Remediation of foundation wall pour issues
I had a foundation wall poured last week and looked things over this weekend, I was shocked at (what I think) is the poor quality and craftsmanship. There are many issues re: errors in measurement as compared to the plans (window openings are incorrect size, not in the correct place on the wall, missing sleeves, beam pocket is incorrect size, etc etc) – however, what I am hoping for is some information on the “imperfections” found in the material. I will attach pictures, I’m hoping to know the following:
What could have caused an issue like this?
Is it structural OR could it lead to premature deterioration? How?
Will this foundation even pass inspection this week?
What are some possible ways to resolve the issues if they are structural/a problem for deterioration – or does the whole thing need to be torn down?
Is there anyway to test the structural integrity or density of the material? (I am worried about “air” inside of the wall due to the amount of pockets on the outside).
Obviously I’m looking at hiring a structural engineer to take a look at it (mostly due to the windows) before I build on it, but just curious to get some information from others about what is seen and what possible remedies may be so that I know if what contractor proposes is smoke on water or legitimate fixes. Clearly lacking trust here…
What I’m looking at in the pictures:
Large and very frequent blow holes
Deterioration around the window wells (this pour is less than a week old)
Deterioration / chipping around beam pockets
Their “Footing” that should have been formed per plans as a 2x2x1′ block is a 2″ “blob” (notice the concrete in the picture is NOT the full depth of the tape shown, that is gravel below – tape is only 6″ down
Replies
“[Deleted]”
Let me express my condolences. What you show is just an abomination. Your engineer should have enough to give your lawyer for an easy win, but that won't solve the problems.
I would doubt if the 'contractor' will make it right if you can even find him.
That's a pretty bad pour. I'd be interested to hear what the engineer and the contractor have to say about it. Good luck.
I don't know the terms of your agreement with the concrete sub or your drawings' information and clarity and therefore can't comment on locations, dimensions or why you're in this predicament, so I'm going to offer a solutions oriented approach -
Pics 1 & 2 - The damaged window openings can be repaired/ squared-off using a Mapei product formulated especially for this purpose - PlaniTop X or XS
https://www.mapei.com/us/en-us/products-and-solutions/products/detail/planitop-x
https://www.mapei.com/us/en-us/products-and-solutions/products/detail/planitop-xs
Pis 3 - Pock marks are typical though more uniformity in pour is preferred. I don't think that's enough to fail an Inspection. Is this foundation wall for a 2 story woodframed structure? Pin Tests can be performed on site to determine the hardness of the concrete at various locations. The test should be performed after 28 days (cure). The reason you wait for full cure is because you DON'T want to remove the existing. $$, time, lots of effort and a definite delay in schedule.
Pic 4 - This is a possible concern, mostly because there is no context. What I do see, seems to be too much aggregate, perhaps the end of a pour, which will be continued, and only a local concern. Is that exposed rebar to the left? How representative is this of the rest of the job?
Pic 5 - Beam pocket. It should be deep enough to accommodate the beam + leveling material. Damaged corners can be repaired as noted above.
Advice: Pause. Take a breath and try to relax. You're building a foundation, not a dining room table. Without proper testing, there's no reason to move into Demo Mode. As for window locations - compromise might be in your future. How far off are they? 2" or 2'?
In my experience, I have found that construction frustration stems from investing the least amount of effort or money and expecting the greatest possible result. This may not playout as planned, but even so, the result might still be quicker or cheaper, including repair cost, than having initially invested more. Other times it won't. Either way, we constantly need to evaluate so we can improve means, methods and results.
Hope this helps. Keep us posted.
Frankie
The condition of the window and beam pocket edges indicates very low quality concrete, so I would recommend testing (somehow) the strength of the rest of the pour. In an ideal situation, there would be sample cylinders, but that seems unlikely. Hopefully the concrete contractor has a bond and insurance.
I think Frankie's advice is good. I like it when people take the trouble to provide links.
Calm down, but don't back down.
Like Frankie says, keep us posted. You're going through an extreme version of something we've all dealt with.
Take a core sample of the fully cured concrete at 28 days and send it to lab for analysis. They will be able to calculate the PSI of the concrete for you.
The bug holes are probably due to not enough vibration of the wet concrete but they are purely cosmetic and can be parged (often done by rubbing a concrete slurry with burlap into the voids) check out the concrete supplier's recommendations for such (as well as for patching)
I appreciate everyone’s advice and ways to move forward. That’s what I was looking for; how can I salvage this and then test it to ensure I have confidence to put a house on it. I also appreciate the validation that this is a poor quality job, just to confirm my beliefs since I am not familiar with concrete work.
Unfortunately, this was the highest bidder and with good reviews...so the advice that you get what you pay for I can’t apply. The windows are off by 4 feet, not inches at all. And while on a traditional build this wouldn’t matter too much, this foundation is for a post frame building and two windows are now directly below where two of my posts that hold the weight of my house go. I’m trying to be creative in solutions to that.
He is meeting me at the property to Look over mistakes and the quality...hopefully he stands by his name, but thanks to everyone’s ideas I now I have some things I may be able to ask for in order to resolve my lack of confidence in this job.
Thanks again! And keep them coming if there are more ideas!
Arming myself with information.
"The windows are off by 4 feet, not inches at all... and two windows are now directly below where two of my posts that hold the weight of my house go."
This should have been caught, by the Foreman and/ or Building Inspector during the Footing/ Foundation Inspection -
"Footing inspections shall be made after all trenches are excavated, all grade stakes are installed, any support steel and its Foundation are in place and tied all necessary forms and bulkheads are in place and braced, and before any concrete has been poured."
"Foundation inspection(s) are conducted to verify the correct installation and proper bearing support. Poured concrete and masonry units that have reinforcement steel shall be inspected prior to the placement of concrete."
Though no one wants the Inspector to pull out his/ her measuring tape, a window mislocated as far off as 4', which conflicts with a point-load should be pretty obvious, as point load details are specifically the focus of an Inspection. That doesn't mean you can blame the Building Inspector. I'm just laying out the process. Having it happen at two windows and thus 2 point loads, something greater may be amiss.
The solution/ infill for the point loads is pretty standard. Creating 2 new windows is doable, but a PITA. If you have a concrete chainsaw it's easier, but I have yet to work with someone who has one.
Frankie