American Terracotta

Historic Masonry Restoration

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Emory Beacon Methodist Church, Washington, DC

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Emory Beacon Church originally built in the mid 1800s was razed and rebuilt during and after the Civil War. A 1920 era expansion included the addition of a terracotta façade, pedimented portico and cornice. During the following decades, inappropriate repoints and water intrusion issues led to spalling, staining, and some breakage of masonry units comprising the columns of the portico.

Once historically accurate materials matching was completed, repairs were executed on the portico columns. A complete joint removal and replacement was necessary to remove inappropriate prior repoints. Sensitive repoint was done using minimal power tools and hand tools only to prepare the joint for repointing with a historically accurate mortar. Edison coatings provided superbly matched mortars and coatings to help restore damaged units to match intact original units.

The final results are a freshened look which maintains the historic qualities of the building to the greatest degree possible.

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Empire Building, Syracuse, New York

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The 1930 terracotta additions to this historic building were heavily damaged over the course of decades of renovation and changes to the façade. Removal of 1950s and 60s façade renovations revealed both the terracotta features and the extent of damage. My work began by assessing this damage and preparing a proposal for restoration.

Using a variety of mold making and modeling techniques, several different molds were created in house and replacement units were made. In this case local masons were employed to install the replacement units. The project was completed with a lab matched coating to create a unified, compatible, and historically accurate result.

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Ridgewood Community School, Ridgewood, New Jersey

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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.

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427 Granby Street, Norfolk, Virginia

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Original façade was 1917, destroyed in early 50’s and covered with stucco. American Terracotta’s research into historical records located historical photographs of the building facade that were previously unknown. Study of these images informed the design and proportion of the reproduction terracotta units. Renovation replaced original façade. We made most of the ornamental trim with terracotta.

427 Granby Street is now the headquarters for the digital agency Grow.

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Historic Reproduction – Modeling, Mold Making, and Unit Production

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Historic Reproduction – Modeling, Mold Making,  and Unit Production Services:

We research historical information as needed to replace missing features.

Once we have approval of the model or prototype, we make the mold or molds that will produce the replacement parts needed for your unique building. Most architectural and ornamental features are unique to each building. Historically, and today, Terracotta or cast stone molds can almost never be reused from one building to a new or different project. This is due to the unique characteristics and dimensions of historic structures. In order to repair your historic masonry, an individualized and unique approach is required.

These services include:

• Historical research
• Raw material and color matching
• Model and mold making
• Customized casting or hand forming
• Precise matching of visual texture and color
• Installation of replacement parts and pointing

Special Projects:

Empire Building, Syracuse, New York

427 Granby Street, Norfolk, Virginia

Wilton Public and Gregg Free Library, Wilton, New Hampshire

Cruise Project, Lincoln Park, Chicago, Illinois

Spartanburg Community College, Spartanburg, South, Carolina