American Terracotta

Historic Masonry Restoration

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Empire Building, Syracuse, New York

January 10, 2019 by Jeff Roush Leave a Comment

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.

1-Empire Bldg 472 S. Salina St. Syracuse New York-badly damaged facade
2-Empire Bldg 472 S. Salina St. Syracuse New York-reproduction in progress
3-Empire Bldg 472 S. Salina St. Syracuse New York-after reproduction, restoration-2
4-Empire Bldg 472 S. Salina St. Syracuse New York-after reproduction, restoration-3
5-Empire Bldg 472 S. Salina St. Syracuse New York-after reproduction, restoration-1
6-Empire Bldg 472 S. Salina St. Syracuse New York-after reproduction, restoration-4
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Filed Under: Special Projects Tagged With: American Terracotta, Architectural Terracotta, Empire Building, Facade restoration, Historic masonry consulting, mold making, Restoration mold making, terracotta reproduction

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

427 Granby Street, Norfolk, Virginia

September 21, 2016 by Jeff Roush

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.

427 Granby Street, Norfolk, VA before
427 Granby Street, Norfolk, VA after
427 Granby Street, Norfolk, VA Grow headquarters
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Filed Under: Special Projects Tagged With: 427 Granby St, American Terracotta, Facade restoration, Restoration mold making, Terra cotta restoration, terracotta reproduction, Terracotta restoration

Historic Reproduction — Color Matching, Modeling, Mold Making, Unit Production

September 21, 2016 by Jeff Roush

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

Filed Under: Featured Services Tagged With: American Terracotta, Facade restoration, Restoration mold making, Terra cotta restoration, terracotta reproduction, Terracotta restoration

Our Services

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

View Our Work

  • 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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