Today we’re diving into everyone’s favorite renovation topic – the costs to remedy unexpected structural problems. We’ll provide the knowledge, and you can provide the schadenfreude.
Our latest Philadelphia renovation project gave us the perfect opportunity to discuss some valuable lessons and to highlight why it’s so important to have experienced construction professionals managing your home remodel from start to finish.
What We Planned For
Going into this renovation, we knew we’d be tackling two key structural changes:
Fixing the leaning staircases
Widening the opening to the rear yard to accommodate a larger door
What We Didn’t Plan On
Of course, renovations in older Philadelphia homes love to surprise you. Once demo started, our list grew to include:
Rebuilding the 3rd-floor back wall
Resheathing (and recladding) the 2nd-floor back wall
Replacing rotted LVL beams
Removing the chimneys entirely
The Structural Surprises We Found
Once we completed demo, we uncovered several serious issues hiding behind the walls.
1. Rotted Structural Beam
We found large gaps and stair-step cracks in the 3rd-floor brickwork, prompting a second round of demo. Behind the wall, we discovered a triple LVL beam that was nearly 50% rotted through and it was supporting the entire 3rd-floor masonry wall. From the outside, this house looked solid, but this hidden decay could’ve led to catastrophic failure.
We give huge credit to our AXE Builders team for not taking shortcuts and for always investigating the root cause instead of covering up surface issues.
2. Unsafe Chimneys
We also discovered that a previous renovation (about 20 years ago) had hollowed out the chimneys to run ductwork and left them in poor shape. They were literally crumbling behind the walls, and we found a pile of fallen bricks at the base. Even worse, the chimneys were sitting on just ½ inch of joist, meaning they weren’t properly transferring their weight. This was another serious safety concern waiting to happen.
3. Rotted Wall Sheathing
On the 2nd floor, the sheathing had completely deteriorated because someone had applied stucco directly over plywood without proper waterproofing. As a result, the entire wall was rotted and required replacement. We resheathed the wall and installed new cladding for proper protection and long-term durability.
Cost Breakdown for Structural Repairs
Here’s what the unexpected repairs added up to:
Demo – $4,000
Chimney removal
3rd-floor rear wall
2nd-floor sheathing
Old rotten beam
Masonry – $1,400
Widening the back door opening
Parge two old 3-story chimneys
Framing – $3,400
Rebuild 3rd-floor wall
Resheath 2nd-floor wall
Replace triple LVL with new quad 2x10 beam
Structural framing around staircases
Cladding – $1,500 (approx.)
New siding on 2nd & 3rd floors
Total: $10,300
From this total, we had only expected and budgeted for about $2,200 meaning $8,100 in unplanned costs. While that might sound daunting, we’re actually grateful we caught these issues early. At AXE Builders, we plan for the unexpected.
Why a Contingency Fund Matters
In our renovation budgets, we always include a $15,000 contingency to cover unforeseen conditions like these. The goal isn’t to avoid spending it… it’s to ensure the finished product meets our high standards of craftsmanship and safety. Delivering a structurally sound, high-quality home is always worth the extra cost.
Pro Tip: Always include a large contingency in your renovation budget. You never know what’s behind the walls of a Philadelphia rowhome until you start opening them up.