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"The Maintenance, Repair and Replacement of Historic Cast Stone" an Historic Preservation Brief November 21, 2008


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The Maintenance, Repair and Replacement of Historic Cast Stone

Richard Pieper
The Maintenance, Repair and Replacement of Historic Cast Stone

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Introduction

History of Use and Manufacture

        Early Patented Systems

        Late 19th and 20th Century Development

        Manufacture

              Dry tamp

              Wet cast

Mechanisms and Modes of Deterioration

        Separation of the Facing and Core Layers

        Deterioration of the Aggregate

        Deterioration or Erosion of the Cementing Matrix

        Deterioration of the Iron or Steel Reinforcement

        Deterioration of Cramps and Anchors

Maintenance of Cast Stone Installations

        Cleaning

        Repointing

Methods of Repair

        Re-securing Separated Surface Facing

        Repairing Reinforcement Spalls and Mechanical Damage

        Surface Refinishing

Replacement of Historic Cast Stone Installations

        Fabrication defects

              Air bubbles

              Surface cracking or checking

              Aggregate segregation

              Surface rippling or irregularity

              Mold lines

        Other Considerations for Replacement of Cast Stone

              Reinforcement

              Surface finishing

              Moist curing

Appropriateness of GFRC as a Replacement Material

        Light-Weight Alternative

        Not for Use in Load Bearing Applications

        Deterioration of GFRC

Summary

Selected Reading

Helpful Organizations

Acknowledgements


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Helpful Organizations

Cast Stone Institute
10 West Kimball Street
Winder, GA 30680-2535

National Precast Concrete Association
10333 North Meridian Street, Suite 272
Indianapolis, IN 46290

Architectural Precast Association
P.O. Box 08669
Fort Myers, FL 33908-0669


Acknowledgements

Richard Pieper, Director of Preservation for Jan Hird Pokorny Associates, Inc., New York, has considerable experience in varied aspects of architectural conservation, including documentation of historic architectural technology and analysis and conservation of building materials. The author wishes to thank Alan Barr of Towne House Restorations, Inc., Ron Moore of Western Building Restoration, architect Theo Prudon, and conservator David Wessell of the Architectural Resources Group for their assistance in the preparation and review of this brief. Chuck Fisher and Anne Grimmer, Technical Preservation Services, NPS, offered valuable comments during its development. MJM Studios provided access for photography of cast stone fabrication. Michael F. Lynch, Vice President, SPNEA, and Michael Devonshire, Principal, Jan Hird Pokorny Associates, generously lent images from their personal collections for the Brief. Kay D. Weeks, Heritage Preservation Services, National Park Service (NPS), served as project director and general editor.


This publication has been prepared pursuant to the National Historic Preservation Act of 1966, as amended, which directs the Secretary of the Interior to develop and make available information concerning historic properties. Technical Preservation Services (TPS), Heritage Preservation Services Division, National Park Service prepares standards, guidelines, and other educational materials on responsible historic preservation treatments for a broad public.



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