When the replicas were being made, many of the original terra cotta pieces were discovered to not be identical in dimensions. This unexpected development caused crews to remove several sound terra cotta pieces from the walls than originally anticipated to create more molds of varying sizes to create the replicas.
Similarly to the method used to create mockups for the custom brick mortar colors, the team created mockups of the terra cotta pieces, displaying a variety of grout color shades for the general contractor and historical consultant to review.
When painting the terra cotta replicas to match the existing, aged pieces, old-fashioned trial and error was used to get the right color combination. They applied various paint colors to the pieces using sponges and brushes of various sizes and even smeared the paint with a cloth to replicate the aged appearance. After viewing the mockups from the recommended 9 m (30 ft) away, the general contractor, architect, and historical consultant approved a mockup color for all of the terra cotta replicas, following several rejected color combinations.
Conclusion
The Freedom Place façade restoration project faced many challenges—from winter weather to extensive vandalism, missing or damaged original materials, unsound floors, and multiple mortar joints to decades of weather damage. Fortunately, the use of modern restoration technology and craftsmanship prevailed on the jobsite.
By knowing which product effectively removes graffiti from matte bricks, which tuck-pointing profile provides the best waterproofing, which product best covers spider cracks, and what to mix with mortar to accelerate its set time during cold temperatures, Western’s crew was able to successfully resolve its challenges and keep the restoration project on schedule.
Jason Holtman is the manager of Western Specialty Contractors’ St. Louis Masonry branch, having been with the firm for four years and focusing on masonry restoration projects. He has been in the construction industry for a decade, with previous experience as a roof and building consultant with emphasis on low-slope roofing and façade/water intrusion problem solving. Holtman can be reached via e-mail at jasonh@westernspecialtycontractors.com.
