Blacksburg High School

Repairs and Gym Replacement

September 23, 2010
 Team

Montgomery County
Public Schools

Dr. Barker –
Independent Structural Town of
Consultant verifying
Blacksburg
OWPR’s methodology

OWPR MBP
Architects and Engineers Construction Manager

Contractors Testing Agencies

 Investigation and Testing
that has occurred at Blacksburg High School

Investigation/Testing
1. OWPR Facility Assessment
• Visual inspection of building components and systems
• Floor elevation survey (documenting floor level and flatness)
2. Wall Settlement
• Electrical resistivity testing
• Used ground probes in a grid arrangement throughout the
building and site to profile subsurface conditions
• Test Borings
• Drilled test borings in several locations inside and outside of
building to identify soils and subsurface conditions
3. Auditorium Structural System Repair
• Forensic Engineer investigation of the gym collapse (FORCON)
• Auditorium structural steel roof framing members and welds
• Used ultrasound to examine full-penetration welds
Findings
Repairs necessary - (Category 1 Items)
Data indicated no large voids under building. Data
found four possible voids outside of the building. Test
borings are recommended at these locations to
determine if open voids are present.
No unusual soil conditions and no unusual subsurface
findings, other than those at three locations where
underpinning can be installed.
Repairs necessary to Auditorium steel construction
(similar to gym)

4. Deficient Concrete Beams Repairs necessary

• Non-destructive testing to determine size, quantity, and location of 100% of beams need to be tested
reinforcing steel in concrete beams (28% of beams tested)
• Used ground penetrating radar (GPR) and ‘R’ meter
• Used destructive testing to verify the results
• Reinforcing steel strength testing
Geology of the Site

Ccr

Ccr

Copper Ridge Formation (lower Knox Group): Inter-

m
bedded medium-gray. fine- to medium-grained. locaJJy
Ccr crossbedded sandy dolomite and medium-gray. fine-
grained, rrKlssive dolomite. s. upper siliceous oolite and
-" " quartzose sandstone; discontinuous sandstone and sili-
_ (, ceous oolite near the middle; and basal {eldspathic
':i sandstone. Tellerina (F-946), an indicator or Tremp-
ealeau age. is found within one horizon. The upper
sandstone marker bed consists of about 10-20 feet
(3.1-6.1 m) of interbedded siliceous oolite and
medium-grained quartzose sandstone. The bm;al sand-
stone marker bed consists of about 10-20 feet (3.1 -
6.1 m) of predominantly light-gray, fine- to medium-
grained feic/$pathic sandstone interbedded with lesser
amounts of sandy dolomite. Total thickness is about
1200 feet (366 m). The soil is characterized by a thick
(10-20 feet; 3.1-6.1 m) colluvial mantle with abundant
siliceous oolite, sandstone, and chert detritus overlying
ATS International
a thick brown subsoil and saprolite. Advanced Technical Services
www.ats-intl.com
Summary of Karst Formation

• Rainwater becomes slightly

acidic with dissolved CO2.

• Water percolates into

limestone bedrock along
fractures, joints, bedding
planes

• Limestone or dolomite
slowly dissolves away,
forming cave passages and
natural conduits for water
flow

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Sinkhole Formation- Cover Subsidence

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Sinkhole Formation- Cover Collapse

Overburden
~mostry day)

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 Types of Karst Features
r •

.-

-"••
E
'0
•
-
8

(~

l ATS International
Advanced Technical Services
www.ats-intl.com
Resistivity Imaging for Identifying Karst

~46 cm (18 in)

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Advanced Technical Services
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Factors Effecting Resistivity

• Moisture
• Grain Size
• Mineral Content

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 Voids

Sinkholes

Voids

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 Cutters and Pinnacles

Cutters and Pinnacles

Potential Ledges or “Float”

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Collected Data for 12 Resistivity Sections

i
(
I

..
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 9
Results of Line 9

Line 9

possible fracture
zones

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5

Results of Lines 1 and 5

1

Northeast bedro
Southwest ck
wall

Line 5

likely fracture
and/or solutional
zones
Tennis courts gymnasium

Line 1

possible likely possible

solutional zone fracture
zone
solutional zones ATS International
Advanced Technical Services
www.ats-intl.com
 Lines of Evidence That the Problem is Not
From Ongoing Geologic Processes
• The Copper Ridge Formation is not a
Strong Karst Former
• There are no Sinkholes, Springs, or
Disappearing Streams on or Near the Site
• Water is the Engine to Ongoing Karst
Formation- Hardscape Prevents Infiltration
• There is no Evidence in the Geophysical
Data of Voids Beneath the Building
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Advanced Technical Services
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 Questions about Testing and Investigations

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ARCHITECTS AND ENGINEERS

 Items to be Repaired

1. Category 1 items from OWPR Facility Assessment

2. Wall settlement in three locations

3. Auditorium roof structural steel

4. Deficient concrete beams

 Repair of Category I Items from OWPR Facility
Assessment
Issue Solution
• Spalling concrete on columns and beams • Epoxy mortar repair

• Cracks • Epoxy injection

• Collateral damage from gym collapse • Repair as required

 Estimate for Cost of Category 1Repairs

Description Budget Estimate Bid or Proposal 

1. Category 1 Items from OWPR Facility Assessment $             141,000.00  General & Mech. Services (GMS)

 Questions about the Repair of Category 1 Items
from the OWPR Facility Assessment

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 Wall Settlement in Three Locations
Issue Solution
• Wall settlement in Boiler Room, Auto Shop, and Wood Working Shop • Install foundation underpinning (helical piers)

Description Budget Estimate Bid or Proposal 

Wall Settlement Repairs in three locations $               66,000.00  RAC Construction Company

 Questions about Wall Settlement Repairs

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 Auditorium Roof Structural Steel
Issue Solution
• Defective full-penetration welds at various locations • Reinforce welds with additional steel plates

• Various under-sized steel truss members • Reinforce with additional steel members

Description Budget Estimate Bid or Proposal 

Auditorium Roof Structural System $             170,000.00  CSE Steel Erection & GMS

Cross Section of Failed Weld from Gym Truss Seat Auditorium Truss Seat

Note: A± 30’ length of the west wall of the auditorium exceeds the
maximum allowable height for its construction and will require steel
bracing to the roof framing. This work will be done when the
auditorium trusses are repaired and will be concealed above the
ceiling.
 Questions about Auditorium Repairs

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MBP ~~H

ARCHITECTS AND ENGINEERS

 Deficient Concrete Beams

Issue Solution
• Inadequate reinforcing steel within concrete beams • Carbon fiber reinforcement or additional steel
and concrete

Area of Destructive Testing to Verify Reinforcing Steel

 Reinforced Concrete 101

• Concrete is artificial stone

• Steel reinforcing is placed in the tension zone

• The two materials are combined, each material utilizing its best
properties
 Basic Civil Engineering Principles

• Water flows down hill

• You cannot push rope

• Bodies in motion produce forces

 Bending Moment – a force times a distance

• Bending moments must balance; externally and internally

 Glossary

• Beam – a horizontal structural member supporting vertical loads by bending

 Glossary

• Cantilevered Beam – a beam that projects beyond a supporting

column or wall
 Glossary

• Column – A vertical structural member supporting vertical loads by

compression

C
 Continuous Reinforced Concrete Beam

I ,I. I ,I. ,I I JJJ "

,l I, ,I. ,I. ,l I ,I. I, I, 11
TI TI TI IT

Where is the tension?

TIT TTIT TTIT TTIT TIT

T T T T
/
/ Where does the steel g07

IT IT IT IT IT
What happens if new supports are added between columns?

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ARCHITECTS AND ENGINEERS

 Independent Review of OWPR’s Methodology

• Used original engineering drawings, specifications, schedules and

building codes

• Verified OWPR’s computations and methodology

• Verified computer output – “all computer results are wrong unless

proven otherwise”
Strengthening and Repair
of Reinforced Concrete
Structures

Ian Wienholt
Business Development Manager
• 34 years of Concrete Repair and
Strengthening Experience
• Over 15,000 Repair Project
• Over 25,000 PT Projects
• 1,500 Employees
• 22 Offices- International
– UAE, UK, Saudi, China
General Repair Group:
Strengthening Division
Carbon Fiber Reinforced Polymer
Strengthening
Externally Bonded FRP Sheet

•550,000 psi Tensile

•10x that of steel

•Lightweight

•Does NOT corrode

 FRP Design Guidelines
ACI 440.2R-08
440.2R-02 440.2R-08

To Date:
Nationwide ≈ 15-18M sqft installed
SPS ≈ 7M sqft installed on over 700 + projects
 What Is FRP Flexural Strengthened R/C?

Yield

Tension Steel

FRP carries
TENSION
Positive Moment
What Is FRP Flexural Strengthened R/C?

Negative Moment
FRP carries
TENSION
TOP
Tension Steel

Yield

Concrete carries
Compression
COMPRESSION BOTTOM

Column
What Is FRP Shear Strengthened R/C?
“SHEAR”
 Installation Step 1:
Surface Grinding/Shot Blasting
to Open Pores
 Installation Step 2:
Remove Dust from Surface

Before After
 Installation Step 3:
Epoxy Primer Application
 Installation Step 4:
Epoxy Putty Trowel Applied
 Installation Step 5:
Saturation Coat and CFRP
 Installation Step 6:
Rib Roll & Final Saturation Coat
 Installation Step 7:
Intumescent Topcoat
External Post Tensioning
Strengthening
 External Post Tensioning

NEW LOAD
F

Live end

Dead end
F
Uplift
at Deviator
 Flexural Strengthening Case Study
“Environmental” Overload

Tension Tension

“YIELD”
 Flexural Strengthening Case Study
“Environmental” Overload
 Flexural Strengthening Case Study
“Environmental” Overload

¼”
Amplitude

Form & Pump

 Flexural Strengthening Case Study
“Environmental” Overload
High Pressure Water Blasting

Dowel Hole Drilling

Dowel Insertion
 Flexural Strengthening Case Study
“Environmental” Overload
 Flexural Strengthening Case Study
“Environmental” Overload
 Flexural Strengthening Case Study
“Environmental” Overload
 Flexural Strengthening Case Study
“Environmental” Overload
 Flexural Strengthening Case Study
“Environmental” Overload
 Flexural Strengthening Case Study
“Environmental” Overload

43’
SCC Section Enlargement
Strengthening
Transfer Slab Cracking

/ I
Demo and Prep

PAM Machine in Action

Supplemental Beam-Column
Connection
Mechanical Anchoring and
Reinforcement Cage

2000
3000 Hilti Undercut
Studs Anchors
SCC Pumping Anyone???

40 Tons of 1100
Steel LF
Finished Product

185 CU YDS /
375 Tons of
Concrete
Finished Product
 Estimated Cost of Beam Testing and Repairs

Description Budget Estimate Bid or Proposal 

Testing of Concrete Beams  $               95,000.00  RadarView

Demolition/Repair Walls for Testing $             325,000.00  Estimate by GMS & MBP

Tear‐off/Patch Roof for Testing  $             259,000.00  Baker Roofing

Subtotal Testing of Concrete Beams $             679,000.00 

Deficient Concrete Beams  $          3,400,000.00  Structural Preservation Systems

Subtotal of Structural Repairs $          3,400,000.00 
Replace Roof after Repairs $             715,000.00  Baker Roofingker Roofing

Subtotal of Structural Repairs & Testing $          4,079,000.00 
Contingency $             1,423,680.00
Total $           5,502,680.00
 Questions about Concrete Beam Repairs

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ARCHITECTS AND ENGINEERS

 Estimated Cost of Gym Replacement
Description Budget Estimate
General Conditions are included in each of the items below $                           ‐
Site work & Demo $             615,257.00 

Concrete $          1,020,386.00 

Masonry $             548,958.00 

Metals $             448,002.00 

Wood & Plastics $                 9,042.00 

Thermal & Moisture Protection $             236,398.00 

Doors & Windows $             112,361.00 

Finishes $             295,720.00 

Equipment $          1,271,599.00 

Elevator $               50,000.00 

Plumbing, Heat, Ventilation & Air Conditioning $          1,460,794.00 

Electrical $             876,003.00 

Sub Total Construction $          6,944,520.00 

Permits $               12,900.00 

A/E Fees $          1,041,700.00 

Cost Estimating $               14,000.00 

Geotechnical & Structural Tests $             100,000.00 

Engineering & Special Testing $               40,000.00 

Quality Assurance & Testing Fees $               17,200.00 

Construction Management $             300,000.00 

Sub Total Fees & Soft Cost $          1,525,800.00 

Total  $          8,470,320.00 

10 % Contingently included in all items above

This estimate incudes cost to  rebuild the entire lower level foundation, structure, exterior and interior walls
 Questions about Gym Replacement Estimate

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ARCHITECTS AND ENGINEERS

 Estimated Total Cost Repairs and
Gym Replacement
Description Budget Estimate Bid or Proposal 

Testing of Concrete Beams  $               95,000.00  RadarView

Demolition/Repair Walls for Testing $             325,000.00  Estimate by GMS & MBP

Tear‐off/Patch Roof for Testing  $             259,000.00  Baker Roofing

Subtotal Testing of Concrete Beams $             679,000.00 
General & Mech. Services 
1. Category 1 Items from OWPR Facility Assessment $             141,000.00  (GMS)

2. Wall Settlement Repairs in three locations $               66,000.00  RAC Construction Company

3. Auditorium Roof Structural System $             170,000.00  CSE Steel Erection & GMS

Structural Preservation 
4. Deficient Concrete Beams  $          3,400,000.00  Systems

CM/Design Documents  $             250,000.00  OWPR & MBP

Subtotal of Structural Repairs $          4,027,000.00 

Replace Roof after Repairs $             715,000.00  Baker Roofingker Roofing

Subtotal of Structural Repairs & Testing $          4,706,000.00 

CM/Design Documents  $             250,000.00  OWPR & MBP

Contingency   $1,423,680

Gym Replacement Estimated Cost $          8,470,320 

Testing, Repairs, and Gym Replacement  $        14,850,000
 Schedule

Pro ct
Repair of Wall
Repair of
Settlement in Repair Deficient
Repair
Boiler Room, ncrete Gym
from OWPR Auditorium Roof
Auto Shop, and (including Replacement
Facility Structural Steel
Wood Working testing)
Assessment

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ARCHITECTS AND ENGINEERS

Work that can be Done to Improve Interior
Environment and Building Operations
Description Estimate 

Replace Heating, Ventilation, Air Conditioning $   3,300,000.00 

Replace Fire Alarm $       265,000.00 

Upgrade Plumbing Fixtures to ADA Requirements $       200,000.00 

Sub Total Building Infrastructure Upgrades $   3,765,000.00 

Replace Vinyl Floor Tile $       256,000.00 

Replace Carpet $          91,000.00 

Paint Interior Walls $       418,000.00 

Replace Ceiling Grid and Tiles $       418,000.00 

Replace Auditorium Seating $       210,000.00 

Sub Total Finishes Replacement $   1,393,000.00 

Replace Furniture and Upgrade Technology $   1,500,000.00 

Add Sprinkler System $       838,000.00 

Sub Total Upgrades $   7,496,000.00 
 BHS Existing Mechanical
• Heating Plant – Two 250 BHP, dual fuel, Scotch Marine 2-pass fire tube boilers,
original
• Heating Distribution – Primary pumps, 20 HP centrifugal. Secondary pumps: several
inline pumps.
• Cooling Plant – Two 325 Ton variable speed Centrifugal Chillers with forced draft
cooling towers, new.
• Cooling Distribution – Primary pumps, 50 HP centrifugal. Secondary pumps: several
inline pumps.
• Auditorium – Four pipe with Air Handling Units.
• Classrooms – Four Pipe unit ventilators in exterior Classrooms. Variable Air Volume
Boxes with hot water heat in interior classrooms
• Administration - Variable Air Volume Boxes with hot water heat.
• Library – Four pipe with Air Handling Units.
• Vo. Tech – Four Pipe air handling units with hot water reheat.
• Band/Coral – Four Pipe air handling units with hot water reheat.
• Cafeteria / Kitchen - Four pipe with Air Handling Units and unit ventilators.

BHS is basically a Four Pipe Fan Coil Unit system.

 Proposed Mechanical
Systems Cost
Heating Plant  Leave as is.
Heating Distribution  Leave as is.
Cooling Plant Leave as is.
Cooling Distribution Leave as is.
Auditorium Replace air handlers and provide CO2 controls. $138,400
Stage Replace air handlers and provide CO2 controls. $48,100
Commons Replace air handler and provide CO2 controls. $65,000
Library Replace air handler and provide CO2 controls. $48,000
Aud. Lobby Replace air handler. $21,000
Vo. Tech Replace air handlers and provide fan coil units in small spaces. $263,000
Band/Coral Replace air handlers and provide fan coil units in small spaces. $72,000
Administration Replace with DOAU w/ active chilled beams or fan coil units.   $126,000
Classrooms Replace with DOAU w/ active chilled beams or unit ventilators. $520,000
Ductwork Clean supply and return ducts that are to remain $200,000
Controls Provide new DDC control system $700,000
Total $2,201,500
OH & P and Contingency x 1.5 $3,300,000

DOAU – Dedicated Outdoor Air Unit
Work that can be Done to Improve Interior
Environment and Building Operations
Description Estimate 

Replace Heating, Ventilation, Air Conditioning $   3,300,000.00 

Replace Fire Alarm $       265,000.00 

Upgrade Plumbing Fixtures to ADA Requirments $       200,000.00 

Sub Total Building Infrastructure Upgrades $   3,765,000.00 

Replace Vinyl Floor Tile $       256,000.00 

Replace Carpet $          91,000.00 

Paint Interior Walls $       418,000.00 

Replace Ceiling Grid and Tiles $       418,000.00 

Replace Auditorium Seating $       210,000.00 

Sub Total Finishes Replacement $   1,393,000.00 

Replace Furniture and Upgrade Technology $   1,500,000.00 

Add Sprinkler System $       838,000.00 

Sub Total Upgrades $   7,496,000.00 
 Questions/Discussions

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