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Maximum concrete cover

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Hasna

Structural
Aug 7, 2021
12
The contractor didn’t placed the wall formwork at the right place, so the concrete cover is now 250 mm , is this acceptable?
 
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Seems like a lot. You'd have to re-analyze the wall with a close eye on crack width and compare it to resilience requirements.

Not sure what standards you're using, but if re-analyzing it checks for strength, ACI 224 covers crack width calculation and controlling cracks.
 
Structurally maybe, but a contractor that either didn't notice it or noticed it and did nothing isn't acceptable. If you accept this, odds are you'll get third-rate quality for the rest of the job.

If it hasn't been poured, make them fix it before the pour.
 
Is the wall wider now or is your rebar just completely in the wrong place?
 
The wall is wider, the rebar are at the right place for the initial thickness. The cover is now 250mm
 
Can’t say I’d be overly concerned (assuming you have no further issues with the weight of the extra 250mm concrete on foundations etc.

It probably will visibly crack though. Is that a problem?

As far as protecting the rebar though, you could view it as 30mm Cover with 23mm excess concrete…
 
Here's a link related to 'too much' cover: - the experts seem to agree it's not a huge issue (depends on the situation though).

The potential issues with having too much cover are obvious. But whether or not they will actually be issues depends on the situation. The extra 10 inches would affect reinforcement in the slab or beam above, but barely. A bigger concern would be with the architect losing floor space... if there's an architect that is... The solution really depends on the project.

A contractor will generally try to chip-out the concrete then finish it smooth. I'm guessing most structural engineers aren't a big fan of this method (fills the member with micro-fractures). There's ways to avoid the associated externalities... it would actually be a good thesis for someone.

One last thing to note is that it might be worth looking at the drawings and making sure the discrepancy didn't arise from the contractor but rather some sort of coordination issue. Probably about half the time we discover that these issues are actually caused by the contract documents being uncoordinated.
 
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