This past week we started a really exciting series on historic brickmaking for which we went and took a look at a traditional type of brick making process, very similar to the historic methodologies used here in the United States over a 120 years ago. The outline of this article follows. Today, we will discuss items #4-7 from the outline below:
We start today, by talking about the steps in how bricks are actually created. Steps in the Process of Preparing for Historic Brick FiringThe historic process of making bricks shares some fundamental steps with contemporary methods, and the steps in the brick making process are relatively simple, to someone, if they’ve done pottery or ceramics in an art class, for example. Just like in pottery or ceramics, the moist clay is flexible and pliable, it can be moulded and shaped into a desired form. The wet clay In this condition is called plug. However, before that clay can be formed and moulded it has to be harvested from the Earth. The notable differences, between the historic and modern processes are mainly in the power or fuel sources and the tools and technology used. When you look at all the pictures in the series, you’ll also see many differences in the kiln assemblies, but those differences have a limited effect of the consistency that vary between the historic and contemporary processes. The typical steps in the historic process of making bricks:
Historic brickmaking relied on manual tools and simple wooden molds. In contrast, contemporary processes often involve mechanized equipment, automated molding machines, and advanced kiln technology for precision and efficiency. Historic methods involved manual extraction and preparation of clay, whereas contemporary processes may use heavy machinery and automated systems for these steps. Historic brickmakers relied on natural air drying, which is a slow process. In contemporary methods, controlled drying environments, such as heated chambers, are used to expedite the drying process. Historic brick kilns typically used wood or other organic materials as fuel. In modern brickmaking, various fuel sources, including natural gas and electricity, are employed for firing. Historic brickmakers had limited tools for quality control, and the product’s consistency could vary. Contemporary processes involve rigorous quality control measures, standardized testing, and adherence to specific industry standards. Historic brickmaking was often localized and small-scale, serving immediate community needs, in small markets. Contemporary brick production is typically larger in scale, catering to regional or even global markets. While the fundamental steps in making bricks remain consistent over time, the shift from historic to contemporary processes reflects advancements in technology, scale of production, and the standardization of quality control measures in the modern construction industry. Historic Brick Firing and VitreousnessVitreousness is a characteristic generally used in relation to homogenity and bond between the smallest units of materials in the brick. Glass for example it’s mostly comprised silica but has been heated to a temperature that has made the substrate materials become vitreous, In that vitreous state the glass is then impermeable. Ceramic tile is very similar, most types of ceramic tileI have some degree of vitreousness, but they are not always entirely vitreous. Glaze helps tile achieve its level of “waterproof-ness”, to a large extent, especially in the cases of semi-vitreous kiln fired clays. Essentially, when clay is fired at a relatively or comparatively lower temperature it will reach a degree of vitreousness but it will not necessarily be completely vitreous. Porcelain, by comparison, is made of very similar substrate materials but is fired at a higher temperature and happens to have a comparatively high degree of vitreousness. Porcelain, for example, will be almost impermeable. Terracotta, on the other hand, is a type of kiln fired clay material that most Americans are relatively familiar with, as it is commonly used for retail goods like flower pots. Terracotta can even be found in big box store alrernatives like luttle mom-and’pops stores. Whereas if you were to buy a brick In most cases you’d have to go to either a big box store or a commercial or industrial supply brickyard, or a large-scale distribution location. Terracotta though, can be purchased at almost any small mom-and-pop garden store or even a corner hardware store. They even sell flowers in terracotta pots at the local grocery store In Capitol Hill, DC. Typically, the red color of a fired brick a reaction of the brick’s iron oxide composition. Hematite is a form of iron oxide found in clay and earthen soils, Fe2O3. Sometime hematite, in mineral form, is rendered to be used a reddish paint in pottery and earthenware. Like clinker bricks, which are different, but also culled from a firing process, the failed bricks in the photo above which are either cracked, deformed, or broken in some way, are set aside but not necessarily discarded in all cases. In some cases those rejected or culled bricks can be used again or recycled into future bricks. A significant portion of bricks are also used in the brick making process to stack and separate the drying bricks from the soil below. Brick Hardness and why it Matters, CounterintuitivelyIntuitively, there is a common perception that harder and stronger materials are inherently better, especially in the context of construction and building materials. This expectation aligns with the logical assumption that stronger materials would generally offer superior performance. However, this principle doesn’t perfectly apply to bricks. For both historic and contemporary bricks, the firing process plays a crucial role in determining several of their key performance properties. When bricks are fired at higher temperatures, they exhibit a higher degree of vitrification and increased compressive strength. Vitrification refers to the transformation of the brick’s composition into a glassy or non-porous state. This results in bricks with reduced permeability compared to those fired at lower temperatures. Additionally, higher vitrification contributes to a more solid structure, yielding a slightly higher tensile strength. Despite their intrinsic advantages in compressive strength and vitrification, bricks, along with other silica-based earthen materials such as concrete, stone, and stucco, share a common limitation—they have relatively weak tensile strength. Tensile strength is the ability of a material to resist a force trying to bend it or pull it apart. In the case of bricks, their tensile strength is notably low. This inherent weakness in tensile strength poses challenges in applications where materials may be subjected to pulling or stretching forces. While bricks intrinsically have very high compressive force resistance, bricks are intrinsically weak in tensile strenghth. They are prone to cracking or breaking when subjected to tensile forces. This characteristic is a fundamental aspect of the nature of silica-based earthen materials and is not unique to bricks alone. However when an assembly is properly designed, brick masonry is not exposed to extreme tensile forces and this issue is very limited. To overcome this limitation, builders often employ design strategies that distribute loads more evenly or incorporate materials with higher tensile strength in conjunction with bricks. Reinforcement with materials like steel or the use of structural elements that bear tension, such as arches or lintels, helps compensate for the weak tensile strength of bricks. Understanding the nuanced properties of building materials allows architects and engineers to make informed decisions, balancing the desirable attributes of hardness and compressive strength with the need to address tensile forces in a comprehensive and effective manner. Compressive strength, in contrast to tensile strength, as it applies to bricks and masonry, representing the material’s ability to withstand axial loads or forces applied perpendicular to its surface. In the context of bricks, compressive strength is a measure of their resistance to crushing or deformation under pressure. When bricks are subjected to vertical loads, such as the weight of a structure or additional loads from above, their compressive strength determines their capacity to withstand these forces without collapsing or breaking. Higher firing temperatures during the brick manufacturing process often result in increased compressive strength, making the bricks more resistant to crushing. This property is vital in ensuring the structural integrity of masonry constructions, as it influences the load-bearing capacity and durability of the entire assembly. Engineers and architects carefully consider compressive strength when selecting bricks for various applications, aiming to match the material’s capacity with the anticipated loads the structure will bear. Additionally, the understanding of compressive strength guides the design and construction of masonry elements, ensuring they meet safety standards and contribute to the stability and longevity of the built environment. Repointing Historic Brick MasonryRepointing historic brickwork with new lime mortar is a meticulous process that prioritizes the preservation of structural integrity and authenticity in heritage buildings. Lime mortar, traditionally used in historic masonry, is specifically made for its compatibility with old bricks, allowing for modulus of elasticity and permeability to prevent damage for natural micro-movement and greater movement and pressures during freeze-thaw cycles. Modern mortar can be too rigid and lead to long-term damage to the bricks of a building. Before repointing, a contractor who ks skilled and knowledgeable on the extensive requirements of this work must conduct an assessment of the existing mortar. Correcting previous mistakes, such as the use of inappropriate materials, is extremely complicated in some cases but may be necessary. The old deteriorated mortar is then removed at the wall surface and new lime mortar is applied through a repointing process. This work must be conducted under proper environmental conditions with attention to pre-hydration and proper mixture of the mortar. Repointing us needed to preserve the historic facades of the building, with the application of ongoing maintenance without compromising authenticity. Regular inspection and maintenance are crucial to monitor and address signs of deterioration promptly. Overall, repointing with lime mortar contributes to the sustained beauty and structural stability of the historic brick buildings of Washington, DC. Overall, brick repointing is a central part of the historic masonry preservation process, but repointing a brick facade alone is not the only element required in full-scale facade restoration. Other types of stone and facade restoration elements are required to keep a building both weatherproof and in good shape for the long-term. Deterioration of historic buildings happens in a gradual but non linear form. This nonlinear relationship is reflected in the fact that as elements of a building go without proper care and or restoration or preservation, their respective deterioration continues but increases at an increasing rate. So not only does it get worse, but it declines faster and faster an increasing rate. We often, in our blogs on restoration and preservation mention the fact that the curve of deterioration, particularly with a focus on historic masonry elements, increases faster and faster, without proper ongoing care. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, it’s not just the loss of value to the property owner, there’s also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, contact us or fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post Traditional Brickmaking – Part II first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/masonry/traditional-brickmaking-part-ii/
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Our company’s work is largely focused on historic masonry restoration, and over the past few years we’ve talked a lot about the exploration and understanding the details around the distinctions between historic and modern masonry. There are over a 100 “deep-dive” (thorough analysis) type articles on our website about the technical aspects of historic masonry restoration and historic brick repointing, but today we start one of the most exciting series of all, to-date. One of the main goals of our website and all the information we post is to inform our clients and stakeholders about some of the exciting technical areas of historic masonry restoration. We pride ourselves on being one of the most technically competent and dedicated companies in the entire industry of historic masonry restoration. For example, if you look through the archived past articles on our website you will find posts about historic lime kiln firing, manufacturing processes, methodologies used over a 100 years ago in masonry construction and near limitless information about historic masonry preservation. Today we actually went out of the United States to see the process, in real life, used over a 100 years ago here in the construction of the historic buildings in Washington, DC, for the manufacturing of historic clay kiln fired bricks. We are very excited to present this new series to our readers. The outline of the new article follows. Today, we will discuss items #1-3 from the outline below:
The picture below shows a brick yard, using the same methodology as used over 120 years ago here in Washington DC for the initial setting of historic bricks. These bricks were initially cast in a form (nould) but set out from the form while wet directly onto the ground to dry in the sun before being fired. Substrate Materials in Historic BrickThe substrate materials of bricks are mostly pretty basic, More than anything the main substrate material is clay. Clay is basically a type of mud, that is an oversimplification, but it’s the type of material that’s available and ubiquitous almost anywhere in the world. Some of the main ingredients in bricks, based both on volume and weight are silica, aluminum, and iron oxide. Bricks do not behave, on a physical or chemical level, much like a metal, but there is quite a bit of iron oxide inside of bricks which often imparts the deep red color that we are familiar with with the most common of bricks. Bricks have been foundnused in very old historic times throughout most of the world, even within places that had no interconnection or communication to one another, even in places that were basically isolated from one another. Brick, as a building material, is one of the examples of “Parallel Invention” in the history of mankind. Now is a good time to also mention that although there are some subtle differences between bricks used all over the world, by and large, bricks from different parts of the world are relatively similar. However, there are a few particular types of bricks that are unique and made, even here in America, both in historic and even in contemporary times. We are mostly referring to the two most common types of brick, in historic instruction, the common brick, and the pressed brick. Both types of bricks were actually pressed into a mold, but the brick we today tefer to as a historic pressed brick was normally put under a mechanical press to squeeze the brick very tightly. Impurities such as rocks or twigs or larger trunks of constituent material were filtered out and you can see pressed brick at many Capital Hill rowhome front facades, for example. You can see that the pressed brick at these rohomes have very consistent shape and planar uniform faces. The lines the mortgage joints of pressed brick are very thin, and this is not possible with a typical common brick because there is great variety, both in the substrate materials and the temperature at which common brick was fired. These differences lead to bricks that have sigmificant inconsistencies from one to the very next. The concept of Parallel Invention is fascinating. Apparently, through historic records in the anthropological history of Mankind, there are numerous examples of isolated peoples creating and using the same type of things throughout the world, interestingly aroubd the same times. Brick is one of the quintessential examples of parallel invention. Basically, on different continents between people who had no intercommunication, around the same time in human history, these peoples began creating and using bricks in the building of their historic structures. The evidence of this parallel invention goes back thousands of years. It’s hard to believe that people who had no communication between each other would start building things the same way, but brick is a bit of a Is naturally perfect type of material for humans to use. As discussed above, these substrate materials are available in almost all parts of the world and the use of brick is interestingly highly adaptable and highly effective in the building of both homes and/or larger structures. Even without advanced technologies, humans were able to figure out that brick could be created with substrate materials available right from the dirt around them and that creation of bricks of relatively consistent or similar size was a perfect building block for creating walls around shelters and homes. The earliest bricks were essentially just dried mud, often reinforced with straw or thatch. The straw or thatch provides a bit of tensile reinforcement, in unfired adobe, But, traditional adobe lacks the very Important characteristic of semi-impermebility. Adobe is often found used, historically, and even through to today in relatively drier or airid climates such as the Southwest part of the United States, but it’s not often found lasting long in wet environments. In some cases horse hair was also used, just as it was used in plaster in later centuries. Unlike sandy mud, muds that are high in clay or even close to pure clay make better bricks. When heated at a very high temperature, clay becomes vitreous, meaning it becomes a bit monolithic and the individual small particles with any brick will fuse together in a bond similar to the way silica will bond and fuse together in glass. One of the most fascinating parts of the concept of the invention of bricks, so many thousands of years ago, is that today, the technology, while still understood in industrial settings, has largely been lost to regular people. Particularly the area of historic restoration, while so importantly needed in the historic cities of East Coast of the United States, like Washington DC for example, is very poorly understood. It’s difficult to believe that something so ubiquitous could be barely understood by the majority of humans on Earth, even though it’s still a critical building material and was discovered independently throughout the world, almost like it was a natural fit for human beings and part of our evolution. Substrate Materials in Historic Lime MortarSimilar to historic brick, the materials used in making historic lime or also basically ubiquitous and available through most parts of the world. It’s very likely that lime was discovered by accident, but, humans throughout the world began using it around the same time in the history of mankind. The earliest lime basically as simple as a mixture of chemicals rich in hydrated calcium hydroxide. The fascinating thing about lime, as a constituent component of mortar, is that lime was also disvovered, like bricks, and used throughout the world in historic times, even between disparate civilizations where there was no intercommunication. People discovered tabby lime, probably at the earliest point of the use of lime, by avvident when seashells end or limestone were burned in or next to a fire pit. When water was added back to that material, in the ash, it would have a relatively violent chemical reaction with bubbles, pops, steam, and small explosions. The water, added to large amounts of fired lime would become extremely hot, even when the lime itself had cooled, after firing, to ambient temperature. In historic times, people notice this and then later realized that the lime, once hydrated by adding water would become rock hard, it’s like they had created a rock out of nothing more than old pulverized stone or seashells and ash. People then mixed this lime together with sand and they were basically creating a mortar that would be strong enough, similar to rock, which could lock masonry into place, similar to the modern mortar we are most familiar with today. Historic lime mortar like this was used for thousands of years. On the coast of the Carolinas, for example, from hundreds of years ago there are still remaining standing ruins of old Tabby construction walls. Tabby construction was a mixture of seashells which have been cooked in a fire and sand and other type aggregate materials with stone, set as a binder to hold the stone in place. Plug and Brick MoldsHistoric bricks were larger and therefore heavier than modern bricks, even in the wet stages. Modern bricks are dried more extensively than historic bricks so that’s an additional differentiation which also makes modern or contemporary bricks actually weigh a little bit less than they would otherwise. Similar yet different than the contemporary clay plug conveyor process, where the mass of clay (called: plug) is extruded from industrial hydraulic equipment, in historic times, the clay mass, also referred to, in historic times as a “loave” for each brick was hand set in a wooden frame or mould like the one shown below. In some cases the historic brick molds were lined at the bottom with a metal ring. The process is a relatively wet process, even though the play is somewhat stiff and it needs to be pounded into the mould, the clay comes from the Earth and is generally at least partially hydrated to the point that it can be formed, a plastic material in nature. These loaves were hand-shaped, essentially squished onto the surface of a tabletop or a board made for this purpose and then forced into the shape of the mold. The general wetness of the material caused the mould to deteriorate and or weaken in use at a relatively accelerated pace. The mould In the picture below is from relatively modern times, but still replicates the historic process and can fit as much as 4 bricks at a time. The edges of the inside of that mould are covered in a plastic laminate which helps decouple or debond the clay from the wood. Without a decoupling material like that, much more sand has to be used to essentially provide a dry release from the mould, in the brick forming process. Clay relatively close to the surface of the Earth can have a variety of impurities in the clay and must be filtered or culled to an extent to prevent things like organic materials, twigs, sticks, vines, etc. from being formed into the clay brick. In some cases, if those organic materials are left in the clay loaf, when the brick is formed, dried, and then fired, during the firing process The organic material can burn, even within the inside of a brick and create a void which can lead to breakage of the brick or a future passageway or a window / pathway of moisture to run through a brick from the exterior to the interior of a building. When the clay loaf is pressed into the mould and then released from the mould, the clay brick is generally set direvtly on in flat area of unshaded ground. If the area is in the woods or under treetops, it will be partially or fully shaded and will not dry nearly as fast. Optimal areas for brick drying yards are relatively large and do not have much shade. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, it’s not just the loss of value to the property owner, there’s also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, contact us or fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post Traditional Brickmaking – Part I first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/masonry/traditional-brickmaking-part-i/ A few weeks back, we took a look at a linear trench drain at an areaway at a well leading to an entry at a basement. Today we are taking a look at different types of linear trench drain, generally above grade and at larger openings. Linear trench drains can be extremely useful whereas in the past, and historic times, only areaway drains were really practical options for draining smaller areas. The outline for today’s article follows:
A picture of a linear trench drain from over 50 years ago follows below. This isn’t exactly a historic element, but nor is it contemporary or modern. The grate, overall, has a lower percentage of area that allow passage of water through and into the drain, than modern drain grates. Why Linear Trench Drains are BetterLinear trench trains have a higher volumetric capacity than areaway drains. This matters because it is the maximum capacity that becomes critical before a drain is breached. Breaching a drain can lead to flooding of a building interior so the damage can be possibly catastrophic. Because of both the overall larger surface area and the longer shape linear drains do not get clogged as easily as areaway drains. For example, when a concentration of debris is deposited onto an area of a drain, with a circular areaway drain, that area is the entire drain and therefore the drain can easily become covered over and clogged. By comparison though with the linear trench drain, even if the area has the same size of debris deposited, water can still flow around to another section of the same linear trench drain. Effectively, it would take a much greater amount of debris to cover the entirety of a linear trench drain than it would to cover the entirety of an areaway drain. Linear drains can be built to adapt to the context of a grade or layout better than areaway drains which often require the modification of a larger portion of the surrounding grade / paving. Essentially, for a areaway drain to serve relatively large area, the entire area has sloped directly to that single sole point. Whereas, by comparison, with a linear trench drain, the drain can follow a roadway or pathway, for example, and the drain can still collect water that runs in towards that direction but the grade doesn’t necessarily have to slope so that they’re all areas feed specifically in that direction. In fact areaway drains can particularly collect water that is built up or amassed during very high points of volume during storms or above average precipitation, for example. The trench drain in the picture below protects the garage area of this building from heavy water flows but may only capture a portion of the water that runs across the roadway. Particularly during the heaviest rains, water may run both directions from the crown of the roadway and follow the gutter of the street. Longer Lasting MaterialsInitially, most areaway drain systems, in historic neighborhoods of DC, such as Capitol Hill, were built with cast iron components. Cast iron is strong and somewhat resistant to oxidation, but it has low ductility and several limitations as a drain material. By comparison, stainless steel has a much higher resistance to rust and oxidation. Stainless steel however, didn’t become popularly used as a common building material until decades after the majority of historic buildings were built. Cast iron is an alloy of iron that contains a higher proportion of carbon than steel, along with silicone and other elements. While cast iron is known for its strength and durability, it is susceptible to rusting when exposed to moisture and oxygen. The presence of carbon in cast iron can contribute to the formation of a protective layer of oxidation on the surface, which can act as a barrier against further corrosion. This layer may be referred to as a patina. Steel or wrought iron, by comparison, will continue rusting, even after the surface rusts, they will rust all the way through. Modular and Customizable DesignsIn modern and contemporary times, many of the components of drain systems are made so that they can be expanded or modular yet semi-customizable to be interconnected with additional pieces to fit the length, configuration, and shape of the needed installation. This is a big improvement over historic systems which did not allow for customization on site. Instead, as an alternative to customization onsite, individual productions could be created to customize the mold to create a system tailored to the content of the construction. This is an example of extreme customization. Today though, systems can be tailored to a large extent using near readily available catalog components. Improved Grate DesignsIn recent decades, grate design has been optimized to increase load-bearing capacity and increae water flow. Every grate has a trade-off in this area. Grates with larger surface area of the base materials are stronger and can support a greater imposed load, while grates that have more open areas are generally weaker but can allow much better water flow. There’s a careful balance between these 2 elements, and the point of optimization is based on being able to handle the imposed loads of vehicle traffic and also allowing the maximum amount of water capacity. Looking closely at an older cast iron drain cover you can see that this appears to be much stronger, from the position of supporting heavy loads of traffic, but the amount of water that can pass through the grade is decreased significantly because only a smaller portion of the area is perforated or open to allow water to flow into the drain body. High-Performance Surface TreatmentsApplication of advanced coatings and surface treatments to trench drains can help to to resist corrosion, reduce maintenance, improve longevity, and provide traction coatings to reduce slippage. The traction to resist slippage mostly applies to foot traffic, but also applies to vehicle traffic as well, particularly where there is a transition in grade or angle of the roadway. The options for surface treatments vary widely depending on the type of base material used for the drain and grate system. Modern steel materials are often treated with a galvanization process which protects the substrate metal from oxidation and deterioration. There are two main types of galvanic treatments, the less expensive option is electro galvanization. Hot dip galvanization. By comparison, the hop-dip process requires submersion of the material in a bath of molten zinc liquid. It’s difficult to hot dip galvanized large materials because particularly large beds are required to submerge variety large steel materials. This makes the hot dip process a bit more costly for large sections of drain grates, for example. Hot-dip galvanization and electro-galvanization are both processes used to apply a protective zinc coating to steel or iron surfaces, but they differ in the way the zinc coating is applied. The key differences in the processes contribute to variations in the thickness, structure, and effectiveness of the zinc coating, which, in turn, affect the resistance to deterioration. Hot-Dip Galvanization creates a zinc-iron alloy layer at the interface between the zinc coating and the base metal. This alloy layer provides a metallurgical bond, contributing to the durability and effectiveness of the coating. Electro-Galvanization, in contrast, typically forms a pure zinc coating without the same degree of alloying with the base metal. The bond is generally less robust compared to hot-dip galvanization. Hot-dip galvanization generally provides a more robust and thicker coating, along with the formation of a zinc-iron alloy layer, resulting in enhanced corrosion resistance and durability. This makes hot-dip galvanization particularly effective in applications where extended protection against deterioration is crucial, such as outdoor structures, marine environments, or industrial settings. However, electro-galvanization remains a viable and cost-effective option for many applications, especially when a thinner coating is acceptable, and a smoother finish is desired. The choice between the two processes depends on the specific requirements of the application and the environmental conditions the coated material will face. By comparison, as a contemporary alternative to steel and metal grate systems, polycarbonate plastics are relatively strong. They can handle a relatively high degree of tensile strength resistance and have almost no commensurate deterioration related to moisture or exposure to water. Polycarbonate materials though, are highly susceptible to exposure to ultraviolet rays and therefore while they are better in some ways, have one inherent weakness which may render them less effective, in some cases. Polycarbonate is lightweight compared to steel, making it easier to handle and install in certain applications. One of the significant weaknesses of polycarbonate is its susceptibility to UV degradation. Prolonged exposure to sunlight can lead to yellowing, loss of transparency, and reduced mechanical strength over time. Polycarbonate surfaces are relatively soft and can be prone to scratching, which may affect their appearance and optical clarity. While polycarbonate has a wide operating temperature range, extreme temperatures can affect its mechanical properties. It may become brittle in very cold conditions and soft in high-temperature environments. To mitigate the effects of UV exposure, manufacturers often add UV stabilizers or coatings to polycarbonate products. UV-resistant polycarbonate formulations are available to address this weakness. The choice between polycarbonate and traditional materials like steel depends on the specific environmental conditions of the application. If UV exposure is minimal, and impact resistance and moisture resistance are critical, polycarbonate may be a viable option. In summary, while polycarbonate plastics offer several advantages, their vulnerability to UV degradation is a significant consideration. Properly addressing UV exposure through protective coatings or choosing UV-resistant formulations can help extend the lifespan and performance of polycarbonate materials in outdoor applications. The picture below shows an example of a polycarbonate drain grate. The top upper surface of the grate is covered with an embedded texture surface, iitger uniting silica or aluminum oxide, similar to a sangmdpaper, to provide texture and prevent pedestrian slippage. Efficient Water Filtration SystemsIntegration of advanced filtration systems within trench drains to improve water quality by capturing debris and pollutants has improved in recent years. Often, in many parking lots, to achieve environmental credits related to construction, as imposed or promoted by municipalities, gutters are often installed which go to a tree base which allows water to run through the area below the base of the tree and also some potentially are filtered before water returns to the natural drain points such as the Anacostia River. Environmental damage to the Anacostia River from paved area runoff has decreased significantly in recent decades. In fact, there are currently projects, in tge planning stages, which will both celebrate and further develop on the revitalization of the Anacostia River to bring a mixed retail and other type elements to neighborhoods along the river which have been food deserts and lacked variety of services for many decades. Water filtration systems are not typically integrated directly into linear trench drains. Linear trench drains are primarily designed for the efficient conveyance of surface water, capturing runoff from paved or landscaped areas and directing it to a proper drainage system. However, there are related components and systems that may be used in conjunction with linear trench drains to address water quality concerns. While not traditional water filtration systems, separators and sediment traps are components that can be installed upstream of a drainage system, including linear trench drains. They help to capture and settle out sediments and pollutants, preventing them from entering the drainage network. In some sustainable drainage systems (SuDS) or green infrastructure designs, bioswales or vegetated channels may be used alongside linear trench drains. These features help filter and treat water through natural processes, promoting the removal of pollutants through vegetation and soil. Bioswales are not often found in the middle of the concrete urban jungle, but they are used along parkland, for example. And while bioswales are not highly common in the middle of the urban concrete jungle, permeable paving, by comparison has become extremely popular, even in the middle of the city urban environment. In certain applications, permeable pavers may be installed along with linear trench drains. These pavers allow water to infiltrate through the surface and into the ground, promoting natural filtration. Infiltration basins or underground systems may be used to enhance water quality by allowing water to percolate through soil layers. While not integrated directly into trench drain, removable inserts or filtration devices may be added to the outlet points of the drain system. These devices can capture debris and prevent it from entering the downstream drainage system. It’s important to note that the primary function of linear trench drains is to manage surface water runoff efficiently, and they are not designed as advanced water treatment systems. For more comprehensive water filtration needs, dedicated stormwater treatment systems or detention/retention basins with specific filtration elements may be employed. These systems are designed to remove pollutants and contaminants from stormwater before it is discharged into natural water bodies or municipal sewer systems. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, it’s not just the loss of value to the property owner, there’s also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, contact us or fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post Trench drains in walkways and roadways first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/masonry/trench-drains-in-walkways-and-roadways/ A few weeks back, in the article in the following link, we took a look at several elements of historic building facades which are unique elements of historic architecture. Today we look at other aspects of historic architectural building facades elements, following the outline below:
The picture below shows a decorative historic relief set in a historic pressed brick facade. Pressed brick, as opposed to the more prolific common brick, is much more uniform in texture, durable, vitreous, and consistent in rectilinear form. Pressed bricks used both a finer clay in the plug (substrate the brick itself, pre-firing) and were fired using more dense hardwoods creating a higher temperature in burning. Historic Materials are difficult to replicateReplicating historic building materials like masonry and elements such as hand-carved sandstone in modern times is challenging primarily due to the following reasons:
The next picture below shows a greater expanse of the same historic pressed brick facade. From this low angle you can see that this decorative element is set among a corbelled column in the brick facade. The picture below also shows the full height of the windows at the front facade. These windows have a Gothic Arch and the glass units are historic and are cut to the shape of the opening. In modern glass, it is much more common for glass to be cut in a rectilinear shape as it is produced in sheets in a float process on a bed of molten tin. Much of this type of work today is done through heavy Manufacturing processes. 3. Availability of Materials: Sourcing materials identical to those used in historic construction, such as specific types of stone or clay for bricks, can be challenging. Some materials may be rare or no longer quarried. The picture below shows a once beautiful but now deteriorating sandstone facade. The Sandstone plates that clad the face of the building are solid and inches thick, yet the outer layers of that stone is delaminating over time with exposure to the elements, including acidic rainfall. The corbels that support the original entry header water table are intricate and beautiful and the detail is more apparent here where they are covered by the platform above. These elements were not as directly exposed to rainfall and have maintained a greater extent of their original detail. 4. Customization: Modern construction often relies on standardized, machine-produced materials to ensure consistency and structural integrity. Replicating historic elements may involve inherent variations that impact quality control. Preservation of Originals: In many cases, preserving and maintaining the original historic elements is prioritized over replication. Attempts to recreate may risk damaging or altering the authenticity of the existing structure. Due to these challenges, truly replicating historic building materials and elements requires a commitment to preserving traditional craftsmanship, access to rare materials, and a willingness to invest in the time and expertise necessary for a faithful reproduction. A perch style Stone balcony once was built just outside of these openings at the front facade of this pressed brick row home building. As the original masonry deteriorated, in an effort to save money and without any care about the preservation of the building, contractors came and installed a wood platform deck as a makeshift type of temporary solution. Interior drywall screws were used here on an exterior installation as no one involved cared much about the quality or the value of the construction. Our company wasn’t involved in the work, so we are not sure about the long-term plan, but there are many similar types of installations in the city where people look for good contractors and end up making their final decision based on the quick and dirty option. At the corner where the boards of this makeshift type of installation meet, the quality is so lacking that even a slapdash type approach could be done better. 5. Cost Prohibitive: Skilled labor, specialized tools, and the time required for replicating historic elements contribute to significantly higher costs compared to modern construction techniques. Budget constraints often deter attempts at precise replication. Loss of Traditional Knowledge: With the shift towards contemporary construction methods, traditional knowledge and techniques have eroded. Many aspects of historic craftsmanship are not well-documented, making it harder to reproduce accurately. In our company, we see this issue firsthand, the knowledge we have acquired over the decades of our experience lives in our minds alone as it was taught to us decades ago by the people who taught us. We try to teach that knowledge to all of our staff, we require them to learn lots of it, and we even write it here in this blog, but understandably not everyone of our readers want to dedicate themselves to a deep endeavor of learning all the secrets of historic restoration. It’s easy to make excuses and to give people the benefit of the doubt. but there are subtle details about the elements of the historic facade of this building that show that care has been lacking for decades. The beautiful iron work at the guardrail has been repainted many times but really has never been cleaned back to the substrate, at least in recent decades, to the point that a good coat of paint could be applied. The deterioration curve is nonlinear. Where rusty metal is repainted without being cleaned, it rusted through again and it deteriorates the paint faster and therefore becomes worse, but more so and at an even faster rate. The pictures below show a series of rowhomes built together. The building at the center of the photograph has a tympanum at the center of the head of the facade. The entire collection of details in these particular buildings are made with kiln fired clay brick and terracotta elements. Like many historic brick buildings in Washington DC, these buildings are built with structural brick and structural demising walls and facades. Once historic architecture is lost, it’s lost forever and why preservation and conservation is valuable.The picture below shows a simple facade and yard, yet simple in both scale and detail it is well maintained entry and building exterior. Another similar example with a cast iron stairway, leading to the front entry, follows below. This particular example is also small and scale and simple in level of intricacy in detail yet it is well maintained and treated with proper care. even in these two examples, a significant amount of effort and upkeep and maintenance is required and even though they look great as shown here, they still need work to repair and maintain many elements of the front facade. Unlike modern construction, here there are no shelf / relief angles used in the construction. The building at the right has two angled soldier course freezes. The Roman arches are decorated with a rounded bricklayer following the contour of the openings. Preservation is very expensive, but it’s important to really understand the Alternatives and the points of comparison because expense, for example is only really assessed as an empirical value through comparison. In other words, you can say something is expensive, but it doesn’t really accurately have a meaning or value unless it’s compared to an alternative. Historic preservation is costly, but only when compared to Modern production construction. Modern production construction is cheap. assembly line style labor requires very little training and almost anyone can do it. The work is clearly hard on the body and fraught with risks, but it doesn’t require the extensive amount of study and training and development of human resources. people can do it almost right away as their very first job. That makes the job very cheap. So when people say or think that preservation is expensive, it’s important to consider that comparative argument in terms of the alternative. A stick framed tract home in the country may only cost $400 per square foot, but when you think about the drivers of both cost and value, it’s hard to imagine why it even cost that much. The real details of historic construction are almost Irreplaceable for many reasons. We explained that the trade craftsmanship is not largely present in the construction industry today. Companies like ours are unique. The vast majority of companies or contractors in the industry do not focus on historic restoration. Materials such as historic pressed bricks are not available. Even lime mortar today is technically different than historic lime mortar. This is a very important topic and element to understand when taking on a historic brick-repointing project. Our company specializes in this type of work, but most people don’t even understand the basics. An elaborate Italianate door pediment and surround is shown in the image below. The small projecting header above the door surround works as a water table, effectively a very small roof, like a modern awning. This projection, like many of the architectural details in a facade, where there is a projection, protects the architectural elements below from the full exposure of the majority of horizontal precipitation and rain. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, it’s not just the loss of value to the property owner, there’s also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, contact us or fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post Unique Elements of Historic Brick Architecture – PART II first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/masonry/unique-elements-of-historic-brick-architecture-part-ii/ Last week, we published an article starting a conversation about several fundamental aspects of basement foundations and waterproofing. Not all houses in Washington, DC or even commercial buildings for that matter have basements. Some of those buildings are set on relatively shallow footings, generally built below the height of a frost line, but in some cases even shallower than what is required by modern code (to be above a frost line). In Capitol Hill, Georgetown and other historic neighborhoods of Washington DC though there are thousands of buildings built in rowhome type configurations with basements. Not all of these basement areas were originally finished and even today some of those areas remain unfinished, just used for the sake of utility purposes. Today we’ll take a closer look at areaway drains, typically used on the exterior of buildings in areas that are significantly or even just slightly below grade. Areaway drains can also be installed in interior spaces. In some cases areaway drains are similar to shower drains. The outline for today’s article follows:
In a coming article, we will also follow up on areaway drains and touch on the following topics:
Where Areaway Drains are NeededBasement entrances are often set below grade, the level of the ground surrounding a building. Area drains in below-grade contexts, such as external below-grade entryways or window wells, collect water runoff precipitation or as heavy rains may flow at the base of a building. Areaway drains prevent water infiltration into basements or lower levels of buildings by providing a drainage point for water that collects in these below-grade spaces. Last week we talked about basement wells and we presented the photo below. This particular example is a bit of an anomaly. It’s very common for an entry well such as the landing at the bottom of the stairwell, below grade at the entrance to a basement, to have an areaway drain or a linear trench drain. It’s rare though for an entrance like this to have both a linear trench drain and an areaway drain. Normally it’s either one or the other. It’s important for the concrete base floor of the landing or bottom of the stairwell to be sloped towards the drain. In this case though since there are effectively two different drains it’s an odd context or configuration for the slope to go in both directions. It’s possible to build a crown between each of these drains but that’s not the case in this particular circumstance and it would be an odd unique configuration. In the context of construction and architecture, a “well” can refer to various features designed to create access, allow natural light, or provide escape routes in below-grade or partially below-grade structures. Common types of wells include window wells, entry landing wells, and root cellars wells, common in historic masonry buildings of Washington, DC, for example. A window well is an excavation or structure built around a below-grade window to allow natural light into basement or below-ground spaces. It often includes steps or a ladder for safe egress and may serve as an emergency exit. Codes, outside of the building code, in many circumstances require multiple means of egress. A below-grade stairwell well is an enclosure or shaft that provides access to a basement or lower-level area through stairs. It is typically designed to facilitate safe and convenient movement between different levels of a building. These wells can vary in design, shape, and purpose but are generally constructed to enhance the functionality, safety, and aesthetics of below-grade spaces. Window wells, for example, are particularly important in basements to provide natural light, ventilation, and emergency egress. Stairwell wells are essential for safe access to lower levels, and coal cellar wells are used to create conditions for coal storage, in historic heating applications. Each type of well serves a specific function in the context of a building’s design and use. Similar to a well, in some ways but different in overall context, the picture below shows an areaway drain in a paved patio area. Like a well, one side of the paved patio area is below the upper grade, but the other side of the paved area leads to steps going further downward. Instead of installing an areaway drain as shown in the picture below, the water could be directed down the steps. However, in climate such as here in Washington DC where there are numerous freeze-thaw cycles every winter, draining water down a set of masonry or brick steps can cause a slip hazard area where ice slicks can build up with flowing water in rains at temperatures hovering around 32°F. When simply walking on the brick paved area, it basically feels natural in flat, but there is a very slight grade headed towards the drain. Graded areas like this should have a pitch of at least 1/4 inch of fall per linear foot and no more than about ½ of an inch per linear foot. 3/4 of an inch of grade per linear foot, for example, is relatively extreme. More than about 1/2 of an inch will make the area feel like a palpable or noticeable angle, slope In the range of about 1/4 to ⅜ of an inch per linear foot is a better range. Hydrostatic Pressure Relief Weep HolesThe picture below shows the greater context of the area, entrance to the lower level from the exterior, the landing, the stairwell and the base of retaining walls at the below grade entrance stairwell at the side of the building. The masonry walls at the sides of the stairwell were built without proper or modern types of waterproofing and or hydrostatic pressure relief systems. You can see efflorescence on the surface of the brick including discoloration from prolonged exposure to groundwater without proper mitigation systems. Retrofitted weeps have been installed into the historic brick masonry walls of the retaining wall but those weeps or a secondary type of mitigation and are treating the symptoms instead of the disease. (In this particular case, we refer to this type of weep hole as “retrofitted” because it has been installed after the original construction of the wall and it is not a proper hydrostatic pressure relief system.) If the hydrostatic pressure relief system was installed or built at the time of construction of the retaining wall then it would be an overall more elaborate system with additional components. Some of the additional components include a horizontal or parallel perforated collection pipe that runs in line with the base of the wall and a filter fabric type sock or blanket that wraps around the pipe only separated by crushed stone or aggregate rock. Together, these elements allow the system to effectively drain water, and mitigate build up of water on the exterior or Earth side of the wall. Weeps allow a near-constant stream of water to run from the retaining wall and then land on the concrete area way and across the area away towards the drain. While this type of installation may be better than no weeps at all, this particular installation is still fraught with a list of shortcomings and problems. One of the key sources of these problems is that as water builds up against the wall, as the hydrostatic pressure increases, it leads to permeation of the water into the joints of the masonry retaining wall which accelerates deterioration. Restoration and remediation attempts such as repointing or tuckpointing or joint pointing are largely effective in most cases of restoration at facade walls, for example. However, in cases of hydrostatic pressure, repointing only addresses the common symptoms, not the root causes. Water can enter from above, run down the steps or permeate and or drain through the retaining walls. This particular stairwell has an enclosure built above, yet, it’s not a permanent or fully weatherproof envelope. The old masonry walls of the surround lack proper hydrostatic relief. The drain has been applied after the original construction and is undersized. As well, more weeps should have been installed, one is insufficient, and they should be installed lower in the base of the wall. A full perimeter water collection system could have avoided dumping water directly at this location which leads to an icing / slip danger in the winter. Dumping a concentrated load of water directly at a walkway is a danger and a nuisance which could have been avoided through better initial design. There are different levels of potential problems associated with drainage and areaway drains at paved areas, particularly at wells or suppressed locations like landings at stairwells. One of the main and primary concerns is preventing water from building up and reaching a weir or dam location like a door transition or threshold. Once water builds up to a point that is higher than the threshold, water will enter in around the door. Like we mentioned above, residential or even commercial or industrial doors may have strong properties of water tightness or waterproofing, but they are not as watertight as a submarine door. Water will get around the opening between the door jamb and the door leaf itself once water builds up to the height of the transition or threshold, so the primary concern is understandable: keep water flowing away so it doesn’t flood into the interior of the building. A secondary but nonetheless important goal of these drain systems is to prevent water from deteriorating the concrete, cementitious-based, and or brick or masonry paving at the patio and adjacent retaining walls. Several different types of building materials are available for building things like dug out or excavated stairwells, window wells or other suppressed areas below grade. By and large though the number one type of material used for this type of construction, in Washington DC and surrounding areas, is brick and masonry. In some cases concrete or stone are also used but brick is one of the largest types of classifications of materials used in retaining wall construction in Washington DC. Protecting this masonry from accelerated deterioration is essential in preserving the health of the structural elements of the building. Brick pointing and or repointing are types of restoration that are typically done to improve the condition of brick masonry, particularly in the case of historic brick, but repointing or tuckpointing alone is not enough to fix the problems associated with drains in areaways or paving that do not work properly. The collage of pictures below shows several different types of catch basins and or ground drains that are similar to areaway drains but instead of being installed in typical patios or areaways, they are installed in areas where ponding or flooding happens because of low grade, in comparison to the adjacent grade. They work very similarly. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, it’s not just the loss of value to the property owner, there’s also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post Areaway Drains – Part I first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/blog/areaway-drains-part-i/ Over the next month or so we’re going to talk about several fundamental aspects of basement foundations and waterproofing. Not all houses in Washington, DC or even commercial buildings for that matter have basements. Some of those buildings are set on relatively shallow footings, generally built below the height of a frost line, but in some cases even shallower than what is required by modern code (to be above a frost line). In Capitol Hill, Georgetown and other historic neighborhoods of Washington DC though there are thousands of buildings built in rowhome type configurations with basements. Not all of these basement areas were originally finished and even today some of those areas remain unfinished, just used for the sake of utility purposes. The basement shown in the adjacent photo has been finished throughout, except for mechanical closets. The back room was converted into a tool workshop. Glass block was installed in the original window opening, allowing the opening to provide light from the outdoors, but not to provide ventilation or fresh air from the outside. The positive trade off though here is that this opening can no longer easily leak from precipitation and or rain. The outline for today’s article follows: Using a basement to add additional interior spaceIn many cases, even in circumstances of finished basements, there are often utility rooms within the basement areas. These utility rooms are often used for laundry equipment, slop sinks, heating and or cooling equipment, electrical distribution panels, and boilers. The majority of the buildings built in the historic neighborhoods of Washington DC we’re built over 100 years ago. At that time, Most of the buildings in the historic neighborhoods of Washington DC were considered sufficiently ample by the inhabitants and occupants of the buildings. In fact at that time basements were rarely considered a useful part of the building. In some cases basements were used as root cellars, but in most cases they didn’t even have floors installed, it was mostly just bare compacted dirt. The majority of the now common basement renovations didn’t happen in Washington DC historic neighborhoods until about 30 to 40 years ago. The picture below shows a window well to a basement interior space at the exterior of the building at a granite retaining wall foundation of a building. The light well is covered with an iron grate with a mesh applied on top of the heavier steel bars. This particular grate was not installed just for security, but it was also created to prevent someone from accidentally stepping on top of the area of the well and falling down and injuring themselves. The foundation walls, generally surrounding the perimeter of the basement, and in some cases with internal load path footings as well, generally provide the structural bearing points of the building. These elements of the structure are considered part of the backbone and fundamental elements of the structure. The condition and upkeep of these elements is important, but basement waterproofing or damp proofing, and associated failures or defects, are also a recurring issue that is constantly discussed by building owners in Washington DC. Square footage, interior space, and building space for that matter are all very valuable here in Washington DC. Real estate is simply very expensive and for that reason, people attempt to optimize the use of all of the space they have within their property. Often people will build out parts of the basement to convert the space into children’s play areas, bedrooms for guests, or even permanent bedrooms and or offices in the basement area. Also it’s very common to find dens or rumpus rooms or living room type areas in the basement, generally not the main living rooms of the house, but often used as places for watching TV or just relaxing, more cloistered and away from the rest of the world. The purpose of windows and fenestration in a basementBasements tend to be much darker space but also quieter than the upper levels of the building. For that reason sometimes they have a little bit more of a relaxed feel. basements are a bit more secluded and private. Fenestrations within a building bridge the gap between its exterior and interior, in many ways. Nevertheless, they serve as the most vulnerable points through which heat can escape or enter, as well as light can penetrate. Addressing the escalating energy requirements of a structure necessitates the incorporation of both active and passive strategies. Particularly, with windows and basements, generally the below ground portion of the window area will be installed in a well, set up to essentially allow an excavation below ground to service the window. The excavated well both allows for airflow to come in and out of the window for exhaust and or fresh air intake and also allows a degree of light to enter the building. By and large though these windows can be also problematic because of their points of significant problems with water entry. The infrastructure type framework around the well must be built to drain water or moisture that accumulates in the area of the well and also must be built with a cover of some sort to prevent water from flowing directly down into the well or at least have an integral drain in the well so that water can flow away. Yet drains are not always found in window wells. Without a drain installed in a well, it’s extremely important that a cover is built above the drain to keep the well dry. The picture below also shows a closer view of the inside of that window opening from the interior basement. The glass block, in addition to a higher degree of protection from leakage, also provides a higher level of security than a regular window. regular double hung or double sash windows provide significant benefits over glass block. Some reasons window wells leak and preventionWhether it be a roof leak, a plumbing drip, or a foundation leak, water in a building or a home is a big problem, scary enough to keep the occupants, residents and or building owners awake at night worried about potential problems of rainstorms or the pipe leaks associated with these problems. The picture below shows a view of a basement window well from a wider angle. You can see that the eave of the roof projects away from the building, a little bit further away from the building then the depth of the window well. In most non wind driven rain or precipitation conditions, this will allow water to flow away from the building and not fall into or run towards the window well. A lot of the preventative types of best practices related to preventing problems, failures, and defects which result in flooding related to window wells stem from design errors and or omissions. Before a contractor is even engaged, if an architect or designer is involved in the original construction, these types of problems should be rooted out through the design itself. If the building is already built though, it is essential that you work with a good contractor who understands the principles of waterproofing and structural building elements. If the building wasn’t designed properly and doesn’t have systems in place to channel and divert water flow away from window wells, for example, then a contractor will have to do a much more extensive type of work to retrofit existing conditions. retro-fitting is generally more complicated than the same work ceteris paribus, at the time of the original construction. A list of types of elements used to retrofit or build better from the beginning, follow below.
The next picture below shows a very common type of areaway drain in the center of the landing outside of the door. Areaway drains are often installed in paving areas, such as a concrete slab where the slab or paving area cannot drain from gravity alone. In this particular case, this is an entry access pathway, excavated below grade with a stairwell leading up to the ground level of the exterior yard of the building. Traditionally, in historic times, when most of the buildings in the historic neighborhoods of Washington, DC were built, drains were often built with cast iron. The drain shown below is made from PVC. In addition to the round drain with a square trim around the perimeter of the round drain, there’s also a linear trench drain closer to the entry doorway. The picture below shows a typical rear entrance to the back of a row home building. Most Washington, DC row homes with basements, in historic neighborhoods, have rear entrances similar to this one. This particular entrance though is shared between the two neighboring buildings. It was originally built with one areaway drain only. That areaway drain at this point in time is completely clogged with dirt. Even now, here in early fall, in mid-October, most of the leaves are still on the nearby trees yet the leaves that have fallen are already have drifted down into this basement stairway floor. Tree leaves, like this are very problematic with areaway drains. Typical round areaway drains are not very large, they’re commonly only roughly six to nine inches in diameter and therein have a area of less than one half of a square foot. By comparison though linear trench drains are about 5 in x 36 in at minimum and therein have a larger rectilinear area with a lineal shape which is harder to clog. As water builds up and washes around an area drain, leaves can pile up right in the center but with a linear trench drain, leaves have a tendency to wash to one side or the other as water runs towards that area of the drain, normally in the lower slope part of the patio or paving. The next picture below shows a different basement entry. This particular basement entry has an enclosure around the perimeter and has an aluminum roof overhead. This type of assembly essentially keeps water out of that area, especially at regular and even heavy rainstorms. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, it’s not just the loss of value to the property owner, there’s also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, contact us or fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post Basement Window Wells – PART I first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/interiors/basement-window-wells-part-i/ Today, we are starting a multi-part series on the unique elements of historic brick architecture that are not easily effectively replicated in modern or contemporary construction. It’s not only often difficult to replicate historic elements of design and architecture, but sometimes attempts at such replication fails so badly that the poor quality of the forgery stands out looking very badly. Often, new buildings are placed in historic neighborhoods and are given requirements by the AHJ to include elements of historic details, as a type of conformity, but most often the differences are glaring. The adjacent picture shows a historic brick and Brownstone row building. This building, like many buildings in historic Urban environments, is in need of an extensive level of restoration and repair. overall though, the original historic elements are still apparent and even in a dilapidated form look beautiful. The hooded window and door lintels at the ground level, the elaborate cornice, the corbel supported balcony, the grand front stoop and recessed entryway are elements that highlight the beauty of the original architecture. The next picture below shows the beautiful historic masonry elements of this front building facade. The hand carved stonework is unique, it is rarely found in modern or contemporary masonry construction. You can learn more about brownstone construction at the following link. Although the architectural details of the original construction are incredibly beautiful and unique, there is significant deterioration to this particular Brownstone facade. Brownstone is a relatively weak stone, susceptible to acid rain and deterioration over time. in the picture below you can see significant deterioration at the facade around the front main entrance opening and at the front balcony guard rail. Unique elements of architectureWhen you look over and survey the elements of a historic masonry facade, you can see there are several elements that are common in historic buildings that don’t really exist in modern construction. Modern alternatives may exist, but they’re noticeably different from their historic predecessors. The list below includes many of the different types of architectural elements common in historic brick buildings of Washington dc. We’ve talked about many of the items below and have even posted articles showcasing these types of elements:
The picture below shows a grand front stoop to a historic brick mansion now with an interior converted to many condominiums within the building. The building base is clad with at stone panel, likely a sandstone, possibly a limestone, but now that stone, along with the front stoop stringers and newells are now painted making it difficult to see the original stone surface. The main entrance to the building is recessed with a stone surround. The majority of contemporary or modern construction, even the most high-end and expensive or Elite type building designs will often use materials as alternatives to stone. would entryway surrounds our common, but these types of elements have significant downsides such as rot and deterioration over time. Even though this particular door opening is over 100 years old, it is held up very well and is still in its (near) original condition. Stone deteriorates very slowly. Brownstone as an alternative as shown in the first building displayed at the top of this article is a bit of an aberration. In contrast, other types of stone, such as granite or limestone, are generally harder and less porous, making them more resistant to weathering and erosion. Brick facades, when properly constructed and maintained and pointed or repointied, in a timely fashion, are also durable and can withstand the test of time. Brownstone is a type of sandstone that is relatively soft compared to other stone materials. It’s composed of grains of sand held together by natural cements. This composition makes it more susceptible to weathering and erosion over time. As well, brownstone is relatively porous, meaning it can absorb moisture and is more susceptible to water infiltration. When water enters the stone, it can cause cracks, spalling (surface peeling), and erosion. Within the grand entrance of this building there is an additional door, this type of installation is common in many buildings creating a vestibule to keep out the cold while people enter or exit the building. The door itself and the adjacent wainscoting are carved wood panels, adding to the aesthetic beauty of the entryway. The stone surround at the perimeter of this large door opening is several inches thick, proud of the adjacent substrate brick wall, cut with a pitching chisel by hand. Historic stone was shaped with a pitching chisel, and elements of carved stone were often used as door and window casings and headers in historic brick buildings for several reasons:
For example, brownstone was a common building material in some East Coast cities like New York, and its ease of carving and attractive color made it popular for decorative and structural purposes. As Brownstone constructions became popular in NYC, some of those designs made their way down to cities like Washington, DC. Using carved stone elements as door and window casings, lintels, and headers in brick buildings was a common practice, especially during the 19th and early 20th centuries. It combined the durability and strength of stone with the aesthetic and architectural needs of the building, resulting in structures that were not only functional but also visually appealing. Other buildings have similar Grand entryways, but in the picture below an alternative type of construction shows a landing before the front door with a turn in The stairway to limit the length of the stair treads into the public walkway. Some of the elements of the historic ironwork have been replaced, but in a manner that is relatively consistent with the design of the historic buildings of the time. The brickwork of the building in the pictures above was reported with a red mortar, similar to the motor of the original brickwork and similar to the color of the remaining bricks. whereas by comparison the brick in the pictures below has been reported with a white color mortar. Both buildings are built with pressed bricks with a relatively thin butter joint, however the joints of the brick work in the photo below. On the right hand side of the photo below, you can see a iron work type panel. this is either cast iron or made to replicate cast iron but it is not original to the construction of the building and has been applied as a decorative element. It doesn’t look bad, but is an example of the lengths people take at times to replicate historic design elements or at least the look of historic elements. Although it is inauthentic, it’s still an example that highlights the value of real authentic historic elements. If you look closely at the photograph above, you can see that the iron work has rusted and some of that iron oxide rust has leached down onto the white marble stone below at the stair treads and risers. Even though this particular ironwork installation is not historic, it’s still been here for some time and now that it is without care and upkeep it is beginning to deteriorate. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, it’s not just the loss of value to the property owner, there’s also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, contact us or fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post Unique Elements of Historic Brick Architecture – PART I first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/masonry/unique-elements-of-historic-brick-architecture-part-i/ In the past we’ve discussed a variety of different types of repairs to masonry construction. Some of the main restoration types include repointing and tuckpointing of historic brick masonry. Today we are taking a close look at a very specific type of repair within stone masonry units. By comparison, repointing or brick pointing is a type of masonry restoration that addresses the mortar joints surrounding the individual masonry units within a wall or construction assembly. This type of restoration can apply to both brick and stone, but it specifically applies to repairing the historic mortar where it has deteriorated in the joints that surround each individual masonry unit. With large masonry units, such as stone treads, in the example that we are going to look at today, the size or area of the damage may be relatively small in comparison to the overall size of the masonry unit. In such cases where the damage is limited or small in overall scale, sometimes it makes sense to repair the area within the unit instead of replacing the unit. Dutchman patches are commonly used in the conservation of historic stone buildings, monuments, and sculptures. They can be applied to a wide range of stone types, from limestone to marble and sandstone. The picture below shows a historic marble staircase. The treads and risers are monolithic, together, one piece of cut stone. These individual pieces are cut from much larger stones but exrraxted entirely whole. At a glance, you can see that there are signs of dirt and stains on the face of the treads and risers, but it almost looks as if there is no significant damage. When you look closer though you can see there are spots in the middle of the treads and parts of the nosing and risers as well where patches have been installed. In the past, there was a handrail installed in the middle of this stairway. Sometime ago that handrail was removed but the locations where the handrail post mounted to the stair treads left an omission. That omission was filled with a Dutchman patch. A Dutchman patch is a type of patch, different than filling a void with mortar, in this case the area of the stone was cut out larger than the original void or core cut-out After the larger area was cut, a new piece of closely resembling or matching stone was cut to the same shape and then installed within that void to create a near seamless patch. When you look closely though you can see the evidence of the patchwork. In the picture above, you can see several areas where the patching was installed. The patching was intended to blend in with the adjacent stone, however there are several places where the rusting iron oxide, from the ferrous metal handrail and post left iron oxide, rust stains, on the face of the stone treads. Iron oxide stains on the face of stonework can be challenging to remove because they result from the oxidation of iron particles which have entered into the stone, which can penetrate deep into the material. The process to remove these stains depends on the severity of the staining and the type of stone involved. Iron oxide stains often penetrate deep into the stone’s pores, making surface cleaning insufficient. The method for removing stains depends on the type of stone. Some stones are more sensitive to cleaning agents, and aggressive approaches can cause further damage. Aggressive chemical treatments can alter the stone’s appearance, weaken its surface, or cause discoloration. Striking the right balance can be difficult and complicated. A chemical poultice can be used, in some cases, for light to moderate staining. It involves applying a thick paste made from a chemical cleaner and an absorbent material to the stained area. The poultice draws out the iron oxide stains over time. Common chemicals include rust removers or diluted acids like citric acid. Some stains can be treated with biological agents like poultices made from specific types of fungi or bacteria. These organisms can break down the iron oxide over time. For more severe stains, acids like oxalic acid are used. However, using acids requires caution as they can harm the stone surface. In some cases, high-pressure steam cleaning can effectively remove iron oxide stains without the use of chemicals, but special equipment is required and efficacy can be limited. This method can be less invasive and more environmentally friendly. For extremely stubborn stains on harder stones, sandblasting or abrasive cleaning may be employed. However, these methods are aggressive and most often damage the stone or masonry surface. The choice of method should be determined by the type of stone, and the severity of staining. It’s important to assess the specific situation and follow the most appropriate and least invasive method to remove iron oxide stains without causing further harm to the stonework. Part of the challenge of Dutchman patches is the creation of an aged or weathered appearance on the new patch. This helps the patch to blend seamlessly with the older, weathered stone around it. The patch below is not completely visually effective because of the difference in the color of the two stone sources. The same challenge applies with brickwork, when replacing bricks selectively within a wall, for example, it may not be possible to procure bricks that convincingly match or visually resemble the original adjacent brickwork. In historic buildings, in DC neighborhoods such as Capitol Hill, for example, most of the original historic construction is from over one hundred years ago and bricks of the exact same source may not be available today, at all. In other cases though, even when procurement of a brick from the original source is possible, that brick, to be used for installation within an existing building assembly, may not have had the same exposure and aging or weathering required, over the past 100 years, for example. These varied characteristics can make a noticeable visual difference. The picture below shows an area of repair from a closer distance. At this location or within close proximity, there are two different patches that have been applied. One patch is within the field of the tread itself, in the middle of the flight of stair treads. The other smaller patch is at the nosing. These patches were likely needed for different reasons, and just coincidentally happened to be in proximity to one another. The patch at the middle of the tread was at the location where a post was formerly installed. The smaller patch at the nosing of the tread is likely a repair that happened after damage at the tread. Often, the noses of stair treads and risers are the most vulnerable parts of the structure of a stairway. Often the nosings will take the full brunt of equipment like hand trucks, often used to carry heavy materials or furniture and heavy equipment in and out of buildings. When a hand truck frame hits the edge of a stair nosing it not only is a strike with a hard force, but it’s also a concentrated area so it essentially multiplies the overall force of the impact. This outside corner of the nosing is at the most vulnerable spot because a 90° or near 90° corner has the least amount of support from adjacent materials at the sides of the outside corner. Here in the picture below you can see debris on the edge of the stair riser. It’s also interesting that the Dutchman patch in the stair nosing, both into the field of the tread and into the field of the riser has had an additional area of damage, after the original patch. A piece of the broken patch area was then used to fill in and plug an additional patch within the original Dutchman patch. It is a patch within a patch. The next picture below shows a different angle, from a closer distance at the same area of repair. You can see the outline of the patch I’m within the Dutchman patch more clearly. Although this particular type of repair is not always perfect, in some cases it can be executed in a way that is almost good enough, and sufficiently difficult to notice. Essentially, the overall visual integrity of the masonry area can remain aesthetically near indiscernible. The alternative of removing and / or replacing and rebuilding the stairway altogether may be exorbitantly expensive and may also not achieve the desired historic or classical architectural aesthetic. Preserving historic masonry and repairing damaged elements without fully replacing them is central to maintaining the authenticity and historical integrity of architecturally unique historic buildings. There are several techniques, in addition to dutchman patching, used in historic masonry restoration to achieve proper repair and preservation:
These techniques, often carried out by experienced conservators and restoration experts, play a critical role in preserving historic masonry and architectural elements. The emphasis is on retaining as much of the original material as possible, thus maintaining the historical authenticity and aesthetic of the structure. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, it’s not just the loss of value to the property owner, there’s also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, contact us or fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post Dutchman repairs in stone stair treads first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/masonry/dutchman-repairs-in-stone-stair-treads/ This past week, we started a discussion on the topic of how brick repointing and restoration in historic masonry can prevent detrimental failure. Masonry deteriorates over time, inevitably. Evidence of deterioration of historic brick buildings is visible throughout the historic neighborhoods of Washington DC. Unless a building has been uniquely and carefully protected and repaired, you can find signs of historic masonry deterioration. In fact, signs of deterioration, wear and aging are visible throughout the historic neighborhoods of Washington DC like as Capitol Hill. This past week we looked at how deterioration and destruction can be mitigated by repointing and historic masonry preservation, understanding the repointing process, and critical areas of restoration Today we will talk about why once historic architecture is lost, it’s lost forever and why preservation and conservation is valuable. We will also talk about cost implications, elements of historic architecture and why historic elements are difficult to replicate. The outline if today’s article follows:
In an upcoming article we will go into closer detail on the following topics:
The picture below shows a quintessential example of brick deterioration, the kind of mortar breakdown that leads to significant damage if not treated and restored properly and relatively quickly. Bricks and masonry generally deteriorates on a very long time scale slowly, but when left untreated, it can lead to much worse problems, exacerbating the actual core issue into a problem of structural failure. In this picture, several problems are readily observable. There are plants growing between the adjacent walkway concrete and the brick facade of the building. The deterioration of the mortar joints is so extensive that you can see the dark shadows between each brick where the mortar has receded. The adjacent property was built with a cold joint, in other words that adjacent facade is built against this next building’s facade, but they are not connected or interconnected with bricks in a continuous bond. That space at this point has deteriorated further to the point that plants are growing between the interstitial space caused by untreated masonry deterioration where restoration was and is still needed today. Simple restoration can include nothing more than repointing if done at the appropriate time. Here though in this example, that time has passed and it’s too late, now loose bricks have come out of the wall and need to be replaced. Once historic architecture is lost, it’s lost foreverWhy preservation and conservation is valuableOnce historic architecture is lost, it’s lost forever due to the irreplaceable nature of historic masonry elements. These elements, such as brickwork, stonework, and intricate mortar joints, are exceedingly challenging to replicate with the same authenticity and character as the originals. Preservation and conservation are valuable because they protect these unique masonry elements, which serve as integral components of historic buildings. When historic masonry is damaged or lost, replicating it becomes an arduous (near impossible in since cases, as we explain below) task. Modern materials and construction techniques often lack the aesthetic qualities, materials, and techniques used in the past. Attempting to recreate historic masonry may result in a diminished visual and structural quality, failing to capture the essence of the original. Furthermore, even if close approximations can be achieved, they may not possess the same historical and cultural value as the authentic elements. Historic masonry contributes to the storytelling of our past, showcasing architectural techniques, styles, and the social context of its time. Losing these elements means losing essential chapters of our collective history. Preservation efforts recognize the intrinsic value of historic masonry and strive to safeguard it for future generations, acknowledging that once these elements are gone, the opportunity to authentically recreate them diminishes significantly. Historic masonry not only bears the marks of time, weathering, and the installation methodologies of bygone eras, which cannot be easily duplicated, but it also was manufactured through different processes for which the plant and equipment no longer exists today. Subtle differences are readily available in the clay and lime of the past. For us to build a plant to manufacture these materials today in the way they were manufactured over 100 years ago, it would be extremely expensive because the original elements just don’t exist any longer. At the time of the construction of the majority of the historic buildings in Washington DC, the plants used for construction of these materials were built with a major economy of scale because one plant could produce materials to build hundreds of buildings. Today, no one would be willing to invest on a scale that significant just for the sake of replication of historic materials with a higher degree of authenticity. Instead, cheap attempts at forgery are used to replicate a few of the historic elements. The picture below shows an example of a garden wall between properties. This is a triple wythe wall, in other words, built in a three brick width. The masonry is currently significantly deteriorated in experiencing a type of failure called lateral deflection. We looked at this wall more closely, and showed photos from different angles, in a previous article a few weeks ago. In this case, you can see a fast growing Princess tree, aka Empress tree, Royal Paulownia (Paulownia tomentosa), growing into and out of the brick mortar. this plant is an example of biocolonization and will be one of the several factors that lead to complete destruction of the wall. The next picture below shows the same side of the same wall but from a lower angle. Here you can see the extensive bowing typical of severe lateral deflection. Lateral deflection is similar to bowing, or even undulation and buckling, of the wall. The extent of lateral deflection and associated bowing can only reach a certain point before the wall is no longer stable and the problem eventually then leads to collapse. This particular wall has a combination of structural problems, in addition to the lateral deflection. A cement parge coat has been smeared on the surface of the wall. This cement application, unlike stucco, is a single thin application, largely delaminated in this case. Parge coats, in some cases, can protect walls such as in bases of splashback, but also can lead to trapped moisture where partially delaminated and deteriorated. Cost ImplicationsMany of the urban centers of the eastern United States experienced a period of significant economic depression starting in the 1950′ and 1960’s. There are tons of signs that while this economic depression was largely caused by policy choices, manufactured to a large extent, it affected many people who had no direct power or control in that choice. In fact, throughout the 20th century, urban centers in the eastern United States, including Washington DC, experienced significant economic fluctuations. While some periods were marked by growth and prosperity, other times were filled with economic depression. The onset of these downturns often followed major historical events, such as World War I and II, which temporarily spurred economic activity, only to be followed by post-war recessions. Moreover, the mid-20th century saw a shift in economic dynamics, with the decline of traditional industries like manufacturing and the movement of populations to suburban areas, contributing to the economic challenges faced by urban centers. Cities like Washington, DC experienced significant social and economic struggles during this time following the 1960s. The root causes of economic depression in Eastern U.S. urban centers encompass a complex interplay of factors. Deindustrialization and the shift of manufacturing jobs led to a decline in economic opportunities, concentratedly with the working class. Social policies exacerbated disparities, resulting in underinvestment in specific neighborhoods. Furthermore, inefficient public administration, budgetary constraints, and the flight of tax revenues to the suburbs strained city finances. These challenges, coupled with inadequate infrastructure, contributed to deteriorating living conditions and increased crime rates, further deterring economic growth. Overall, the economic depression in urban centers like Washington DC was a multifaceted issue stemming from demographic shifts, industrial changes, public and private programs to drive inequalities, and governance challenges. Meanwhile, today while many parts of America are trying to make it harder to teach the truth about the past, the scars are left on the buildings right here in our city in Washington DC. The picture below shows another facade that we looked at in weeks past, but from a different side of the same building. You can see a steel structure that has been installed and created for temporary application to support the exterior facade of the building from collapse. This particular building is in such a deteriorated state that other parts of the building have already collapsed. This particular photograph is an example of the significant cost required to stabilize structures from further deterioration or debilitation once they reach a critical point. This is also a case where minimal routine preservation and maintenance could have been provided earlier in the life of the building to avoid the massive costs required now at this point. Restoration, even as simple as historic brick repointing, is expensive but saves so much money, this paradoxical relationship cannot be overstated. People intuitively think that deferring maintenance and upkeep will save money, and it does for a while, but there is a nonlinearity to the deterioration curve. That means that as building materials deteriorate they get worse and worse at a faster rate. Therefore, deferring required upkeep and maintenance for a month or year or decade may seem like a way to save money but the cost of that upkeep would have been small in comparison to the cost to fix the same things once they are further deteriorated. Around the other corner of the building, from the section shown in the photograph above with the steel support system, the area shown in the picture below has already collapsed and thousands of loose bricks lay in piles and strewn about on the ground. The next picture below shows the deteriorated interior structure hidden behind the large front facade of this building at the street side. This was once a beautiful historic industrial building, potentially worth millions of dollars, with the potential to be converted into a multitude of contemporary urban uses. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, it’s not just the loss of value to the property owner, there’s also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post How Brick Repointing Can Prevent Detrimental Failure – PART II first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/masonry/how-brick-repointing-can-prevent-detrimental-failure-part-ii/ In an article last week, we looked at the issues of insidious damage in historic brick walls. This week we are looking at how proper restoration, such as repointing, can prevent detrimental failure. The outline of todayâs article follows:
How deterioration and destruction can be mitigated by repointing and historic masonry preservationDeterioration and destruction of historic brick masonry can be effectively mitigated through repointing and historic masonry preservation. Historic brick masonry repointing can be a tedious and laborious process, but it pays off. The benefits of repointing can be the difference between a building that last for decades more, even indefinitely, with few incidences of water ingress through the masonry walls and walls that are drought with problems and eventually collapse. The picture below shows an example of a deteriorated area of historic brick mortar. You will notice that the existing brick is actually in ok condition, in this case, over 114 years after the original construction of this Capitol Hill rowhome in DC. Understanding the repointing processHistoric brick repointing involves several steps to ensure the longevity and aesthetics of the structure. Last week we looked at areas of significant deterioration which led to drastic failure of brick masonry structural walls. First, an assessment of the brickworkâs condition is conducted. Different walls of a building may be built with different types of mortar, even when those walls were built at the same time. This examination helps identify areas with damaged or deteriorated mortar joints and bricks, and disambiguate between pressed brick and common brick and butter joints of mortar and low lime binder mortars.. Once identified, the next step is to carefully remove the deteriorated mortar. This process is referred to as joint ârakingâ and it must be done carefully to minimize damage to the surrounding bricks. The reporting process, in itself leaves the bricks as they are, in their current state and just removes and replaces the mortar at the outer edge of the wall, generally to a depth no greater than 1.25 inches. In some cases selective bricks may also need to be removed and replaced, where they are damaged or failed. this is relatively rare in most cases and is technically separate from the reporting process itself but it may be advantageous to do these types of work at the same time. After removal, the new mortar mixture is prepared to be similar to the historic mortarâs composition with highest focus on compressive strength, followed by permeability. People often misunderstand the process and believe that color and texture matching are central to ensuring the repointing work blends seamlessly with the existing masonry. In reality though, those elements are second to strength and permeability. The repointing process then involves the tedious process of filling the grooves left by the removed mortar with the new mortar mixture. The exposed mortar joint is tooled to give it a contour or tooled shape. Often common walls of historic masonry had a flush strike. Finally, after the repointed mortar has mostly cured, the area of repair is cleaned to remove any excess mortar and to reveal the restored brick masonry. It is important to NOT use the same acidic cleaners used on new modern âhardâ mortars. Overall, historic brick masonry repointing requires a careful approach, attention to detail, and a commitment to preserving the historical integrity of the building. This process not only indirectly bolsters or ameliorates the structural concerns but also ensures the continued longevity of historic brick structures. The picture below shows a different and unique circumstance, an aberration from a typical pointing process. This particular wall was built next to an adjacent finished wall. Often in rows of rowhomes, buildings will be built together at the same time and share the internal side walls of the buildings. In this particular case though this wall was built with the other one in place in a âblindâ type of process. The builders of the currently remaining wall shown in this picture could not access the outer side of the wall, currently viewable in the picture below. At that time, the other older building, now collapsed and gone, was built right up to the property line and this new building, the wall shown here, was built tight against that building. there was a small interstitial space, but that space could not be accessed by the builders. Critical areas of RestorationOften we find that particular areas of the building need a higher level of attention than the remainder or larger portion of the buildingâs historic brickwork. The picture below shows a thickened triple wythe base of an exterior wall at the ground level, next to a concrete walkway. You can see the few small remnants of a scam pointing done years ago by an untrained contractor. There are deep voids remaining in the older mortar behind the areas of scam pointing. scam pointing is a process of smearing newer mortar on top of an existing joint without providing the essential step of raking the old mortar away from the brick mortar joint. Above, we explained that the raking step is an important part of the brick repointing and restoration process. That process involves removing deteriorated mortar to a depth of up to 1.25 in into the wall area. That is relatively deep compared to the amount of raking done in the section of the wall shown in the photo below by prior contractors, years ago. you can see that there is a stark visual difference in the color and texture of the newer mortar and the original mortar from over 100 years ago. the small few pieces that are left that are basically flush with the surface of the brick are the areas of newer mortar. the areas of mortar behind that of a lighter, whiter, color are areas of original mortar and those areas of original mortar are only removed to a depth of approximately 3/8 of an inch, except for a few critical areas where erosion of that remaining existing mortar has dug out the joint to a depth of over 2 inches deep. those areas are critically damaged from deterioration. The next photo below shows a closer view of the same area of the wall. With this clearer detail, you can see the extreme amount of deterioration at the lowest areas of the wall. At the brick at the corner, next to the stone threshold to the entry door of the building, the mortar is recessed all the way through to the depth of the brick, over 3.5 inches deep. This level of deterioration, if more extensive than the area shown, can indicate the building is in imminent danger of collapse. There though this most extensive amount of deterioration is limited to just affecting a few bricks at the edge of the wall. There is extensive damage to the other areas, but those areas of deterioration are not nearly as extensive. When a wall gets this bad though, especially in a larger area, repointing or tuckpointing may not be enough, the wall and its extensive deterioration may be too far gone at that point. Although we use the standard of 1.25 inches as the maximum amount of raking for repointing of joints in brickwork, there are cases when specific or acute areas of mortar must be repaired to an even deeper depth. If the amount of deterioration though is not limited to just spots and few spots at that, then repointing without needle shoring or an additional method of temporary stabilization of the wall may not be safe. Temporary needle shoring is a method of masonry stabilization, primarily used during construction, renovation, or restoration projects to provide immediate support to unstable masonry structures. The process involves strategically inserting temporary metal rods or âneedlesâ through the masonry to prevent further movement or collapse while necessary work is performed. First, a thorough assessment of the masonryâs condition is conducted to identify areas of weakness, structural damage, or instability. Here in our article from last week we show several examples of this type of critical instability. Once these areas are identified, holes are carefully drilled through the masonry at specific locations to accommodate the needles. The holes are typically larger in diameter than the needles to allow for adjustments. Metal needles, often made of steel or a similarly strong material, are then inserted through the drilled holes. These needles span the thickness of the masonry and protrude from both sides. On the exterior side, nuts and washers are often used to secured the needles to a temporary supporting structure and hold them firmly in place. The needles function as temporary reinforcements, redistributing the structural load and preventing any further deterioration or movement of the masonry during construction or repair work. Once the necessary work is completed, and the masonry is stabilized, the temporary needle shoring can be removed and the temporary holes used to allow for the needles can be removed. Temporary needle shoring plays a vital role in preserving the safety of workers executing the repairs (in cases of unsecured overhead loads) and the integrity of historic or damaged masonry structures during construction or restoration projects. The next three photos below show more examples of scam pointing. This particular photo in the next picture below is from a direct facing view of a portion of a brick wall. The contractor ostensibly doing the supposed repairs just smeared a white mortar paste onto the surface of the underlying substrate mortar. The underlying original mortar was already significantly aged and deteriorated and the new mortar smeared on top never really made cohesion or an effective bond to the substrate mortar. One of the problems with pointing without a raking process is that the new mortar needs to bond to a relatively stable substrate and the outer deteriorated edges of remaining mortars, where a wall is aged and deteriorated, are not strong. They are mostly sand and have lost the majority of the original binding components in the mortar mixture. The next picture below is actually a collage of two different photographs, looking at different angles of the same wall. This is the same wall as shown in the photo above. This historic brickwork still shows both the newer fake or scam mortar and the remaining original mortar, just below the surface. The original mortar is clearly from the time of the original construction of the building. you can see chunks of unslaked lime left and remaining in that original mortar. Historic masonry upkeep and preservationTo properly maintain, repair, and care for these historic buildings, a knowledge, interest and understanding of historic building principles is required. Here in Washington DC, historic masonry buildings are extremely expensive and the amount of financial loss caused by improper repointing and low quality construction is staggering. However, in addition to the direct financial value of the property, there is also a cultural loss when historic buildings are damaged. By comparison, consider neighboring poor cities, when historic buildings are damaged, itâs not just the loss of value to the property owner, thereâs also a loss to all inhabitants and visitors of a city, present and future, who care about architecture, history, and culture. We encourage all of our clients, and all readers of this article and to our blog in general, to prioritize the historic built environment of Washington DC and neighborhoods such as Capitol Hill, Dupont Circle, and Georgetown and become educated on on the difference between proper historic preservation versus improper work which leads to significant damage to the historic fabric of a building. From a conservation and preservation perspective, several approaches can be taken to improve conditions related to deteriorated historic brick masonry. Primarily, lime mortar brick joints and low temperature fired soft red clay bricks should be inspected and checked on a routine maintenance schedule, either seasonally or at least annually. If brick masonry is kept in good condition, the life of embedded wood elements can be significantly extended. Hire a professional contractor which specializes, understands and appreciates historic construction elements and buildings. You can learn a lot more on our blog. Feel free to check it out. If you have questions about the historic masonry of your building in Washington DC, contact us or fill out the webform below and drop us a line. We will be in touch if we can help. <p>The post How Brick Repointing Can Prevent Detrimental Failure first appeared on Infinity Design Solutions.</p> Via https://www.ids-dmv.com/masonry/how-brick-repointing-can-prevent-detrimental-failure/ |
About UsInfinity Design Solutions LLC (IDS) is a full service general contracting company in the heart of the Dupont Circle neighborhood of Washington, DC. We focus on repair and renovation of buildings and facilities in both historic designated neighborhoods and the commercial-zoned central business district of the city. Follow Us
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