There has been a problem with a concrete pour at the Sewer Treatment Plant project. Apparently the concrete did not meet the specification of the project in the specification book or as interpreted in the prints, however the concrete did exceed the strength tests. According to the Engineer the Concrete needed a fiber reinforcement additive in order for it to work properly for its intended use. The total amount of the concrete that needed to be coated , if kept, or jack hammered out and replaced was approx. 4 yards. The concrete may have worked, however it would need to be inspected annually and possibly coated with a concrete coating referred to as Xypex. This may have cost added maintenance, and problems due to freeze and thaw of sewage. This area would have been submersed in sewerage at all times during normal plant operation. I have copied below a list of questions in which I asked of the contractor when I was asked to accept this. I did not accept this and it was the opinion of the Engineer, Floyd Browne, that it be removed and replaced with the correct concrete per specification. This problem was not done deliberately from what I understand. I have also attached a second email in which I received a response from Floyd Browne, that the Village will not be held liable or have to pay any additional costs associated with the replacement of this concrete.
-----> BELOW IS A LIST OF QUESTIONS WHICH I SUBMITTED TO THE CONTRACTOR BEFORE THE CONSTRUCTION MEETING LAST FRIDAY REGARDING THE CONCRETE MISHAP
I spoke with two members of Council. Due to the fact this may have adverse affects in the future I am going to have to default this decision to Council. I can attempt to have the Chairman call an emergency Public Works meeting, and see what they would recommend. The Council Meeting approval could not happen until Thursday the 15th of the month.
I would recommend that a proposal is submitted in writing on behalf of Sunesis outlining the product, which i did review the specification. It needs to be something that is official, legal, and binding. Our legal counsel would have to approve it. I do know that the Council will take Floyd Browne and Burgess and Niple's recommendations into consideration. This is an important decision, and it will ultimatley affect the entire community.
Some questions I have and have been asked of me, from Two Council Members:
Who is going to inspect yearly for reapplication?
Who is going to reapply material?
Who is paying for this added maintenance?
Who is going to purchase the Xypex for future applications?
Who will stand behind the warranty of the product?
What if the product does not work and the warranty is void due to application issues?
Will the plant have to be taken offline for this maintenance in the future?
How long will the plant have to be shut down?
Can the system handle a shutdown?
Will it be easy to clean areas for reapplication if needed?
How clean does the area have to be during reapplication?
Who will be responsible for draining and cleaning for reapplication?
How long will the maintenance take if reapplication is needed?
What if cracks occur in the future and Xypex does not work?
How long is he warranty? (given the fact that the plant will be good for the next 20-30yrs)
What if a company who stands behind the warranty goes out of business? Is there a backup?
EMAIL BELOW REGARDING THE LIABILITY AND COST OF REPLACING THE CONCRETE. JIM DID REPLY WITH APPROVAL AND SAID THE EMAIL IS CORRECT AND THE VILLAGE WILL NOT HAVE TO PAY ANYTHING FOR THE REPLACEMENT OF THE WRONG CONCRETE WITH THE CORRECT CONCRETE PER SPECIFICATION ACCORDING TO THE ENGINEER, WITH THE UNDERSTANDING OF THE CONTRACTOR.
Sent: Monday, May 11, 2009 9:02 AM
To: James J. Klamet
Cc: Fred Beery
Subject: Construction Meeting Follow Up from 5-8-09
Jim,
I thought about the Construction meeting over the weekend. I just wanted to be clear
what I understood and took away from the meeting on Friday. Today, weather permitting, Sunesis would be removing the concrete that was poured wrong per the specifications and replacing with the correct grade concrete. I believe from the meeting that everyone agreed that the concrete would not work, was not correct, and it either had to be removed or sealed. It was the recommendation of Floyd Browne that it needed to be removed and replaced with the correct concrete per the specifications and the plans. From my standpoint and on the Village of Lynchburgs behalf, I do not believe the Village government or community should be responsible in any way to pay for the unfortunate event of removing and repouring the concrete, that has to be done because it did not meet the specifications of the project portrayed within the plans and or spec book. I believe that the cost, if any should arise out of this re pour should be borne by the Contractor, Sunesis, and or Floyde Browne, the Engineer. In conclusion, from the Friday meeting it was clear to me the Village will not be burden with additional responsibility, costs, or liability for this issue, and that we have done everything within our power to maintain a project has been done in the best interest of the community and with quality workmanship.
Jeremy Shaffer
Village of Lynchburg
937-364-2241
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My name is Greg Hansen. I drove a concrete mixer for Cemex for 9 years. To my knowledge, you need to tear out the concrete and use XYPEX waterproofing admixture in the mix. I have never heard of a coating of any sort of XYPEX applied on top of cured concrete. Nobody ever adds the XYPEX admixture correctly, so why don{t you be the first ever to facilitate the proper method. (1) Require the engineer to be at the plant when the truck is loaded. (2) The engineer needs to insist that the batchman only load about 30% of the 4.5 yard load and then lower the batch plant drum. The truck stays still while someone carefully and safely places the XYPEX in through the loading hopper of the batchplant. Now the XYPEX will be thoroughly mixed evenly through the batch after the remaining 70% of the 4.5 yards is loaded on top of the XYPEX. (3) Anyone watching the driver after unloading, washing the chutes of the truck will know if there was XYPEX in the load. WATCH.... after the concrete is washed down to bare metal, if no foam when water is still applied to chute, then NO XYPEX WAS IN THE LOAD! If foam is visible when water is still sprayed on the chute, then Xypex was in the load. (4) Please note that the xypex powder will pack into the front corner of the fin in the nose of the drum if someone-anyone insists that it is added before the concrete. Also if it is added on top of the load it will not be properly mixed either. Manufacturers instructions is where I think I learned the latter. Most batchmen know about the problem of adding it first and how it packs in the front corner of the fin and some are too lazy to use the 3 stage loading process of adding Xypex in the middle of the load.
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