University of Pennsylvania ScholarlyCommons Theses (Historic Preservation) Graduate Program in Historic Preservation 2016 Architectural Precast Concrete Wall Panels: Their Technological Evolution, Significance, and Preservation Grace Meloy University of Pennsylvania, [email protected] Follow this and additional works at: https://repository.upenn.edu/hp_theses Part of the Historic Preservation and Conservation Commons Meloy, Grace, "Architectural Precast Concrete Wall Panels: Their Technological Evolution, Significance, and Preservation" (2016). Theses (Historic Preservation). 608. https://repository.upenn.edu/hp_theses/608 Suggested Citation: Meloy, Grace (2016). Architectural Precast Concrete Wall Panels: Their Technological Evolution, Significance, and Preservation. (Masters Thesis). University of Pennsylvania, Philadelphia, PA. This paper is posted at ScholarlyCommons. https://repository.upenn.edu/hp_theses/608 For more information, please contact [email protected]. Architectural Precast Concrete Wall Panels: Their Technological Evolution, Significance, and Preservation Abstract Architectural precast concrete wall panels played an important role in mid-twentieth century architecture by providing a concrete technology that could be applied to the curtain wall system of construction utilized in this time period. Moreover, the precasting process, which enabled the controlled production of expressive facing concrete mixes and surface treatments and finishes, made this a concrete technology that could contribute to the architectural expression of the building. To promote the preservation of these panels, this thesis investigates and illuminates their historical and architectural significance in the United States in the mid-twentieth century. There are, however, numerous technical challenges to the physical preservation of architectural precast wall panels, the most significant of which is due ot their specially designed concrete mix and surface finish. Given the importance of preserving these characteristics, the general retroactive preservation action of applying patches to deteriorated concrete is unsatisfactory; instead, we must adopt a preventive approach. Towards this end, this thesis examines documents published in the United States between 1945 and 1975 that informed the design, production, and assembly of architectural precast wall panels. The information from these documents is used to trace the technological evolution of these panels and, ultimately, to identify potential material vulnerabilities and associated deterioration mechanisms to which they may be subject. This methodology provides foundational information to be used in the creation of preventive conservation plans for buildings constructed with this concrete technology. Keywords cast stone, concrete masonry units, American Concrete Institute, Precast/Prestresse d Concrete Institute, MoSai Disciplines Historic Preservation and Conservation Comments Suggested Citation: Meloy, Grace (2016). Architectural Precast Concrete Wall Panels: Their Technological Evolution, Significance, and Preservation. (Masters Thesis). University of Pennsylvania, Philadelphia, PA. This thesis or dissertation is available at ScholarlyCommons: https://repository.upenn.edu/hp_theses/608 ARCHITECTURAL PRECAST CONCRETE WALL PANELS: THEIR TECHNOLOGICAL EVOLUTION, SIGNIFICANCE, AND PRESERVATION Grace Meloy A THESIS in Historic Preservation Presented to the Faculties of the University of Pennsylvania in Partial Fulfillment of the Requirements of the Degree of MASTER OF SCIENCE IN HISTORIC PRESERVATION 2016 ________________________________________ Advisor Michael C. Henry, PE, AIA Adjunct Professor of Architecture ________________________________________ Program Chair Randall F. Mason, PhD Associate Professor ACKNOWLEDGEMENTS First and foremost, I would like to thank my advisor Michael C. Henry, PE, AIA. He pushed me throughout this thesis process, and throughout my two years in the University of Pennsylvania’s Historic Preservation program more broadly, to always think critically and consider how the gap between engineering and preservation may be bridged. This thesis allowed me to explore both of these fields, and Michael Henry’s encouragement was essential. I would also like to thank Randall Mason, Frank Matero, and the rest of the Historic Preservation faculty for their guidance and support over the last two years. From their teaching, I have learned more about preservation than I could have ever imagined. Additionally, I would like to thank my classmates for all of the wonderful and critical conversations we have had, and I hope we will continue to have, about preservation and its place in the world. It has been a pleasure to work with you. Finally, I want to thank my family and friends for their efforts to appreciate my interest in preserving concrete; I hope this topic has become a little more intriguing after all of our conversations. In particular, Alex Host read and edited my thesis in its entirety, and for that I am exceedingly grateful. ii TABLE OF CONTENTS ACKNOWLEDGEMENTS .......................................................................................................................... II LIST OF FIGURES ...................................................................................................................................... V LIST OF TABLES ..................................................................................................................................... VII CHAPTER 1: INTRODUCTION............................................................................................................... 1 CHAPTER 2: EARLY PRECAST CONCRETE BUILDING PRODUCTS—THE DEVELOPMENT OF ARCHITECTURAL PRECAST WALL PANELS .............................................. 6 Introduction ....................................................................................................................................................... 6 History of Reinforced Concrete .................................................................................................................. 6 Obstacles to Architectural Use of Reinforced Concrete ................................................................... 8 The Predecessors of Architectural Precast Wall Panels ................................................................ 12 Nascent Architectural Precast Wall Panels ......................................................................................... 16 World War II and Concrete ........................................................................................................................ 22 Conclusion......................................................................................................................................................... 23 CHAPTER 3: APPLICATION OF ARCHITECTURAL PRECAST WALL PANELS IN MID‐CENTURY ARCHITECTURE ....................................................................................................... 24 Development of the Curtain Wall System ............................................................................................ 24 Flourishing of Architectural Precast Wall Panels ............................................................................. 2 9 Modernist Architects and Architectural Precast Wall Panels ...................................................... 31 Variety of Buildings and Aesthetics ........................................................................................................ 37 Preservation Implications .......................................................................................................................... 45 CHAPTER 4: LITERATURE REVIEW—PATHOLOGIES AND PRESERVATION OF ARCHITECTURAL PRECAST WALL PANELS ................................................................................. 48 Introduction ..................................................................................................................................................... 48 Reinforced Concrete Pathologies ............................................................................................................ 48 Deterioration of Architectural Precast Wall Panels ........................................................................ 53 Deterioration Detection Methods ........................................................................................................... 55 Current Architectural Precast Wall Panel Preservation Strategies .......................................... 57 Conservation Strategies with Potential ................................................................................................ 58 Towards a Preventive Conservation Approach ................................................................................. 61 Conclusion......................................................................................................................................................... 64 CHAPTER 5: TECHNOLOGICAL EVOLUTION OF ARCHITECTURAL PRECAST WALL PANELS, 1945‐1975 ................................................................................................................ 65 Introduction ..................................................................................................................................................... 65 Precast’s Potential: 1945‐1950 ................................................................................................................ 67 1950‐1965: Pre‐ACI Symposium ............................................................................................................