work with and yet never willing to compromise details that would have any adverse effect on the project. Whenever unforeseen conditions arise, they are immediately back to the drawing board without any hesitation in order to keep the project moving. I would highly recommend Vital Structures llc for any structural or building envelope projects.

Brett Emery

Emery Construction LLC

“An Eye for Detail”

We have been working with David Morand of Vital Structures on a few different projects over the years.  We are completely impressed as he is professional, has an eye for detail, is very thorough, and always answers all our questions.  David & the Vital Structure’s team are very knowledgeable about the industry, very proactive with their approach, and always do a great job.  I would not hesitate to use David and his team on the future projects.

Laurie Ferrari

CEO, Peters Property Management
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