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Existing CMU reinforcement analysis and questions 2

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Structural
Jan 15, 2021
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This is a carry-over thread from the Moment Frame forum where a few of us have been having some fun with a project that might progress ahead depending on what we discover here.

I’ll refer you to that thread for a detailed background but the Coles Notes are these:
[ul]
[li]We have an existing private residence that had an addition put onto the back of it (CMU enclosed) a few years ago.[/li]
[li]The owner now wants to replace the rear shear wall with a full height curtain wall.[/li]
[li]We decided on a steel portal frame to wrap the opening to provide the required lateral resistance / shear transfer.[/li]
[li]Scanned the existing CMU and found that the previous contractor short changed the owner and only poured grout w/ bar in certain areas (see pictures below).[/li]
[li]We checked to see if unreinforced + ungrouted CMU could do the job. Alas, it could not.[/li]
[li]Owner has agreed to place bar + fill cells / pretty much do any work from the outside that is required. Note: only one side is accessible from the exterior[/li]
[li]Inside is finished to the nines, it won awards, I am not allowed to touch it.[/li]
[/ul]

P0_txt287.jpg

P0.1_kaznij.jpg


That brings us to this thread. I’ve come up with three ways of looking at the load distribution in the wall with two of them working and one failing. I am hoping you all can take a look to see if I can actually analyze the wall this way or if there is a better options or basically any thoughts.

Option A: Treat the wall as a simply supported spanning member from ground to top of roof

If you look below, you’ll see that the tensile resistance of the masonry is well overcome (1.5x) by the design force at the height where the existing grout stops. This is a problem because at that juncture I cannot drill to lap bars, and on one side of the building, I cannot do anything from the exterior. If the moment induces a tensile force in excess of the masonry tensile resistance, I think this fails with no way to reconcile the issue.

P1_tb65fg.jpg


Option B: Treat the wall as hinged at the point where old grout ends and new grout begins with a fixed(ish) base

This alleviates any issue with tensile resistance as both top / bottom components work for that (top can be designed to and bottom checks out). The loads are relatively low and even when modelled as a cantilevered structure the base only deflects a trivial amount at the top (where I assume the hinge is).

Couple questions
[ol 1]
[li]Is there a reason why I cant view the wall like this? Footing connection will need to be confirmed but that'll happen when we dig for the portal frame. Presumably there is something there.[/li]
[li]What do we need to provide at the contact point between the old grout line and the new grout line? I cant add much connection via steel so I have to be comfortable with simply friction + shear resistance of the grout bed to provide the hinge. I’ve run the numbers and friction alone does the job, just barely.[/li]
[/ol]
P2_xpdwtx.jpg


Option C: Treat the wall as spanning the 12 foot direction and consider the nearest fully grouted / reinforced masonry sections of wall vertical “beams” spanning from footing to roof

Here I would be relying on the empirical guidelines that allow for up to 16 foot spans for 10” block. The question is a matter of will the masonry act in this way?

Another complication is to make the numbers work, the masonry “beam” on the left (the one not in front of the portal frame) will need to take 1/3rd of the load. Otherwise it fails in tension. To accomplish this I’ll need to make the portal incredibly stiff + design connection from the flange to the wall for shear flow. But…I think it could be done since I can make the steel members as deep as I want.

Do people feel it would be reasonable to be able to distribute the load this way via relative stiffness?

P3_sq5roz.jpg
 
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"Owner has agreed to place bar + fill cells / pretty much do any work from the outside that is required. Note: only one side is accessible from the exterior"

Any option to just do a low clean-out hole and drop bars/grout from the top of the parapet?

From an analysis standpoint have you tried looking at the wall as a two-way plate?

Screenshot_from_2021-06-18_08-58-26_cepzmf.png





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Thanks Celt. I did check it as such and still a no-go. But as it turns out I goofed my wind calculation (not sure I should be so happy about that, but I am) and utilized the open terrain exposure factor by mistake. Switching it to the appropriate exposure factor gives me wind pressures that I think I can reconcile.

The West wall (the one we have access to / you see the bar markings) is open(ish) at the back and could experience all wind conditions. And a solid but unreinforced wall does fail under one condition. So, I am going to chip into the existing CMU, lap bars coming from the top, and grout the entire thing solid. This works for all conditions.

The East wall (which is 4” away from the neighbors) cannot be fashioned in the same way as there is no access from the outside to chip + extend bars. However, the one wind condition that overloads a solid but unreinforced wall is not one of the principal wind directions in the area. And on top of that, the one wind condition that pushes it over the top (a very minor amount like 3%) seems unlikely to be able to materialize because of the obstructions immediately at that corner (it’s covered by buildings at the side, and back). So, I feel okay about just grouting this side.

Questions

A) Extent of grouting is 15-20 LF but the max allowable in a single lift appears to be 12’-8”. What does everyone think would be the best for lifts? The first at the max of 12’-8” and then one that tops it up to height or half the area the first time + half the area the second time?

B) Any advice on making sure the grout actually gets all the way from the top to the bottom? These walls were built by others, I can’t really clean them, and going to be hard to inspect cell condition. I assume a fine / high slump grout is in order (maybe 12” slump)?

C) I cannot put cleanouts on the East wall due to its proximity to the neighbor. Aside from not conforming to recommended practice for cleanouts at the bottom of high-lift grout pours, is there any detrimental issue associated with this (beyond the obvious that I can’t inspect the cells)?

D) Because of lack of visibility, I was thinking of boroscoping from above to confirm cells are not blocked. Also, on the West wall I would do a confirmation scan to make sure grout got everywhere + bar was placed in correct cells. What do you think?
 
I don't have a lot to comment on regarding your analysis options, but I have some comments on the construction side.

Consider using self-consolidating grout (SCG) instead of regular grout. You will get better flow and won't be hampered by some of the size and height restrictions of regular masonry grout. BTW, you really can't do a regular grout with a 12" slump, 11" may be the limit, but that's what SCG does. If you use regular masonry grout, you'll have to have cleanouts as celt83 mentioned to see knock any mortar debris to the bottom. Both ASTM C476 and TMS 402/602 allow SCG, although it does tend to be a little more expensive.

As you grout, you should be able to see where the grout is flowing as the water dries out of the grout and into the block. Make sure to get construction photos as they grout to verify placement. You can also do thermal imaging to determine where the grout is located. I don't know if you have room to conduct that, but it might be easier, and cover more area, than a boreoscope.
 
Thanks Masonrygeek. I use SCC regularly so I should has suspected it would be available for grouting purposes. Duh.

Just to clarify something, if we go with SCG grout it seems like you're saying codes allow us to get away without requiring a cleanout. Is that correct? Also, I looked at a Quickcrete version and their max pour height is listed as 12'-8" so still under the amount I need to grout. What lifts do you recommend I pour in (9'+9' or 12' + 7') or does it matter?

Thanks!
 
Unfortunately, it appears that cleanouts are still required even for SCG, but its not real clear since this is an existing wall. Here is an article that explains grout lifts and pours in more detail: The maximum amount of SCG to place in one operation is what is allowed in Table 6 of TMS 602 (2016 version) depending on the size of the cells. If the cells are 3" x 3" then you could grout 24', but you still may need the cleanout.
 
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