36C24219B0016-002.pdf

BRICK FAÇADE REPAIR B-135

Project Number: 561A406-150

VA NEW JEASEY HEALTHCARE SYSTEM

LYONS, NEW JERSEY

DESIGN NARRATIVE

DESIGN DEVELOPMENT

SUBMISSION

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Prepared for:

Department of Veterans Affairs Lyons, New Jersey

Prepared by:

TOMPKINS ARCHITECTS

Architecture + Project Management

561A4-12-150

DESIGN NARRATIVE BRICK FAÇADE REPAIR B-135 | LYONS VA | 561A406-150

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TABLE OF CONTENTS

PREFACE

i. TABLE OF CONTENTS …………………….....…..…….…….. 02

ii. CONTACT INFORMATION ……………….…………………

DESIGN NARRATIVE

1. SECTION 01 ……………………………………..………….….. 04

PROJECT INFORMATION AND BACKGROUND

2. SECTION 02 …………………………………………...………… 05

ARCHITECTURE

3. SECTION 03 ……………………………………………...……… 13

STRUCTURAL

4. SECTION 04 ……………………………………….…………..… 14

IMPACT ANALYSIS

DESIGN APPENDICES

A. EXISTING CONDITION PHOTOGRAPHS

B. PREVIOUS MEETING NOTES

C. EXISTING SECTION DETAILS

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LYONS VA HEALTH CARE

SYSTEM

PROJECT MANAGER

ARCHITECTURAL

CIVIL

STRUCTURAL

COST

ESTIMATING

LYONS VA HEALTH CARE SYSTEM

GARY BOEHNER

151 KNOLLCROFT RD

LYONS, NEW JERSEY 07939-5001

(732) 979-1786

TOMPKINS ARCHITECTS

ADAM SHULER

612 NW KAY DRIVE

LEE’S SUMMIT, MO 64063

(816) 472-5656

WATSON ENGINEERING, PC

JOHN EVANGELISTA, PE, LEED AP

1112 STATE ROAD

OWEGO, NEW YORK 13827

(607) 223-4334

CONSTRUCTION MANAGEMENT RESOURCES

MICHAEL OREL

5201 JOHNSON DRIVE, SUITE 330

MISSION, KS 66205

(913) 262-6715

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SECTION 01 – PROJECT INFORMATION AND BACKGROUND

1. PROJECT HISTORY

1.1. The original building was constructed in the late 1980’s and has had additions throughout the years.

1.1.1. The hospital is a working nursing unit with patient rooms and administrative offices.

1.1.2. Damage due to cracked and broken brick have been simply patched, repaired or boarded up to stop further damage.

1.1.3. The project location is in a designated “Moderate Low” area for seismic activity as stated by the US Department of Veteran Affairs.

1.1.4. The government estimate for this project is $500,000 and $1,000,000.

1.1.5. Preliminary site investigation took place on April 28th, 2017.

1.1.6. 25% design review was held on July 19th, 2017.

1.1.7. 65% Submittal was provided on August 25, 2017.

2. PRIMARY DESIGN GOALS:

2.1. Repair the brick façade and parapet walls of the existing building 135.

2.1.1. Repair parapet capstone joints

2.1.2. Repair brick at building exterior

2.1.3. Repair leaning parapet wall section

2.1.4. Replace joints at exterior windows

2.1.5. Replace joints at clerestory windows

2.1.6. Repair entry canopy roof

3. CONCLUSION:

Over the years, water has been getting into the brick facade and causing extensive damage on many elevations. The damage ranges from efflorescence on the face of the bricks to bricks being cracked and falling off the wall. Some areas are worse than others but it is a matter of time before the entire parapet and portions of the brick façade completely disintegrate. Not only has water been a problem on the façade but for the entry canopy as well. This problem is due to the fact that it does not have the proper drainage to get the water off the roof. With the recommended repairs and cleaning, we believe that building 135 will be able to continue operation for many years to come.

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END OF SECTION 01

SECTION 02 - ARCHITECTURE

1. DESIGN CRITERIA:

1.1. The design shall comply to the extent feasible with all current applicable codes, Guidelines and Standards as follows:

1.1.1. VA Architectural Design Manual (2014)

1.1.2. Ambulatory Care (Hospital Based) Design Guide (2009)

1.1.3. PG-18-13 Barrier Free Design Standard

1.1.4. International Building Code 2015

2. EXISTING CONDITIONS:

2.1. General Cleaning

2.1.1. Presence of white staining on the brickwork which can be a result from many factors.

2.1.1.1. Some of the stains identified were lime run and efflorescence, which both have a white chalky appearance.

2.1.1.2. It visually appears as though a white substance is leaking out of the mortar and/or bricks.

2.1.1.3. Lime run and efflorescence can be a result of water getting behind the brick face and reacting with the salts often found in the brick or mortar.

2.1 Efflorescence on Brick 2.2 Efflorescence on Brick

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2.2. Capstones and stone sills

2.2.1. Capstone and stone window sills show visible staining from pollution, dirt, dust, and oil.

2.2.2. Sealant and caulk at joints have deteriorated, letting water into the joints.

2.2.3. Water that is freely moving through the joints then moves down into the brick wall below.

2.2.4. It was noted that grout was being pushed out from underneath the capstones.

2.2.5. It was also noted that in other construction projects on the VA campus, seismic tape was being used at the capstone joints. This VA campus is in a “Moderate Low” area as classified by the US Department of Veteran Affairs and has been in an area known for moderate seismic activity. Seismic tape would reduce the effect this activity would have on the joints and grout by letting the capstone act as one unit.

2.3 Deteriorated Sealant at Capstone 2.4 Staining on Window Sills

2.5 Damage below Window

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2.3. Brick

2.3.1. In many locations, cracked brick and deteriorated mortar are present.

2.3.1.1. This damage can occur with age but most of the damage that was observed is a result of water being able to get behind the brick with nowhere to go.

2.3.1.2. The original parapet detail called for the air space between the back of the brick and CMU to be grouted solid. This does not allow for water to make its way to the weep holes and out of the wall. This causes the damage seen in figure 2.6 and 2.7.

2.3.1.3. In many locations, weep holes were not installed during construction. This causes the damage seen in figure 2.1.

2.3.1.4. The most extreme damage has occurred near the entry vestibule which has caused temporary sheathing to be put up to keep bricks from falling out and a metal cap installed on the parapet to keep water from continuing to infiltrate the wall.

2.3.1.5. If not corrected properly, the extreme damage noted could occur around the entire building.

2.6 Damaged Brick 2.7 Damaged Brick

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2.8 Original Parapet Detail

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2.4. Entry Canopy

2.4.1. Entry canopy has been stated to have leaked from the day it was installed.

2.4.2. It was observed that water was pooling in the corners because of inadequate sloping of the insulation below the roof membrane.

2.4.3. Pooled water has been leaking into the roof below, causing damage to the gyp board below.

2.9 Pooled Water in Corners 2.10 Water Damage at Entry Canopy

2.5. Clerestory Windows

2.5.1. Deteriorated sealant and caulk has caused leaking into spaces below.

2.11 Clerestory Window 2.12 Deteriorating Sealant

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3. CONSTRUCTION PHASING:

3.1. Due to most work taking place on the exterior, day to day hospital functions should not be effected by construction.

3.1.1. The entry canopy will be fitted with protective scaffolding to ensure the security of and use of the front entrance.

3.2. Phase I - correct any damage on all elevations.

3.2.1. Repair brick

3.2.2. Tuck-point

3.2.3. Repair joints at capstone and windows.

3.3. Phase II - wash staining and effloresces from elevations.

3.3.1. Once repair and washing of the elevations is complete, windows are to be cleaned of all dirt and debris.

3.4. Phase III - repair the entry canopy.

4. RECOMMENDATIONS AND SOLUTIONS:

4.1. General Cleaning

4.1.1. A professional, qualified brick cleaner should be used to correctly identify each stain and employ the proper cleaning solutions and tools to remove each stain without causing further damage or staining to the existing brickwork. It is best to brush and remove as much of the residue off the surface in a dry state prior to using water or cleaning solutions. If a water is used to remove the chemicals, it should be directed in a downward angle to avoid driving water and chemicals back into the wall. The prevention of water from penetrating the wall is a top priority and the only way to correct the issue from reoccurring.

4.2. Brick

4.2.1. Cracked, broken and deteriorating brick and mortar should first be repaired.

Since the current parapet wall is not draining correctly behind the brick or contains the proper weep holes, we would recommend the following options:

4.2.1.1. Remove lime run and efflorescence from face of brick.

4.2.1.2. Remove lime run and efflorescence from face of brick.

4.2.1.3. Removing the top courses of brick completely from capstone to flashing

(approx. top 12 courses).

4.2.1.4. Clean out all grout, mortar, dirt and debris.

4.2.1.5. Install proper flashing

4.2.1.6. Install new brick with weep holes every 2’-0” O.C.

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4.2.1.7. Repair or replace any additional cracked and damaged brick

4.2.1.8. Tuck-point additional areas with mortar failure.

4.3. Parapet Capstones

4.3.1. Remove existing sealant / caulk, backer rod and grout around all original B-135 exterior capstone joints.

4.3.2. Clean dirt and debris from inside joints

4.3.3. Replace sealant / caulk, backer rod and grout around all exterior capstone joints

4.3.4. Clean all parapets staining of pollution, dirt, dust, and oil.

4.4. Windows

4.4.1. Remove existing sealant / caulk around all exterior windows and cast stone sills

4.4.2. Clean dirt and debris from inside joints

4.4.3. Replace sealant / caulk around all exterior windows and cast stone sills

4.4.4. Clean cast stone sills

4.4.5. Clean windows from any dirt or debris from construction

4.5. Entry Canopy

4.5.1. Remove portion of existing roof membrane and insulation

4.5.2. Install new tapered insulation and crickets to existing roof drains

4.5.3. Install new roof membrane

4.5.4. Remove existing drywall soffit and replace with aluminum soffit.

4.6. Clerestory Windows

4.6.1. Remove existing sealant / caulk around exterior clerestory windows

4.6.2. Clean dirt and debris from inside joints

4.6.3. Replace sealant / caulk around all exterior windows

4.6.4. Clean windows from any dirt or debris from construction

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5. CONCLUSION:

The first item that needs to be taken care of are the areas that need brick repair. The potential for bricks falling on people and property is very high as can be noted with the fenced off and boarded up areas. Once this is complete, the issue of stopping water from getting into the wall is the next biggest item. This should be first addressed at the parapet capstone and window sills with the deteriorating sealant and caulk. It has been noted that in many areas of the façade, there are no weep holes present. This would explain the heavy efflorescence and extreme damage to the bricks at the parapet. It would be recommended that the top courses of brick be removed to properly flash behind the bricks and install the necessary weep holes to keep similar damages from occurring. After repairs are made, the leaking entry canopy should be corrected.

The last item should be cleaning the entire exterior of the building from pollution, dirt, dust, and oil.

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END OF SECTION 02

SECTION 03 – STRUCTURAL

1.1. To design a scaffolding system that will allow the safe removal and replacement of the existing brick façade over the skylight at the main entrance to Building 135.

2.1. Currently the existing Building 135 contains various sections along the roof, under window sills, and along the main entrance where the existing brick façade is in deteriorating shape. This is due to excessive amounts of water entering behind the brick face and causing water damage in the exposed spaces between each brick.

3. RECOMMENDATIONS AND SOLUTIONS:

3.1. The intention is to remove and replace the sections of existing brick façade that have been effected by water damage.

3.1.1. The sections will have a 6 foot #4 bar embedded at 9-inch spacing into the existing 8-inch CMU blocks and be grout filled afterwards to ensure no future horizontal movement.

3.1.2. All sections where existing caulk is deteriorated will be replaced and water tight sealed.

4. DESIGN OPTIONS:

4.1. A scaffolding system will be erected over the existing skylight as shown in the drawing set at the main entrance to Building 135 to allow access to the roof and sections above the main entrance. Once the scaffolding system is erected, work will commence replacing the brick façade in troubled areas along the entrance in accordance with the approved stamped drawings provided by Tomkins Architects.

5.1. The work to commence will not influence the structural integrity of Building 135 if the sequencing of construction is in accordance with the approved drawings.

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END OF SECTION 03

SECTION 04 – IMPACT ANALYSIS

1.1. To design a scaffolding system that will allow the safe removal and replacement of the existing brick façade over the existing skylight at the main entrance to Building 135.

2.1. Currently Building 135 contains various sections along the main entrance roof, under window sills, and wall sections above the main entrance where the existing brick façade is in deteriorating shape. This is due to excessive amounts of water entering behind the brick face and causing water damage in the exposed spaces between each brick.

3. RECOMMENDATIONS AND SOLUTIONS:

3.1. The intention is to remove and replace the sections of existing brick façade that have been effected by water damage around the main entrance to Building 135.

3.1.1. The sections will have a 6 foot #4 bar embedded at 9-inch spacing into the existing 8-inch CMU blocks and be grout filled afterwards to ensure no future horizontal movement.

3.1.2. All sections where existing caulk is deteriorated will be replaced and water tight sealed.

4. DESIGN OPTIONS:

4.1. A scaffolding system will be erected over the existing skylight as shown in the drawing set at the main entrance to Building 135 to allow access to the roof and sections above the main entrance. Once the scaffolding system is erected, work will commence replacing the brick façade in troubled areas along the entrance in accordance with the approved stamped drawings provided by Tomkins Architects.

5.1. The work to commence will not influence the structural integrity of Building 135 if the sequencing of construction is in accordance with the approved drawings.

END OF SECTION 04