Horizontal Cold Joint in Beam
I have a situation where a horizontal cold joint was created in a reinforced concrete beam, about 300 mm down into an 800 mm deep beam.
I am of the opinion that this joint severely compromises the capacity of the beam. Specifically, I have shown through interface shear calculations that the ability of the beam to resist transverse shear across this joint is somewhere between 33%-60% of the original monolithically designed section.
A typical shear flow calculation (VQ/It) would show just how much transverse shear this plane should be resisting - highest near the ends of the span where direct shear is highest. However - when I apply the cracked moment of inertia of the transformed section into a shear flow calculation - I get outrageously high stresses - stresses that are orders of magnitude higher than even a monolithically cast section would be able to resist. It makes sense when I compare the same calculation to the gross moment of inertia though - my cracked moment of inertia is lower by similar orders of magnitude.
I am of the opinion that the beam was not poured in conformance with the drawings and specifications and should be demolished and replaced. The contractor is of the opinion that everything is perfectly fine because it's just concrete. My project manager is of the opinion that I should do some calculations that show it either absolutely doesn't work, or that it does in fact still work and we can accept it as-is.
I thought I was on the right path with checking shear flow, and comparing that to the interface shear transfer resistance that can be developed across the joint, however it is clear to me from the math that once the section cracks (not the cold joint - just cracking from bending) that shear flow calculation doesn't seem to be valid for this scenario as it is no longer a homogenous unit.
Does anyone have any ideas on how to analyze the new capacity of this beam? I am considering just analyzing the bottom portion of the beam, below the cold joint, as the "beam" and ignoring the portion above. The stirrups should be fully developed into the top portion still so there shouldn't be an issue with ensuring they are developed. This would be a pretty simple way of checking the bending capacity at mid-span, but it doesn't seem feasible at the supports (designed as continuous span over columns), as then I'd have a "really thin beam" over the columns - but again maybe that is the way I show that it certainly doesn't work?