Saint Francis Health Center

Title: Saint Francis Health Center

Award Category: Exterior Wall

Project Address/Location

1212 W St Francis St

Dexter, MO 63841
United States

Submitted By: Aaron Rosen

Company Info

RosenBEC

400 Chesterfield Center, #400

Chesterfield, MO 63017
United States

636-322-6122

[email protected]

Project Description and Background: The Saint Francis Health Center is a 2-story, 47,500 ft2 building located in Dexter, Missouri. The building enclosure is comprised of brick veneer, EIFS, punched windows, curtain wall, and TPO roof membrane. Shortly after substantial completion, water leakage was observed at numerous conditions throughout the building. As time went on it was apparent there were even more leaks; it was reported there were a total of over 20 different water leak locations. There was also an aesthetic concern associated with the brick veneer due to various types of staining and discoloration on the face of brick and mortar. RosenBEC was tasked with performing a forensic investigation to address the reported water leaks, as well as performing a failure analysis with respect to the brick veneer related issues.

Scope: The roles and responsibilities for RosenBEC evolved throughout the duration of this project. At first, RosenBEC performed investigative hose water testing at a select few conditions to recreate the reported leakage and identify the paths of travel through the enclosure. RosenBEC also coordinated exploratory openings so the concealed as-built conditions could be reviewed. Other portions of the forensic investigation included field static air/water testing of the punched windows, as well as laboratory testing of mortar samples from the brick veneer wall. Once the failure analysis had been completed, the project transitioned into the repair phase. RosenBEC discussed the various issues with the owner and elaborated on different options for corrective action. There were so many issues associated with the brick veneer that a complete replacement was warranted.

Solution: The general repair plan was to replace the entire exterior wall systems in general compliance with the original construction documents, thus the technical aspects of the repair process for this project were rather straightforward. However, there were significant challenges associated with repair logistics, timeline, coordination, as well as being mindful of pending dispute resolution proceedings with the original project stakeholders. RosenBEC performed their work in an objective, thorough, and accurate manner while at the same time providing clear direction so the repair process could proceed smoothly.

Value: RosenBEC evaluated the as-built conditions as well as the original design documents, then performed an objective failure analysis with respect to the reported problems. RosenBEC then provided conceptual repair options to address the deficient conditions. Given the severity and prevalence of the issues associated with the brick veneer, the owner chose to proceed with complete removal and replacement. With respect to the EIFS, there were several concerns associated with the original installation. RosenBEC provided different repair options, but ultimately the owner proceeded with a complete removal and replacement of this system as well. As the owner was preparing to commence the repair phase, RosenBEC was asked to facilitate the technical considerations of the repair program. RosenBEC performed a constructability review of the original contract documents and provided additional commentary in attempt to prevent recurrence of the same mistakes. References of industry best practices were also shared so the repair contractor was aware of the expectations. There were mockups for the typical building conditions and performance validation testing was conducted to confirm the repairs would perform as intended. Upon the initial mockup testing of the punched windows, it became apparent they also had significant installation issues that prevented them from performing in accordance with project requirements. This was also the case for the curtain wall assemblies as well. Accordingly, the repair scope of work was revised to also include these glazing systems. Rather than complete replacement, and in effort to be respectful of repair costs, RosenBEC suggested the punched windows be removed, disassembled, and then reinstalled in accordance with the manufacturer’s installation instructions. RosenBEC devised a minimally invasive repair for the curtain wall, which was more cost-effective than the other options being considered. In summary, RosenBEC was able to help guide the repair process of this occupied building. There were many challenges along the way, but RosenBEC’s involvement help the contractor stay on schedule, budget, and rectify the known issues. The cost to investigate and implement repairs on this project was approximately $2 million.

Project Images

Additional Info: This would make for a really good case study! I have numerous high-quality photos of the corroded steel members within the brick wall cavity. I can also discuss how we performed in-situ field static air/water testing that grossly failed the specified performance criteria. Repairs were then installed and the same conditions re-tested, which showed a significant improvement in terms of performance. There were a lot of lessons learned from this project!

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