Projects and Photos
Below are a number of projects that Existing Structures Engineering, Inc. has either completed or is in progress.
Ocean Sands North, Indialantic, FL (2010 - 2011)
Ocean Sands North is located in Indialantic, FL. Due to the harsh coastal environment and previous improper repairs, the balconies were severely damaged beyond economical repair. Falling edge debris caused pool closure prior to restoration. After hiring ESE for a condition survey, repair design and bidding process, the condo elected to replace all of the balconies in lieu of repair based on ESE’s recommendation. The first stack of balconies were all removed from the top down and replaced from the bottom up. Demolition of the next stack was started midway through the first stack replacement. One at a time, the second set of balconies were removed and replaced from the bottom up with a modern corrosion resistant concrete mix design. This allowed the local restoration contractor to work on multiple stacks while still maintaining the structural integrity of the building. By totally replacing all the balconies, the condominium will not have to perform any major concrete restoration processes for approximately 40 years. This will greatly save them money in the long run. [Note: Move mouse to right side of photo(to see the next picture) or left side of photo (previous picture]
Harbour Ridge Golf Course, Culvert Inspections (2008 – 2009)
ESE was hired by the golf course community to determine the condition of multiple underground steel culverts which connected various lakes around the course. Some culverts ran under roadways which caused a need to ensure long term safety of the residents. To determine metal loss of the corrugated steel culverts over time, ESE performed visual inspections and ultrasonic thickness measurements. This inspection required the use of professionally trained commercial divers (Callaway Marine Technologies) to enter the pipes to collect data and conduct the visual inspection. The combined efforts ultimately provided the owner with a remaining service life prediction and future inspection schedule.
Twin Towers Condominium Carport Restoration, Cocoa Beach (2009)
Located in Cocoa Beach, Twin Towers Condominium has large carports in the front of the building. The carports were originally constructed using conventional reinforced concrete as well as precast concrete beams with corrugated roof panels. Due to the harsh coastal environment in which the structure is located, many beams were damaged to the extent of failure in turn causing hazardous conditions for the owners. After an extensive condition survey and pricing estimate, ESE determined that the most cost effective restoration procedure involved replacing the beams and roof panels with new aluminum components. The traditionally poured concrete support frames were repaired using conventional methods. Ultimately, the structure was restored to a more resilient, durable and aesthetically pleasing state.
Seaport Canaveral Tank Farm, Construction Engineering and Inspection (2008-2009)
ESE is providing CE&I and QA/QC for the above ground storage tank farm being constructed on the north side of Port Canaveral, FL. The project is the largest construction project in Brevard County. ESE has overseen the construction and installation of over 120 miles of prestressed concrete pilings and over 3400 truckloads of concrete for the pile cap construction. Presently the steel tanks are being built on the concrete foundation and are in various stages of completion.
Bonner Bridge Jacking and Staging (2008)
A most interesting job that ESE worked on was the jacking and staging of the Bonner Bridge, NC. The jacking plan was utilized to raise the bridge slightly so the restoration contractor could repair the bearing surfaces. View a 3 image photo gallery here.
The staging design was unique in that we used “off the shelf” trusses and joists to make a lightweight floating swing stage that was then hoisted and pinned into position.
The structure was light enough to float but robust enough to hold restoration debris, personnel and materials.
La Vista del Mar Condominium (2007) – Extensive Concrete Restoration
Winner of the International Concrete Repair Institute, Award of Merit, 2008
La Vista del Mar Condominium is located in Cocoa Beach, FL. ESE was hired by the condominium association to survey the damaged building and to recommend and oversee a repair procedure. It was concluded that many locations of the building were unsafe and needed to be dealt with immediately. The elevated walkways and the south staircase were completely replaced as well as a buckling partition wall. (Please click image for larger photo)
The old construction was pre cast double tee whereas the new construction consisted of durable reinforced concrete secured to the building with epoxy dowelled rebar. Dowels, or rebar, were embedded into the existing structure to an adequate depth and then epoxied into place. The rebar was subjected to many tests including, but not limited to, pull testing to ensure the reinforcing steel could withstand the required loading. Corrosion inhibitors and corrosion resistant rebar were used throughout the repair process and will ensure that the buildings require little to no maintenance in regards to corrosion control. This is also carried through to the new corrosion resistant thermoplastic rail system which was installed. (Please click image for larger photo)
Russ Marek House (2007-2008)
Homes For our Troops (http://www.homesforourtroops.org), is a non-partisan, non-profit 501(c) (3) organization that provides specially adapted homes for severely wounded members of our military. Through a growing network of donations from building contractors, suppliers, corporate supporters and volunteers, HFoT is able to provide assistance at no cost to the veterans that serve our nation. The volunteers below are finishing the building plans for the home Russ Marek is to live in after his rehabilitation. Russ was seriously injured by an EFP while serving as a tank commander in Iraq. Pictured below, from left to right, are: Byron Evetts, P.E., Existing Structures Engineering; Scott Armistead, Armistead Drafting & Design (www.ArmisteadDrafting.com); Russ Gambil, HFoT/United Space Alliance; Todd Marek, Space Coast Surveying and Russ’s brother; Seated Russ Marek, Disabled American Veteran. (Please click image for larger photo)
“Construction has begun and the slab is poured. The concrete contractors did a great job and we now await the framers!”
Stonewood Towers Condominium – Balcony Restoration Project (2006)
Stonewood Towers Condominium is located in Cocoa Beach, FL. Existing Structures Engineering, Inc. was hired by the condominium association to conduct a condition survey of all balconies of Building B. We concluded that the corrosion damage related findings from the survey warranted a restoration project of all balconies. Existing Structures Engineering, Inc. helped the condominium association properly bid out the job to qualified contractors. After the bid process, the association hired ESE for construction management and inspection. During the construction phase all damaged concrete on the balcony slabs and/or columns was removed and repaired. A urethane coating was installed on all of the balconies after the repairs were inspected and completed. ESE inspected all repairs to make sure that they meet the known industry standards that are addressed in the Florida Building Code 2004. We also helped manage all pay requests between contractor and owner that helped the project stay within budget and time schedule. The condominium association and owners were very pleased with the overall outcome of the project.
VAB – Roof Restoration Project (2005-2006)
Existing Structures Engineering, Inc. was hired to conduct a condition survey of the underside of the 4” thick flat concrete roof of the Vehicle Assembly Building at Kennedy Space Center. The Vehicle Assembly Building was built in 1966 and is 525 ft tall and 716 ft long by 518 ft wide. The condition survey included sounding out the entire underside of the roof surface, locating all damaged areas, and marking out the damaged areas for the contractor. We also inspected the installation of a cathodic protection system that was installed to arrest any further corrosion damage to the concrete roof.
JEA – Concrete Restoration of Unit #2 Cooling Tower (2005-2006)
Jacksonville Electric Authority/Florida Power & Light Company operates two coal fired 640 MW power plants at the St. Johns River Power Plant in Jacksonville, Florida. Corrosion related damage to Unit #2 Natural Draft Cooling Tower had progressed to the point where structural integrity and safety was a concern. The tower was built in 1985 (at a cost of over $50 million) and is 450 feet high and 320 feet in diameter. Existing Structures Engineering, Inc. (ESE) was hired to perform an engineering condition survey coupled with recommendations, and repair/remediation design. The scope of the project ultimately grew to include construction engineering and inspection.
The restoration project was accomplished in 3 phases: detailed condition survey and recommendations, restoration/corrosion control research and design, and construction with the goal of avoiding replacement of the structure. The condition survey was designed to quantify the scope of repairs and determine the root cause of corrosion, and the reasons for the poorly performing corrosion control actions previously taken. The research and design phase involved a review of existing technologies and demonstration testing of innovative technologies. A repair/cathodic protection zinc mesh jacket system was selected for the tower’s legs and lintel ring beam (18,000 ft2). The veil (58,000 ft2) presented unique challenges due to height and proximity to in-use services. The selected system: robotic ultra high pressure water demolition for removal of deteriorated concrete, machine applied application of repair mortar, application of zinc mesh, and a final application of shotcrete to encapsulate the zinc mesh. The resulting system provides a combined repair process and cathodic protection of the embedded reinforcement, estimated to protect for more than 2 decades without further maintenance actions. This project recently won the Grand Award in the 2007 Florida Engineering Society Engineering Excellence Awards Program, the ICRI 2007 Award of Excellence, and the American Shotcrete Association 2006 Outstanding Shotcrete Project Award. (Back to Home page)
Royal Mansions and Ola Grande Condominiums, Aluminum Balconies (2003 and 2004)
On 2 different projects, ESE has designed and overseen the installation of cantilever aluminum balconies. The balconies were designed with modern structural engineering software (Staad) and fabricated with corrosion resistant marine grade aluminum (5000 and 6000 series). The balconies are completely powder coated before installation. Further, the decks are composed of a rot resistant synthetic material and all fasteners are stainless steel. For the Royal Mansion project, 6’ windows were replaced with 6’ sliding glass doors as well as the addition of a balcony. On the Ola Grande project, rotten wood balconies were replaced with modern aluminum ones.
Sea Dip Condominium – Balcony and Walkway Restoration Project (2003)
Sea Dip Condominium – Balcony and Walkway Restoration Project (2003) Sea Dip Condominium is located in Daytona Beach, FL. Existing Structures Engineering, Inc. was hired by the condominium association to conduct a condition survey of all balconies and walkways. We concluded that the building had severe corrosion damage to balconies, and that the best option both structurally and economically would be to replace all of the balconies.
The walkways were also severely damaged but most were able to be salvaged with extensive repairs. Existing Structures Engineering, Inc. helped the condominium association properly bid out the job to qualified contractors. After the bid process, the association hired ESE for construction management and inspection. During the construction phase, all balcony slabs were replaced and all concrete damage to walkways and columns was removed and replaced. An acrylic coating was installed on all of the balconies after the repairs were inspected and completed. ESE inspected all replacements and repairs to make sure that they meet the known industry standards that are addressed in the Florida Building Code 2001. We also helped manage all pay requests between contractor and owner that helped the project stay within budget and time schedule.
The condominium association and owners were very pleased with the overall outcome of the project. Also, the resale value of the units in the building increased due to the drastic change in appearance and structural integrity of the building.
SeaLife Park, Oahu, Hawaii, 2003
ESE is often involved in condition surveys and corrosion control engineering in the marine park, theme park and aqauria industry. We have provided engineering services to Audubon Zoo, New Orleans; National Zoo, Washington; and the Baltimore Zoo. At SeaLife Park we conducted a condition survey and helped prioritize the upcoming remediation. We also performed an engineering study of the acrylic face and stanchions of the dolphin tank. (Please click image for larger photo)
Ft. Lauderdale Ship Yard – Inspection of Syncrolift (2002)
During May 2002, Existing Structures Engineering, Inc. conducted a structural evaluation of the Syncrolift structure and surrounding concrete civil works at Ft. Lauderdale Shipyard, Ft. Lauderdale, FL. The Syncrolift is a 32’-wide by 90’-long mechanical lift dock built in 1969 -1970. The platform is constructed of rolled and welded structural steel members, usually covered with a wooden deck designed for pedestrian and light equipment loading.
To perform a survey of the structure, we did a visual inspection and a UT inspection of the entire structure. A UT gauge (Ultrasonic Testing Gauge) sends a sound wave through a substrate, listens for the back wall echo and measures the time to return. Using, velocity over time equals distance, the thickness can be determined. After inspection, the structural steel platform looked to be in precarious condition, but thorough examination indicated that the platform was in serviceable condition. This survey saved the client money and prevented lost time since the structure was salvageable and did not have to be replaced. (Please click image for larger photo)
Staad Model of Estancia, Costa Rica
The American owner of this classic construction estancia was sick of rebuilding it every time they experienced a high wind event. The building had already failed 3 times and the local mentality was to just keep rebuilding it. We created a computer aided structural model on Staad and determined that the connections to the ridge pole were inadequate. We designed a robust pole beam to ridge connection and the structure has been in place and intact for 5 years now. (Please click image for larger photo)
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