Façade Restoration and Challenges
NYC Building Code 1 Section RCNY 103-04 mandates the façade of any building over 6 stories is inspected every five years to determine the conditions and safety of the façade elements and that a restoration plan is put in place to address any potential safety or deterioration issues. CTA Architects, which has been performing FISP inspections since the inception of the program in 1980, utilized photo equipment and telescopes to inspect the building’s façade in detail to determine its condition. CTA Architects personnel also used suspended scaffolding to gain physical access to the façade. Although localized repairs were warranted based on the inspection results, the façade in general was structurally sound. However, building management reported continued issues of extensive water penetration at the upper stories and decided to incorporate leak remediation into the project. CTA Architects with the structural engineer, GACE Consulting Engineers, developed design documents to address structural and waterproofing issues.
The original brick masonry walls are fully bonded and did not contain a cavity, flashing or other mechanism for water drainage. To effectively address the water-penetration issues, the design team directed the removal of the outer wythe of the brick façade at the upper four floors to reveal the underlying steel structure and brick lintels and other supports, as well as the steel armatures for the projecting terra-cotta pieces. Because the structure was exposed, CTA Architects and GACE Consulting Engineers inspected the steel and directed restoration where required. The team designed a new brick cavity wall system to replace the original masonry. The new system improves drainage and protects against water infiltration.
Because the building is located in the Brooklyn Heights Historic District, all exterior changes fall under the jurisdiction of the New York City Landmarks Preservation Commission (LPC). LPC regulations mandate any new masonry, mortar, and terra cotta must match the color, texture and bond pattern of the existing façade. As part of the previous façade renovation project in 2008, CTA Architects had submitted six different bricks to match and received LPC approval. These bricks were also utilized for the current project with LPC’s approval. The mortar color was matched to the original mortar exposed during the removal of the face brick.
The building contains extensive terra-cotta ornaments. Six-foot tall Egyptian figures flank windows at the 27th floor, and eagles project approximately 5-feet horizontally from the base of the monumental parapet wall.
“Each oversized terra-cotta element was removed from the façade and sound tested with a mason hammer to determine its structural condition,” explains Frank Scanlon, AIA, an associate with CTA Architects. “All eagles and Egyptian figurines were salvaged, cleaned and reinstalled on newly fabricated steel armature. Other pieces, including several heads, could not be salvaged and required replacement.”
General Contractor Adelphi Restoration’s team removed more than 20 different terracotta component samples from the building so the terra-cotta manufacturer could create molds for replication. The manufacturer then produced color samples, which were reviewed and approved by the design team and LPC prior to manufacture. Likewise, Adelphi Restoration and its steel subcontractor custom-fabricated armatures as required to support the terra-cotta pieces after providing shop drawings for review by the design team.
The project included the replacement of 11 monumental, arched, rolled-steel-framed windows with new stainless-steelframed windows in two profiles at the 25th and 30th floors. Original windows were top-ofthe-line at the time of construction but were deteriorated and no longer operable as intended. The new windows are thermally broken with insulated glass. One profile, 6.5-feet wide by 11-feet high, has a floating hopper vent; the second, 7-feet wide by 13-feet high, has a combination of fixed panels and operable casements.
The windows are historically true, matching the original profiles, frame material and frame color, as well as comply with the requirements of the LPC master plan. LPC approval was required prior to the start of fabrication. “There were many challenges associated with the window installation,” notes Hugo Ramirez, director, Adler Windows. “Every opening size was unique, and precise field measurements were required before shop drawings could be produced.”
Adler Windows’ team carefully planned the installation of these oversized windows at a height of close to 300 feet, often in cold and windy conditions. Each unit was hoisted from the street along the exterior of the building. Sidewalk closures were enforced during hoisting operations.
During construction, the discovery of a deteriorated load-bearing beam within one of the exterior walls presented a significant challenge, which could have adversely impacted the work schedule. The project and ownership team worked together to analyze repair and replacement options. Following GACE Consulting Engineers’ recommendation, the board and property manager expeditiously replaced the beam so the schedule was not delayed.
PHOTOS: PERICLE GHEORGHIAS/CTA ARCHITECTS unless otherwise noted