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Terra Cotta Skyscrapers

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Terra Cotta Skyscrapers SEALANT, WATERPROOFING & RESTORATION INSTITUTE • EARLY WINTER 2017 • 39.5 THE HEIGHTS WE’LL GO FEATURE Figure 2. Home Insurance Building. Constructed in 1885 and often considered the fi rst skyscraper (demolished). Represents the prototype of stone cladding near grade and more economical clad- ding materials such as brick and terra cotta above. Figure 1. Marquette building constructed in 1895 with a one bay addition in 1905. View following completion of repair work. availability of Empire State Building, Terra Cotta structural metals New York, NY in the mid-19th century. The Soaring 1,454 feet into the Manhattan skyline, the Empire State skeleton frame Building is an icon of American culture. When they called ILD to enabled cladding test the observation level, various fl oors, and the fi rst vegetated systems to be roofs for leaks, we rose to the challenge. Our goal? Accuracy as lighter, resulting legendary as the building itself. in the decreased necessity for mass TRUSTED BY THE BEST. Skyscrapers masonry solely for Figured 3. Representative structural support. example of polychrome and Toll Free: 1.866.282.5325 [email protected] metallic glazed terra cotta By Edward Gerns and Anita Simon Several new uses popularized in the 1920s. of metal framing ollowing the 1871 Chicago Fire, building construction changed dramati- components, both cally as a result of several factors including availability of inexpensive for the primary rolled metal shapes, improved elevator technology, increased urban density, building structure and for cladding systems, and the desire to develop “fi reproof” buildings. Stone and brick had been were developed. With this evolution came new used extensively for centuries to construct buildings. The development fl exibility for veneer cladding options, particu- of the skeleton frame structural system was possible due to the increased larly for use of architectural terra cotta. 18 39.5 EARLY WINTER 2017 Figure 5. Installation of new GFRC cornice at the Mar- quette building replicating the original terra cotta cornice which was removed in 1950. Figure 4. Repairs in pregress at the Marquette building. The use of terra cotta for cladding was cotta had the same appearance as stone, motifs created innovative architectural The use of terra cotta for cladding was same appearance as stone, but was more colors used in combination with Art Deco generally limited in the United States but was more economical to produce and expressions. However, by around 1930, generally limited in the United States until economical to produce and the lightweight motifs created innovative architectural until around 1890. Around this time, terra the lightweight characteristic of terra cotta construction of terra cotta-clad skyscrapers around 1890. Around this time, terra cotta characteristic of terra cotta made for easier expressions. However, by around 1930, cotta became favored as a cost effective made for easier installation. A system of in Chicago was very limited. While became favored as a cost effective alterna- installation. A system of metal dowels, construction of terra cotta-clad skyscrapers alternative to stone for its fire resistance, metal dowels, J-hooks, wire ties, and shelf numerous terra cotta manufacturers tive to stone for its fi re resistance, durability, J-hooks, wire ties, and shelf angles enabled in Chicago was very limited. While numer- durability, aesthetic appearance, angles enabled terra cotta veneers to be existed in the Chicago area prior to 1930, by aesthetic appearance, and lightweight prop- terra cotta veneers to be attached to the ous terra cotta manufacturers existed in and lightweight properties. Chicago attached to the primary building structure 1950 almost all were out of business. erties. Chicago experienced rapid growth primary building structure with its own the Chicago area prior to 1930, by 1950 experienced rapid growth during this with its own independent system. during this time period and subsequently independent system. Stylistically, enhanc- almost all were out of business. time period and subsequently developed Stylistically, enhancing the appearance As these early skyscrapers began to age, developed the reputation as the origin city of ing the appearance of facades was simpli- the reputation as the origin city of today’s of facades was simplified through the the need to maintain and repair these today’s skyscraper, many of which incorpo- fi ed through the selection of ornamental As these early skyscrapers began to age, skyscraper, many of which incorporated selection of ornamental motifs that were buildings became important for the rated terra cotta cladding. In the Midwest, motifs that were available in company the need to maintain and repair these terra cotta cladding. In the Midwest, available in company catalogs of mass survival of this archetype. Beginning there were 10 terra cotta manufacturing catalogs of mass produced terra cotta units. buildings became important for the sur- there were 10 terra cotta manufacturing produced terra cotta units. around 1950, deterioration of some companies that were founded between 1868 vival of this archetype. Beginning around companies that were founded between elements of the terra cotta cladding and 1912. Chicago therefore provides excel- As the popularity of terra cotta increased, 1950, deterioration of some elements of 1868 and 1912. Chicago therefore provides As the popularity of terra cotta increased, assembly became inevitable. The lent examples of the evolution of skyscraper vitrifi ed (i.e. having the appearance of the terra cotta cladding assembly became excellent examples of the evolution of vitrified (i.e. having the appearance of deleterious effects of time emerged technology and use of terra cotta cladding smooth glass, similar to fi red ceramics) inevitable. The deleterious effects of time skyscraper technology and use of terra smooth glass, similar to fired ceramics) in the confluence of the carbonation for nearly 150 years. The design evolution glazes were used to create more dra- emerged in the confl uence of the carbon- cotta cladding for nearly 150 years. glazes were used to create more dramatic of the mortar within the wall system, and long-term performance characteristics of matic architectural expressions with white ation of the mortar within the wall system, The design evolution and long-term architectural expressions with white the consumption of the zinc coating terra cotta will be reviewed with representa- glazed units. The zenith of terra cotta the consumption of the zinc coating on performance characteristics of terra cotta glazed units. The zenith of terra cotta on galvanized steel components, the tive Chicago buildings constructed in the corresponded to the increased popular- galvanized steel components, the dete- will be reviewed with representative corresponded to the increased popularity deterioration of lead primer after 60 years 1890s through the 1920s. ity of Art Deco and the increased use of rioration of lead primer after 60 years of Chicago buildings constructed in the of Art Deco and the increased use of of service life, and effects of expansive polychrome (i.e. containing more than one service life, and effects of expansive forces 1890s through the 1920s. polychrome (i.e. containing more than forces of corrosion by-product due to Prior to the 1930s, Chicago skyscrapers color;one color; either either with with speckles speckles of one of one or more or ofthe corrosion proximity by-product of terra cotta due in to relation the proxim- to Priorwere typicallyto the 1930s, clad Chicago with a combination skyscrapers of colorsmore colors over a over solid a basesolid color;base color; or color or colorap- itysupporting of terra cotta steel in elements. relation Into supportingaddition, weremasonry typically materials clad includingwith a combination stone, brick, of pliedapplied to toareas areas of ofhigh high relief relief to to accentuate accentuate steelornamental elements. terra In cottaaddition, units ornamental often have masonryand terra materialscotta. Since including one of the stone, early brick, uses ornamental pieces on units;units; oror aa blendingblending terrarecessed cotta mortar units oftenjoints have that arerecessed difficult andof terra terra cotta cotta. was Since an economical one of the early alterna- of multiple individually-colored unitsunits mortarto access joints for pointing that are diffimaintenance, cult to access or for usestive forof terrastone, cotta the glazewas an developed economical during throughout entire facades)facades) andand metallicmetal- pointingnecessary maintenance, overall maintenance or necessary was overallsimply alternativeits manufacture for stone, was intendedthe glaze todeveloped replicate licfinishes fi nishes (Figure (Figure 3) (metallic3) (metallic finishes fi nishes maintenancedeferred. Consequently, was simply water deferred. intrusion Con- duringstone. Terra its manufacture cotta was now was being intended used to on incorporated elementselements suchsuch asas silversilver and and sequently,through joints water became intrusion a common through threat joints replicatethe upper stone. fl oors Terra of the cotta new was taller now building being gold in the firingfi ring process, creatingcreating anan becameto the integrity a common of the threat cladding to the systems. integrity used(Figure on 2). the Visually, upper floors the terra of thecotta new had taller the appearance similar to gilding).gilding). DramaticDramatic ofIn thecombination, cladding
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