I would like to first apologize if I am not in the right place or if I have asked a much more complicated question than most of you have the time to answer.
My home is located in a flood zone near the Delaware River and has been flooded several times. FEMA has provided a small amount of funding for elevation of these homes.
An engineer had drawn plans that will allow the house to be elevated 7 feet, over and above the existing block walls that range from 3' to 7' high, meaning that some areas of the wall will be 14 feet. The plan calls for a bond beam at the start of the new wall and either epoxy of #5 rebar into an existing solid wall or rebar inserted every two feet into existing hollow wall (which is my case), filled with concrete. Additionally, the new wall above the bond beam will have vertical rebar inserted every two feet, filled with concrete. The second course from the top will also have a bond beam, concrete filled.
The problem is that after the wall was completed, it was discovered that many of the areas where the rebar was inserted was not completely filled. The workers blocked some of the voids and filled others, meaning there is usually not a complete row of vertical unfilled voids. Cement poured from the top (below the upper bond beam) cannot fill all the blocks in each column containing the rebar.
The contractor was informed of this and filled some of the voids, saying the rest were ok. However, hundreds of unfilled voids continue to be revealed. My engineer says that "force grouting" from below would be the surest method of filling the voids. This seems excessive and the contractor says it cannot be done. I have suggested using a pump to grout from above, inserting the grout between the 24" spaced rebar sections and with a proper slump, most of the grout will migrate sideways to the empty rebar voids. The contractor said the grout will not move sideways but only down. I believe that the 3/8" to 1/2" space between the block, since the mortar joints are mostly on the inside and outside, will allow the grout to migrate. However, I feel that filling the blocks between the rebar will strengthen the wall overall, even if the rebar voids are not filled. Other houses done by this contractor were filled completely but he claims it was because a different engineer specified rebar every 48" and complete filling of the walls.
The problem is that the contractor says that the only measure he will use is to cut 8" by 8" openings in the empty voids and fill them with cement. Since there are over 1300 cores that contain rebar, short of "radar" there is not way he can determine which ones to open. Is it unreasonable to expect the contractor to fill all the block, since he seems to want to continue to take shortcuts and get paid. I have asked him to provide in writing a detailed explanation of how he will determine which voids are empty, since I have drilled only about 100 of the 1300 and about half were empty.
Now that we both have attorneys, I need to get expert opinions on how the walls can be brought up to the engineer's specifications. I think the engineer doesn't want to be the bad guy, since he does have a working relationship with the contractor, so he may soft pedal the issue.
Thanks for any help or suggestions you may provide.
Don
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