HISTORIC MASONRY CLADDING

Transcription

1 HISTORIC MASONRY CLADDING COLUMBIA UNIVERSITY GSAPP - A4124 BUILDING SYSTEMS AND MATERIALS DEC. 07, 2016 Chris Gembinski, Assistant Adjunct Professor

2 HISTORIC MASONRY CLADDING FUNCTION AND REQUIREMENTS

3 FUNCTION OF CLADDING Separate Indoor Environment from Outdoors Major purpose: Separate the indoor environment of a building from the outdoors In such a way that indoor environmental conditions can be maintained.

4 FUNCTION OF CLADDING Keep Water Out Prevent entry of rain, snow, and ice. Complicated by: Wind at high velocities High air pressures Not just in a downward direction

5 FUNCTION OF CLADDING Prevent Air Leakage Air leaks waste conditioned air Carry water and moisture vapor through the wall Allow moisture vapor to condense inside the wall Allow noise to penetrate the building from outside

6 FUNCTION OF CLADDING Control Water Vapor Vapor moving through a wall assembly is likely to condense inside in cold weather Problems include: Staining, lost insulating value, corrosion, and freeze-thaw deterioration Designed to drain the condensate safely to the outside

7 FUNCTION OF CLADDING Control Light Controlling radiation of heat Controlling the conduction of heat and cold Provide thermal bridges in highly conductive materials (metal framing) Control Sound Noise isolation is best achieved by walls that are airtight, massive, and resilient The required degree of noise isolation varies from one building to another, depending on the noise levels and noise tolerances.

8 REQUIREMENTS OF CLADDING Adjusting to Movement Expansion & Contraction Thermal Differential expansion and contraction of inside and outside faces Relationship to framing Moisture Caused by varying moisture content Bricks and stone can slightly expand and concrete shrink after installation

9 REQUIREMENTS OF CLADDING Adjusting to Movement Structural Movements Movement of the building transmitted between frame and cladding Movements of cladding system Resisting Wind Forces Adequately strong and stiff to sustain pressure and suction from wind Other External Forces Earthquake Gravity

10 Small differences can accumulate to significant problems.

11 THE DEVELOPMENT OF VENEER CLADDING A TIMELINE

12 EARLY AMERICAN MASONRY CLAD BUILDINGS Masonry was the dominant material for civic, public and commercial buildings Stone buildings were consciously designed to be formal Thin-stone veneer cladding begins at the end of the 19 th c.

13 EARLY AMERICAN MASONRY CLAD BUILDINGS Veneer Masonry Walls Massive Rubble-Core Walls Thick Ashlar Clad Buildings Thin Brick Masonry Systems

14 EARLY AMERICAN MASONRY CLAD BUILDINGS c Colonial brick building used old timber framing techniques Floors supported on beams pocketed into the masonry Predominant construction in Georgian Architecture

15 Castle Clinton 1811 New York, New York McComb and Williams

16 THE DEVELOPMENT OF VENEER CLADDING 1850s Architectural terra cotta For ornament Less expensive than carved stone Tontine Building 1853 New York, New York James Renwick

17 1870s End of the monolithic masonry bearing walls Brick jack arches on iron beams Non-load-bearing stone with the skeleton-frame construction Old Equitable Building 1870 New York, New York Kendall and Gilman

18 THE DEVELOPMENT OF VENEER CLADDING 1880s New York Brownstones Nonbearing front facades built after the party walls and floor joists completed Lack bracing between floor joists and elevations Braced entirely on the party walls Likely to move if continuity is lost

19 THE DEVELOPMENT OF VENEER CLADDING 1880s Tall buildings continued to follow traditional wall construction Improvements in methods of attachment Advances in fabrication technology First Leiter Building 1879 Chicago, Illinois William Le Baron Jenney

20 US Archive Building 1899 New York, New York W. J. Edbrooke

21 THE DEVELOPMENT OF VENEER CLADDING 1890s The last major bearing wall building Ten-story-high brick walls

22 THE DEVELOPMENT OF VENEER CLADDING 1900s Stone blocks from the quarry cut into thick slabs and hand tooled 4-8 thick ashlar construction integral with a masonry backup and supported on steel Typical of 1920s and 1930s Architecture Empire State Building 1931 New York, New York Schreve, Lamb and Harmon

23 THE DEVELOPMENT OF VENEER CLADDING 1930s Quarries introduced 1/2-inchthick veneer units Laid up with mortared joints on mortar beds Bent steel rod anchors in drilled holes at edges Often fully grouted to the backup wall RCA Building 1933 New York, New York Raymond Hood

24 THE DEVELOPMENT OF VENEER CLADDING 1940s First use of thin-stone veneer for entire building facades Typically, joints were still filled with mortar Stainless-steel strap anchors introduced, but inefficient Limited to building interiors, street-level facades and storefronts

25 THE DEVELOPMENT OF VENEER CLADDING 1950s New Anchors: The split-tail anchor developed a method of properly attaching thin stone to the steel structure New Tools: Diamond blade tools improved efficiency of fabrication 1¼ veneer becomes widespread

26 THE DEVELOPMENT OF VENEER CLADDING 1960s Defining postmodern architecture Developed bond-breaker sheets to separate the different materials 1970s Diamond-studded cables used to cut blocks into slabs increased efficiency of fabrication

27 THE DEVELOPMENT OF VENEER CLADDING Stone Thickness Progression Reduced from 4' to 1/16" in last 5000 years with major change from 4" to 1/16" in last 60 years Pyramids: Many feet thick Parthenon: Approximately 4-0 Skeleton frame & non-loadbearing walls: 4 facing with clay masonry backup Mid-20 th century fabrication: Typically, 1¼" anchored to backup 1980s: Micro-thin stone 1/16" thick stone adhered to ⅜" honeycomb aluminum core

28 HISTORIC MASONRY CLADDING DEFINITIONS AND WALL TYPES

29 DEFINITIONS Bearing Wall Type$ A wall designed to carry its own weight and the weight of any other structure framed into it to a foundation or transfer girder. All gravity loads carried by walls down to the foundation Interior and exterior walls are solid Interior bearing walls have multiple openings Floor construction is standard fireproof on beams supported by the walls Ames Building 1889 Boston, Massachusetts Shepley, Rutan and Coolidge

30 DEFINITIONS Cage Building Type$ Consist of a frame that carries the weight of the interior floors and roof and is surrounded by selfsupporting masonry walls. Gravity loads are split between the frame and the wall Walls provide stability against lateral wind load The steel frame eliminates interior bearing walls and allows for thinner exterior walls The Ansonia 1899 New York, New York Paul Duboy

31 DEFINITIONS Skeleton Building Type All loads supported by steel frame Curtain wall (non-load-bearing wall) carried on lintels at each floor Curtain wall can be a constant thickness the full height of the building Woolworth Building 1913 New York, New York Cass Gilbert

32 DEFINITIONS Transitional Buildings Built around and onto skeleton frame Masonry curtain walls No expansion provisions

33 DEFINITIONS Curtain Wall$ A non-bearing wall that encloses the perimeter of a building. Exterior wall systems supporting only their own dead weight The wall transfers vertical gravity and horizontal wind loads to the structure UN Secretariat 1951 New York, New York Root and Atwood

34 DEFINITIONS Dimension Stone Stone that has been selected and fabricated to shape for use in building Thin Stone (thin stone cladding or thin stone veneer) Dimension stone not exceeding 2 inches in thickness that is applied to a building façade in a non-load bearing manner

35 DEFINITIONS Veneer Decorative facing; could be any material Before mid-20 th century generally used to refer to materials applied to a substrate Example: Decorative outer facing of terra cotta

36 DEFINITIONS Thin Stone Veneer In early installations stone veneer was set in mortar and anchored using wire anchors or heavy steel straps Later installations used thin steel straps for anchors and sealant rather than mortar in the joints

37 WALL TYPES Composite Masonry Walls Reinforced Masonry Walls Cavity Walls

38 WALL TYPES Composite Masonry Walls

39 Composite Masonry Walls Entirely one type of masonry vs. a composite wall Solid masonry walls constructed with outer wythe of stone or face brick and a backup of less expensive masonry Usually the two are bonded together either by brick headers or metal ties penetrating backup

40 Cathedral of St. John the Divine 1892 New York, New York LaFarge, Heins; Cram

41 Composite Masonry Walls Load bearing masonry units Bonded with either headers or ties

42 Composite Masonry Walls

43 James A. Farley Building 1912, McKim, Mead and White New York, New York

44 WALL TYPES Composite Masonry Walls

45 James A. Farley Building 1912, McKim, Mead and White New York, New York

46 James A. Farley Building 1912, McKim, Mead and White New York, New York

47 WALL TYPES Reinforced Masonry Walls

48 Reinforced Masonry Walls Grouted Masonry Walls Interior joints filled with grout as the work progresses The collar joint varies in width based on the height of the wall Requires a wider grout space than masonry ties.

49 Reinforced Masonry Walls Reinforced vs. Unreinforced With reinforcing, the increasing thickness from the top to the bottom wall can be reduced Each succeeding story can carry an increased load

50 First Battery Armory New York, New York Horgan & Slattery

51 Reinforced Masonry Walls

52 WALL TYPES Cavity Walls

53 Cavity Walls Solid Masonry vs. Cavity Wall Construction Continuous air space between the inner, and outer masonry Metal ties span cavity and hold wythes together Flashing and weep holes drain cavity

54 Cavity Walls Masonry Veneer A single wythe of masonry as weather barrier Anchored, but not bonded to a structural frame. Waterproofing membrane typically installed

55 Cavity Walls

56 Cavity Walls

57 Cavity Wall Advantage 1. Enhances the insulation value of the wall 2. Protects against water penetration

58 HISTORIC MASONRY CLADDING DETAILING CLAD WALLS

59 DETAILING CLAD WALLS Anchors and Ties Flashings and Weep Holes Expansion and Control Joints Thermal Insulation / Thermal Breaks

60 Anchors and Ties Dozens of types Prefabricated Custom

61 Anchors and Ties

62 Anchors and Ties

63 Anchors and Ties

64 Grand Central Terminal 1913, Reed & Stem Warren & Wetmore New York, New York

65 Anchors and Ties

66 Anchors and Ties

67 Anchors and Ties

68 Flashings and Weeps Prevent water penetration Concealed flashings catch water that did penetrate the wall Internal base flashings and where cavity is interrupted External base flashing and counterflashing

69 Flashings and Weeps Through-Wall Flashing Coping Covers

70 DETAILING CLAD WALLS

71 Flashings and Weeps Base System

72 DETAILING CLAD WALLS

73 DETAILING CLAD WALLS

74 DETAILING CLAD WALLS Expansion Joints vs. Control Joints Fxxxxxxxxxxxxxx Exxxxxxxxxxxxxx Txxxxxxxxxxxxxx

75 DETAILING CLAD WALLS Thermal Insulation Three general ways of insulating masonry walls: on the outside face, within the wall, and on the inside face. Insert slabs of plastic foam insulation against the inside wythe of masonry Install fill insulation Adhere insulation to the interior wall

76 HISTORIC MASONRY CLADDING PERFORMANCE AND MAINTENANCE

77 CLADDING PERFORMANCE & MAINTENANCE Compared to preserving traditional masonry preservation Thick masonry walls: most of the preservation effort is related to the behavior of the material Thin clad masonry walls: almost all deterioration has an effect on the structural performance of the system Therefore the preservation effort focus on understanding the causes of stress and preserving/maintaining structural integrity

78 Mechanisms of Failure Building Movement Water Penetration Deterioration of Anchors and Ties Materials Failure Design Variations

79 H. Carl Moultrie Courthouse 1975 Washington, DC Helmuth, Obata and Kassabaum

80 CLADDING PERFORMANCE Water Penetration Water penetrating the cladding can cause corrosion. Rarely is the source of water leakage attributable to water penetrating through the panel.

81 CLADDING PERFORMANCE Deterioration of Anchors and Ties Often distress is related to connections and supports Cracks, spalls and displacement around anchor locations Loss of connections transfers loads Corroded anchors can cause corrosion jacking

82 CLADDING PERFORMANCE & MAINTENANCE Structural and Material Testing Thin-stone veneers do not behave the same as thick stone masonry Surface loss from weathering can decrease strength Thermal cycling of stone veneer is a significant

83 CLADDING PERFORMANCE Material Properties Many types of marble are not volume stable, causing warping and bowing Composition can vary considerably, and stone units may behave differently

84 CLADDING PERFORMANCE Loss of Material Distress from loss of material strength All natural building stone exhibits strength loss with time as a result of mechanical and chemical effects of weathering

85 CLADDING PERFORMANCE Building Movement Cyclical motions can occurs on a cyclical basis Warm days Cold night Wet weather

86 CLADDING PERFORMANCE Design Variations Insufficiently sized joints can cause cladding panels can come in contact Stresses can result in cracking and spalling near the edges and corners, as well as in failed or distorted joints

87 CLADDING MAINTENANCE The main preservation issues for thin-stone veneer revolve around maintenance Treatment of joints between cladding and elements Mitigation of movement of water into the system Proper design

88 CLADDING MAINTENANCE Materials and Systems Behavior: A Changing Perspective Under certain circumstances the only available method of repair may require removal of the deteriorated stoneveneer material and replacement. Large-scale replacement of thin-stone veneers may become more prevalent in the future

89 Materials and Systems Behavior: A Changing Perspective Built, 1966 Clad in 1,500 2"-thick basalt panels 3000 pounds each installed on a steel framework anchored to reinforced concrete By 1996, panels were loose and in danger of falling Whitney Museum 1966 New York, New York Marcel Breuer

90 Materials and Systems Behavior: A Changing Perspective Distress caused by failure of the anchoring system Galvanic corrosion resulting from the use of steel anchors and zinc-coated stainless steel dowels. Rust pushed rods outward, loosening the cladding. Anchoring system was under designed. Whitney Museum 1966 New York, New York Marcel Breuer

91 Materials and Systems Behavior: A Changing Perspective All stone panels and supporting steel members removed New support system was designed and installed Whitney Museum 1966 New York, New York Marcel Breuer

92 Materials and Systems Behavior: A Changing Perspective When we took off the skin, we found galvanized steel, we found brass, we found stainless steel, we found regular carbon steel, we found painted steel, we found unpainted steel. You name it, we found it. It was crazy. Diane Kaese

93 HISTORIC MASONRY CLADDING COLUMBIA UNIVERSITY GSAPP - A4124 BUILDING SYSTEMS AND MATERIALS DEC. 07, 2016 Chris Gembinski, Assistant Adjunct Professor