ICRI 2012 Project Award Winner
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Award of Merit: Low-Rise Category

Shipyard Village Structural and Façade Repairs
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Pawleys Island, South Carolina

Submitted by Sutton-Kennerly & Associates, Inc.

Shipyard Village

Shipyard Village Council of Co-Owners
Murrells Inlet, SC

Project Engineer/

Sutton-Kennerly & 
Associates, Inc.
Greensboro, NC

Repair Contractor
Hanover, MD

Material Suppliers/

S&W Ready Mix Concrete
Castle Hayne, NC

Electro-Tech CP, LLC
Pompano Beach, FL

Built in the mid-1980s, Shipyard Village Buildings A and B are five-story, 40-unit beachfront condominiums with ground-level parking that have a structural system where prestressed hollow-core (PHC) panels are supported by load-bearing concrete masonry walls and reinforced concrete beams. Corrosion-related distress was observed at portions of the exterior PHC panels and beams supporting the panels, as well as the reinforced concrete slab edges supporting the windows. A study was conducted to determine the contamination levels and distress of representative components with respect to the different areas of the building to select the most economical repair and preservation methods. 

The oceanfront slab edges were repaired prior to new window installation. Land-side PHC panels and ocean-side reinforced concrete haunches supporting ocean-side masonry walls with minimal outward distress were protected with thermal-spray cathodic protection (CP) and a breathable aesthetic top coat. CP monitoring stations were then installed at representative locations.

Cantilever beams, along with associated oceanfront PHC and land-side PHC panels with increased oceanic wind exposure, contamination, and distress, were removed and replaced with a high-performance lightweight concrete mixture formulated to resist chloride ingress, cracking, and other deterioration mechanisms. New slabs were either keyed into the existing masonry walls or supported on cantilever beams on the ocean-side balconies. The land-side walkway sections were cast integrally with replaced cantilever beams without control joints. Because some existing beams did not meet current live-load requirements, supplemental reinforcing or pilasters were installed to increase capacity. Cathodic prevention point anodes were installed at interfaces to deter incipient corrosion. Most concrete and repair work was conducted in winter, requiring close attention to placement and curing. Slabs were sloped to promote drainage and components were coated. 

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