The State University of New York (SUNY) Health Science Center parking structure, constructed in 1967 in Brooklyn New York, is a 10-level high traffic parking facility that supports the Medical Complex.

Structural repairs were required as a result of defects and errors in the original design and construction of the building. A lack of negative bending reinforcing steel past the column supports had caused a structural crack. As such a heavily reinforced overlay was installed in the parking area to help combat the loads.

Since the repairs were made, the structure has experienced corrosion damage, column spalling, surface structural slab cracking, ineffective sealants, and overhead delaminations on the underside of the waffle slab system.The concrete overlay was debonding and deterioriating leaving reinforcing steel exposed, reducing clearances, and was becoming a public safety issue for pedestrians and vehicles traversing across this area.

These issues became problematic maintenance for the owner who was constantly trying to repair the structure. After getting multiple opinions from various consultants, the owner selected a new repair option which would strike at the root of the problem –using FRP across the original structural crack, shoring the floor, and removing the existing concrete overlay. The remaining cracks would be injected and FRP applied to the top side of the slab along with an epoxy resin and traffic bearing urethane waterproofing membrane.

STRUCTURAL was contracted to remove approximately 41,000 SF of existing 5” thick concrete and asphalt overlay and 400,000lbs of #11 rebar. In addition, 1,000 SF scaling repairs were performed with an epoxy mortar over select portions of the topping removal area. Full depth slab replacement, partial depth slab repair, waffle rib repairs, beam repairs and overhead slab repairs were performed and all cracks were routed and sealed to prevent water penetration. On the topside of the slab, 13,875 SF of FRP was installed. Deck drains were replaced so water flowed away and wasn’t ponding, improving drainage. In order to protect the FRP and the slab, an application of 50,500 SF of traffic bearing urethane waterproofing membrane was installed.

Tight scheduling and phasing plans posed challenges throughout the project because the structure remained operational and experienced a heavy flow of traffic daily. The work was completed in 11 phases, removing 100 spaces at a time in order to keep the facility operational during repairs.  Careful safety planning and constant communication was vital to prevent congestion, move debris, and place concrete.

STRUCTURAL completed the project in half the time the owner had allotted. Ted Raderman, the Facilities Program Coordinator, said,

“In all my dealings with contractors over the years, few, if any, reached the ultimate milestones of completing projects ahead of schedule, not having sustained any injuries to their workmen and having materials and equipment readily available so as not to delay the project work.”