Terra Cotta Skyscrapers in Chicago. Outline

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Sydney Strickland
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1 Restoration of Historic Terra Cotta Skyscrapers in Chicago Edward Gerns Wiss, Janney, Elstner Assoc. Inc. 10 South LaSalle, Chicago, IIlinois Outline Background Terra Cotta Wall Systems Case Studies Marquette Building, 1890s Santa Fe Building, 1900s Chicago Theatre, 1920s Carbide and Carbon Building, 1920s 1

2 Historic Development of Facades Industrial Revolution 1850s Elisha Otis- 1853/1854 2

3 Chicago Waterways 3

4 Chicago Fire

5 19 th Century Chicago 1880s Chicago 5

6 Fire Protection Fire Protection 6

7 1893 Worlds Fair Traditional Walls 1 ft. 6 ft. Early Chicago Skyscrapers 7

8 Code Requirements: Wall Thickness New York Chicago Chicago Population Growth

9 Chicago Soil Stratigraphy Pile Foundations 9

10 Pier Foundations Foundation Types 10

11 William LaBarron Skeleton Frame Structural System 11

12 Skeleton Frame Structural System Sequencing 12

13 System Loads Lateral Load Resisting Systems Lateral Load Resisting Systems Masonic Temple 13

14 Lateral Load Resisting Systems Old Colony Building 1890s-1920s Chicago 14

15 1890s-1920s Chicago Progress 15

16 Progress Terra Cotta James Taylor 16

Mold-hand packed Pressing Extrusion die Mold-slip cast Filling

17 Terra Cotta Production (in 10 seconds) Piece identification Remove fragment Achieve research Design Shop drawings Color selection Modeling Mold-hand packed Pressing Extrusion die Mold-slip cast Filling Removal/Detailing Drying Glazing Firing Installation!! Terra Cotta Cladding Components 17

18 1900s Detailing 1910s Detailing 18

19 1910s Detailing Sources of Distress Corrosion of substrate metals Loss of section Accumulation of scale Unaccommodated expansion: moisture Differential expansion: thermal Stacking Building movements Gravity Wind Seismic 19

20 Types of Distress Deterioration of joints Cracking Spalling In-plane Cracks Displacements Crazing Glaze Failure Corrosion Loss of Section 20

21 Corrosion Accumulation of Scale Corrosion Progression (loss of alkalinity - carbonation) ph= 12 decreasing Stage 1 Loss of protection Stage 2 Corrosion begins Stage 3 Distress 30 yrs. 60 yrs. time 21

22 Repair Issues Public Safety Repair Maintenance Aesthetics Long Term Performance Marquette Building 22

23 Construction completed: 1895 and 1905 Architect: Holabird & Roche Engineer: Purdy & Henderson 17 Stories tall feet One of the first skyscrapers completed in Chicago ca Foundation System Marquette Building 23

24 Original Terra Cotta Cornice Body Removed in 1950 Terra Cotta Cornice Toe Remained Behind 24

25 2001 Removal of original cornice created two issues: Aesthetically displeasing The toe was unprotected against deterioration Original Section 25

26 Original New 26

27 GFRC Cornice Panels 27

28 Public Streets/Safety Two- 2 hour time windows Minimize panel handling stresses Variations in the existing wall surface EQUALS : Need for expeditious structural connections 220 feet Installation 28

29 Installation Installation 29

30 Installation Installation 30

31 Installation Installation 31

32 Installation Terra Cotta Restoration 32

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34 34

35 35

36 36

37 ca. 1890s ca

38 Santa Fe Building Architect: D. H. Burnham Opened stories The building is significant as a historic site because Daniel Burnham and his staff made the 1909 Plan of Chicago in a penthouse on the northeast corner of the roof. 38

39 39

40 40

41 Strain Relief Strain Relief 41

42 Terra Cotta Restoration Corner Reconstruction 42

43 Corner Reconstruction Chicago Theatre Building 43

44 Architect: Rapp and Rapp 1921 Originally known as the Balaban and Katz Chicago Theatre 3880 seating capacity The building was added to the National Register of Historic Places in

45 Cornice Scope of Work Remove terra cotta Salvage units Install new shelf angles/clean and paint Reinstall new and salvaged units 45

46 46

47 Terra Cotta Support 47

48 48

49 49

50 Watertable Scope of Repair Remove terra cotta Salvage units Install new shelf angle Reinstall salvaged and new units Install sealant in upward facing joints 50

51 51

52 52

53 Carbon and Carbide Building Construction completed: 1929 Architect: Burnham Brothers 40 Stories tall- 503 feet One of the last buildings completed in Chicago prior to the Depression 53

54 Background Like many of the buildings of this time-period, the design incorporates the requirements of the 1923 zoning ordinance. Prior to this ordinance, skyscrapers in Chicago were limited in height (130 to 260 feet, depending on the time period). The 1923 zoning laws allowed skyscrapers to have a tower as long as the tower did not take up more than one quarter of the lot size. 54

55 Spandrel Details Corner Details 55

56 Pier Details Unique Conditions 56

57 Spandrel Conditions Hung Lintels 57

58 58

59 Strain Relief Shelf Angle Location Supplemental Lateral Anchors Previously Sealed Crack In-situ Lateral Anchors Back Spalling Testing-Verification 59

60 Evaluation of Substrate Spandrel Steel Evaluation 60

61 Installation of New Hanger Rod Lintel Replacement 61

62 Replacement Steel 62

Practice Points NUMBER

Practice Points NUMBER 15 T E R R A C O T T A Architectural Terra Cotta E d w a r d G E r n s a n d r a c h E l w i l l Terra cotta has been used as a building material for thousands of years. Literally