American Terracotta

Historic Masonry Restoration

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Lake Hopatcong Train Station, Landing, New Jersey

June 9, 2020 by Jeff Roush Leave a Comment

1911 train station at Lake Hopatcong in Landing, New Jersey. Black paint had to be physically removed. Multiple cracked, broken, and missing parts of the terracotta trim needed to be restored.

The building was cast in place with concrete, and slots were cast into the building to receive the terracotta trim pieces.

In the rear of the station facing the tracks, half of the units were missing or damaged. They were originally made by Rookwood.

Decades of water ingress and misdirection caused much damage, staining, and degredation to the concrete and terracotta.

Replacement units were made in studio using Edison Coatings restoration mortars.

Where spalling occurred, re-profiling was done. Unless too compromised, all remaining terracotta units were repaired and restored.

The historical Lake Hopatcong Train Station was purchased in the fall of 2014 by the Lake Hopatcong Foundation and now houses their offices as well as an Environmental and Cultural Center, hosting meetings and community programming.

1-1911-train-station-at-Lake-Hopatcong-NJ.-2017-condition.-Black-paint-had-to-be-physically-removed.800
2-Condition-in-rear-of-station-facing-the-tracks.-Half-the-units-missing-or-damaged.-Originally-made-by-Rookwood._800x600
3-Building-was-cast-in-place-with-concrete-slots-were-cast-into-the-building-to-receive-the-terracotta-trim-pieces._800x600
4-Decades-of-water-ingress-and-misdirection-caused-much-damage-staining-and-degredation-to-concrete-and-terracotta._800x600
5-Replacement-units-made-in-studio-using-Edison-Coatings-restoration-mortars._800x600
6-Where-spalling-occured-reprofiling-was-done.-Unless-too-compromised-all-remaining-terracotta-repaired800
7-Installation-of-replacement-units-on-track-side-of-station._800x600
8-Left-side-rear-entrance-nears-completion_800x600
9-Right-side-rear-entrance-installation_800x600
10-Matching-coating-was-approved-by-architect-and-finish-work-commences._800x600
11-Track-side-nearing-completion_800x600
12-Final-touches-on-trackside._800x600
13-Concrete-to-be-restored-someday._800x600
14a-Trackside-complete-2019_800x600
14b-Main-entrance-detailing-and-coating._800x600
15-Main-entrance-nears-completion_800x600
16-Lake-Hopatcong-historic-train-station-2019.-Thank-you-Marty-and-the-Lake-Hopatcong-Foundation-for-the-work._800x600
17-Restored-Lake-Hopatcong-Train-Station_front_600x600
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Filed Under: Special Projects Tagged With: American Terracotta, Architectural terra cotta, Architectural Terracotta, Edison Coatings, Facade restoration, Historic structure restoration, Lake Hopatcong Train Station Landing NJ, reprofiling, Restoration mold making, spalling, terra cotta reproduction, Terra cotta restoration, terracotta reproduction, Terracotta restoration

222-230 Bloomfield Avenue, Montclair, New Jersey

June 9, 2020 by Jeff Roush Leave a Comment

A 1929 facade in Montclair, NJ was revealed during renovation. Note the compromised condition of the glazed terracotta.

Any projecting features were knocked off to facilitate the installation of aluminum or stucco facings, a common practice in the mid 1900s. It was thought of back then as urban renewal.

An analysis of the original mortar and glaze was undertaken. Moldmaking was done at this point to recreate missing or broken elements and units. A more flexible rubber is used to make a mold when the detail is deep and intricate.

Edison coatings offers excellent glaze matching. Applied in studio and on site to maximize accurate blending to original surfaces.

1-1929-facade-in-Montclair-NJ-was-revealed-during-renovation.-Note-the-compromised-condition-of-the-glazed-terracotta._800x600
2-Any-projecting-features-were-knocked-off-to-facilitate-installation-of-aluminum-or-stucco-facings-a-common-practice-in-the-mid-1900s800
3-An-analysis-of-the-original-mortar-and-glaze-was-undertaken.-Moldmaking-was-done-at-this-point-to-recreate-missing-or-broken-elements-and-units_800x600
4-a-more-flexible-rubber-is-used-where-detail-is-deep-and-intricate_800x600
5-The-repeating-ornament-at-cornice._800x450
7-Replacement-pilaster-columns_483x600
8-Edison-coatings-excellent-glaze-matching.-Applied-in-studio-and-on-site-to-maximize-accurate-blending-to-original-surfaces._800x600
9-Installation-nearing-completion_800x600
10-Installation-completed-and-matching-finish-work-being-done._800x600
11-Final-detailing_800x600
12-230-Bloomfield-Ave-Montclair-restored_800x600
13-Owl-head_800x600
14-owl-head-complete_800x600
15-Client-happy-Thank-you-for-the-work-Kent_800x600
16-Finished-facade-and-ornamental-pieces-6-months-and-1-winter-later.._640x600
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Filed Under: Special Projects Tagged With: 230 bloomfield ave montclair nj, American Terracotta, Architectural terra cotta, Architectural Terracotta, Edison Coatings, Facade restoration, Historic structure restoration, mortar matching, Restoration mold making, terra cotta reproduction, Terra cotta restoration, terracotta reproduction, Terracotta restoration, unit production

Spartanburg Community College, Spartanburg, South Carolina

November 19, 2016 by Jeff Roush

American Terracotta was contacted by Peachtree Construction to reproduce terracotta bifoils in balustrades at the 1930s era school being refurbished to become an new annex to the Spartanburg community college system in Spartanburg, SC.

In addition, window sill units were also produced. We met with project architects on site to look at and discuss a scale model and the glaze color match. With approvals reached, the units were produced and shipped to site for installation by Peachtree Construction with excellent results.

Founded in 1963, Spartanburg Community College offers more than 100 certificate and associate degree programs via online learning and day, evening, and weekend classes. Learn more about Spartanburg Community College.

original ornamental piece removed to make mold-Spartanburg Community College
close up of cracked original ornamental piece-Spartanburg Community College
original and freshly molded ornamental piece-Spartanburg Community College
finished reproduction and original ornamental piece-Spartanburg Community College
front staircase with reproduced ornamental pieces in place-Spartanburg Community College
Spartanburg Community College-exterior after
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Filed Under: Special Projects Tagged With: American Terracotta, Architectural ceramics, Architectural terra cotta, Architectural Terracotta, Restoration mold making, Spartanburg Community College, terra cotta reproduction, Terra cotta restoration, terracotta reproduction, Terracotta restoration

Ridgewood Community School, Ridgewood, New Jersey

October 12, 2016 by Jeff Roush

48 Cottage Place in Ridgewood, New Jersey houses the offices for Ridgewood Community School.

American Terracotta completed restoration of carved brownstone ornamental features at the main entrance of this building.

Architectural terracotta in need of repair/reproduction-Ridgewood Community School
Terracotta repair/reproduction in process
Terracotta repair/reproduction in process-Ridgewood Community School
Finished terracotta repair/reproduction-Ridgewood Community School
Ridgewood Community School Ridgewood NJ
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Filed Under: Special Projects Tagged With: American Terracotta, Architectural ceramics, Architectural terra cotta, Architectural Terracotta, Facade restoration, Restoration mold making, Ridgewood Community School, terra cotta reproduction, Terra cotta restoration, terracotta reproduction, Terracotta restoration

Cruise Project, Lincoln Park, Chicago, Illinois

October 6, 2016 by Jeff Roush

1887 Residence in Lincoln Park, Chicago IL. A historic renovation presented an opportunity to put a duplicate design from the facade into the addition in the rear. Models and molds were made of tiles and coping units, and installed.

Cruise Project, Lincoln Park, Chicago before
Cruise Project, Lincoln Park, Chicago model
Cruise Project, Lincoln Park, Chicago molds
Cruise Project, Lincoln Park, Chicago after
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Filed Under: Special Projects Tagged With: American Terracotta, Architectural ceramics, Architectural terra cotta, Architectural Terracotta, Cruise Project Lincoln Park Chicago Illinois, Historic masonry consulting, historic reproduction, Historic structure restoration, mold making, Restoration mold making

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Our Services

  • Historic Reproduction – Modeling, Mold Making, and Unit Production
  • On Site Restoration — Conservation, Repair, Repoint — Historic Material Matching

View Our Work

  • 222-230 Bloomfield Avenue, Montclair, New Jersey
  • Lake Hopatcong Train Station, Landing, New Jersey
  • Emory Beacon Methodist Church, Washington, DC
  • Empire Building, Syracuse, New York
  • Spartanburg Community College, Spartanburg, South Carolina
  • Ridgewood Community School, Ridgewood, New Jersey
  • Cruise Project, Lincoln Park, Chicago, Illinois
  • Central School, Warren, New Jersey
  • Wilton Public and Gregg Free Library, Wilton, New Hampshire
  • Horace Mann Elementary School, North Bergen, New Jersey
  • 427 Granby Street, Norfolk, Virginia
  • The Tarratine Club, Bangor, Maine

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