Building Envelope Assessment
• Newly constructed large-scale production facility
• Premature deterioration of exterior wall coatings
• Evaluation required multi-faceted investigation
• Facility operations created variable moisture conditions and sources
Anheuser Busch’s newly constructed Brewhouse facility experienced premature coatings failure shortly upon construction completion. Subsequent re-coating application attempts were unsuccessful. Conley Group conducted a comprehensive evaluation which included visual investigation, drawing review, vapor drive calculations, review of interior operations and inspection of joints sealants. Conley Group specifically reviewed exterior and interior operations environments as potential sources/causes of the coating deterioration. The exterior evaluation concentrated on the coating performance; joint sealants, window sealants and waterproofing sealants. Investigation results indicated that moisture infiltration from exterior and interior sources were probable.
Failure of exterior sealants allowed infiltration from rain while internal vapor/moisture drive was the likely source for moisture accumulation within the panels with subsequent coating deterioration. A “domino” effect occurred from the internal moisture with a resultant oxidation of the reinforcing steel and subsequent development of hair-line cracks in the exterior coating/concrete. Moisture drive calculations indicate seasonal conditions are likely sources of moisture development within the wall panels due to the operating range of interior temperatures and relative humidity. Conley Group provided a scope of items that were recommended for remedial action including items requiring further refinement. An opinion of Probable Cost was developed for each of the recommended items.
Conley Group developed scope of work documents based on the evaluation findings including repair and replacement of existing sealants and specifications for a new elastomeric coating that will allow “stretching” of the coating with future wall movements.