Attachment C - MoDot Architectural Report 241104.pdf

SUBJECT: Building Settlement Problems

PROJECT: MoDot Poplar Bluff Construction Office Structural Improvement

LOCATION: 282 County Rd 523, Poplar Bluff, MO 63901

DATE: October 24, 2024

REPORT DATE: November 4, 2024

CC: Sabin Yanez, CFS Engineers E-mail: syanez@cfse.com

In 2024 Trakas and Trakas (T+T) was contracted to provide an assessment and recommendations for architectural repairs to the MoDot Poplar Bluff Construction Office. The building is experiencing significant interior issues attributed to building settlement. These problems are affecting the safety, functionality, and overall working environment of the facility.

BUILDING FACTS

The building consists of one premanufactured metal building, slab on grade with interior office and support spaces. The building was originally constructed in 2012. The building was built under the 2008 IBC as construction classification type V-B, use group B. There is no active fire suppression system or fire-resistive rating requirements for the structure.

Historically, Poplar Bluff was home to numerous logging companies and manufacturers of lumber products. Well established by 1880 the current site was used for lumber manufacturing until the City’s lumber boom came to a halt in the 1930s. Geotechnical borings have confirmed the site’s previous use by showing that there is wood byproduct, several feet thick, not far beneath the surface. The site was previously undeveloped before MoDot constructed their field offices here.

EXTERIOR CONDITIONS

The exterior material of the building is entirely composed of an exposed fastener corrugated metal panel system.

The condition of the metal panel appears to be generally good. The base has some rippling due to settlement but it appears to be cosmetic in nature and not impactful to the operation of the building.

This rippling likely occurred due to the absence of panel fasteners at the bottom edge of the panel.

Example of panel rippling. Note missing base fasteners

Example of non-deformed exterior panel w/ adequate base fasteners.

The exterior windows appear to be in working order with little operational issues due to the building settlement. Flashing is in good condition and maintaining a water tight envelope without signs of water infiltration apparent on the interior of the facility. There is one window located on the south east corner of the building that appears to be added at a later date and does not match the style and trim of the other existing windows.

Typical exterior window and trim

Non-matching window and trim

A small restroom was added to the north side of the building in the last 2 years according to site staff.

While this addition appears to be in working order with no major issues, it is likely it will experience the same settlement issues as the main building due to soil conditions and foundation types.

Restroom addition

Restroom addition

The exterior gutters and downspouts have little to no extension away from the building foundation;

likely exacerbating settlement issues. While the South side gutters appear to be tied into a drainage system, that piping stops at the south east corner of the building, and lacks the recommended extension from building foundations. Insufficiently directed water can erode the soil around the foundation, compromising its stability. This excess moisture can also cause the foundation to settle unevenly.

Southside building downspout termination

Typical northside downspout condition

INTERIOR CONDITIONS

The interior of the building is showing extreme signs of building settlement. It is likely the issues will continue to worsen if the structural repairs are not addressed.

Extensive vertical cracking was observed in the drywall, particularly along the centerline of the building moving North-South. Cracks range from 1/8 inch to over 1/2 inch in width. Diagonal cracking was evident near window frames, suggesting differential settlement around openings. Paint is peeling in areas with cracks, suggesting moisture intrusion or lack of adhesion due to structural movement.

Example of vertical drywall crack along the N-S centerline

Example of window cracking

Significant cracking has occurred at the floor level, notably along the building center line moving North- South. Areas in the open office have been filled but it is likely the problem will continue to worsen.

Floor crack repair

Floor crack; typical.

Multiple doors are sticking or do not close properly, indicating shifts in the frame structure. This includes the main south entrance and internal office doors.

Main South Entrance shown in the fully closed position

Door misalignment

Building settlement has also contributed to damage in the ceiling grid. Multiple locations are showing signs of deformation and gaps between the wall and ceiling. This grid deformation has led to damaged or missing ceiling tiles.

Ceiling tile deformation

Ceiling grid deformation

RECOMMENDATIONS

A major concern from our group are the potential surprises we will discover when the proposed structural repairs are completed. These structural repairs will likely add considerable stresses to the building and may further damage interior finishes and floor structures. We know the current condition and quantities of repairs needed for interior finishes, door, and window alignments. What we don’t know is if there will be additional damage through the repair process.

To adequately compare contractor bids, we will include requests for unit costs of flooring, ceiling, and drywall repair to cover unforeseen conditions. We suggest the owner carries a substantial construction contingency to account for additional repair to interior finishes.

T+T, in collaboration with CFS Engineers will produce a set of drawings sufficient for competitive contractor bidding and permit procurement. These drawings will document recommended repairs to issues as outlined in the above reporting. We believe all of these areas are in need of significant attention.

Submitted by William Trakas, AIA william@trakastrakas.com mailto:glafferty@fslarch.com