Construction Defect Problem Areas: Cause & Effect.

Common Problems:

·        Improper design.

·        Improperly compacted soils.

·        Settlement (Subsidence).

·        Swelling and heaving (Expansion)

·        Contaminant materials remaining in soils (e.g., organic, wood, animal remains, etc.).

·        Materials (Inferior sand and gravel).

Potential Damage:

·        Cracks in slabs and garage flooring.

·        Cracks in tile floors.

·        Cracks in concrete flatwork.

·        Cracks in drywall.

·        Cracks in stucco.

·        Cracks in windows.

·        Doors difficult to open.

·        Interior distress to cabinets and countertops.

 TOP

FOUNDATIONS

The following is a list of the common water intrusion problems at foundations and several methods to eliminate these conditions.

Common Problems:

·        Cracks in concrete foundation

·        Tears / Laps in vapor barrier

·        Slab penetrations

·        Chronic sub-surface water accumulation

Recommended Solutions:

·        Pour thicker foundations

·        Bi-directional rebar in lieu of welded-wire mesh (WWM)

·        Thicker vapor barrier

·        Extra 2” of sand and 4” minimum of ¾” coarse gravel

·        Bond all penetrations through vapor barrier

·        Install gutters and hard-pipe downspouts to street

·        Slope finish grade a minimum of 6 feet away from foundation

·        Install drip irrigation along foundation

  TOP

WALLS  (Below Grade Walls)

Common Problems:

·        Grade slopes toward building.

·        Inadequate waterproof membrane.

·        No protection board.

·        No extension of waterproof membrane above grade or over footing.

·        No foundation drain.

·        No gravel or filter fabric around drain.

·        No waterproof membrane under slab.

Potential Damage:

·        Efflorescence and water stains on walls

·        Ponding against building and on basement floors.

·        Moisture migration though slabs.

Waterproofing Below Grade Walls:

·        Waterproof membrane

·        Protection board

·        Gravel Fill

·        Foundation Drain

·        Filter Fabric

Recommended Solutions:

·        Slope finish grade away from building,

·        Install a membrane under concrete building slab,

·        Provide a cant strip to transition waterproof membrane at 90 degree angles,

·        Install ultraviolet protection for above-grade waterproofing.

  TOP

WALLS (Retaining Walls)

Common Problems:

Potential Damage:

·        Buckling of soil/pavement in front of wall.

·        Excessive/unsightly leaning (rotation).

·        Subsidence of soil behind wall.

·        Excessive wall cracking.

·        Collapse.

Recommended Solutions:

·        Install continuous drain pipe embedded in gravel and wrapped in filter cloth.

·        Install drain pipe below finish floor/grade and above bottom of footing.

  TOP

WALLS  (Shear Walls)

Shear Failure:

·        Improper anchorage of soleplate.

·        Improper nailing of shear element, e.g., plywood, drywall gypsum board, etc.

·        Tearing of shear element.

Drag Failure:

·        Missing and/or inadequate straps at top plate.

·        Insufficient lap or splicing of top plate.

·        Using an undersized top plate.

Potential Damage:

·        Cracked finishes.

·        Water intrusion.

·        Deflection or collapse of framing members.

·        Ruptured gas and/or plumbing lines.

  TOP

FLOORS & CEILINGS

Common Problems:

·        Inadequate design of floor live/dead loads for structural support.

·        Excessive span of framing members.

·        Undersized framing members at critical moment points of building.

·        Excessive loading of building, deviating from design and type of occupancy loads.

·        Wood rot, resulting from water intrusion and ponding, weakening structure.

Potential Damage:

·        Cracking of finishes, e.g., drywall gypsum board or stucco.

·        Squeaking floors.

·        Excessively sloped and/or springy walking surfaces.

·        Ponding water on exterior surfaces, e.g., roofs, decks or balconies.

  TOP

DECKS & BALCONIES

A common addition to most multi-level building developments are decks or balconies. Typically, if required by code for appropriate egress, they will include exterior stair systems for access. (I won’t get into any ADA issues, but they should be considered to comply with codes). Improper design, material manufacturing, or construction/installation can potentially result in construction defects or damage. Some of these CDs can be caused by unventilated areas where water intrusion causes mold, fungus, dry-rot, etc., which could ultimately result in structural failure of the interior framing system, exposure of plywood decking and warping, and failure of the deck membrane materials.

Common Types:

·     Tongue and groove (T&G) wood decking systems.

·     Wood framed deck with some type of elastomeric coating.

·     Lightweight concrete or tile decks

Common Problems:

·     Improper deck to wall transition.

·     Improper deck to sliding glass door or front door threshold transfer.

·     Improper flashing.

·     Improper drainage or slope to drain.  

·    Improper installation of skupper drains on deck.  

·    Improper finish coatings on deck.  

Potential Damage:

·    Interior leaks.

·    Stucco staining/cracking.  

·    Deck/structural failure.

·    Mold or Fungus   

·    Dry-rot.

·    Surface cracks on deck material and/or coatings.  

TOP

ROOFS

The following is a list of common roof systems that are installed on most building structures. Each one of these systems contains similar components: felt underlayment, plywood sheeting, sheet metal flashing, etc. Improper manufacture or installation of one or more of these roof system components could potentially result in a construction defect and damage to a building structure.

Common Roof Types:

Common Problems:

·        Improper and incomplete sheet metal flashing.

·        Missing or short cut roof underlayment felts.

·        Improper use of materials.

·        Improper slope to drain.

·        Lack of Gutters.

·        Roof leaks.

·        Gutters improperly installed, or missing.

Potential Damage:

·        Stains and or destruction of walls, ceilings, or floors.

·        Wet Insulation.

·        Mold and Fungus.

·        Wood Deterioration, e.g., Dryrot.

·        Termites, Vermin, Infestation.

·        Structural Failure.

·        Defective or broken tiles/shingles.

  TOP

DOORS (Sliding Glass Doors)

Common Problems:

·        Improper flashing, especially at threshold.

·        Inadequate vertical offset between the interior and exterior surfaces.

·        Lack of a bituminous or polymer barrier between aluminum threshold and concrete or sheet metal substrate.

Potential Damage:

·        Water intrusion into framing system and living spaces, which can result in:

• Dryrot of wood framing system.

• Water-stained drywall gypsum board or other wall surface elements.  

• Damaged flooring materials, tile, carpeting and other interior finishes.  

·        Corrosion of aluminum threshold resulting from lack of protection barrier material.

Recommended Solutions:

·        Provide a 1-1/2 inch vertical offset between the interior and exterior surfaces.

·        Provide a weather-tight, fully sealed or seamless sill/jamb flashing system.

·        Protect corners of threshold with counter-flashing of deck system.

·        Provide bituminous or polymer barrier between aluminum threshold and concrete or sheet metal substrate.

  TOP

WINDOWS

The size and style of windows installed on most buildings varies from development to development. Building fenestration is usually a key design element selected by the architect or builder. Windows are commonly manufactured using wood, aluminum or steel as the frame material. Windows typically come with single-glazed (one piece of glass per frame) or double-glazed (two pieces of glass per frame with a scaled air space between the glass, sometime referred to as thermopane).

Common Window Types:

·        Fixed window (a stationary window designed to allow light and not to open).

·        Double hung or box window

·        Sliding (horizontal or vertical) window, with an adjacent fixed or non-moving window.

·        Bay window or green house.

·        Sliding glass doors (horizontal with one fixed and one movable door).

Common Problems:

·        Improper installation of sheet metal flashings or flashing paper.

·        Improper installation of windows at the sliding glass door.

·        Improper use or use of dissimilar materials.

·        Inadequate waterproofing at decks or balconies with sliding glass doors.

·        Leaking windows or doors at framed corners (potential product/mfg. defect).

·        Sliding windows or sliding glass doors difficult to open and close

·        Windows allowing air drafts into building when closed.

Potential Damage:

·        Water leakage into non-ventilated areas adjacent to windows.

·        Staining of walls, window sills, or floors.

·        Mold or fungus visible on window frame, sills, or adjacent walls.

·        Trapped moisture between window panes on double-glazed windows.

·        Fogging between glass airspace in double glazed windows.

·        Mildew, fungus, and/or dryrot.

·        Gaps between stucco and window frames.

·        Cracked stucco.

·        Structural Failure.

  TOP

WINDOW FLASHING

Common Problems: