Garver Feed Mill Condition Evaluation
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1 Garver Feed Mill Condition Evaluation
2 OUTLINE Brick masonry overview Condition assessment & methodology Project overview Existing conditions Stabilization Probable costs Summary
3 BRICK MASONRY OVERVIEW
4 Brick 4000 years old technology Simple technique of stacking to make walls Strong Long lasting Fire proof
5 Brick is like a loaf of bread Hard crust outside, Soft core inside
6 Cross section of early 20 th century mold made brick Swirl is due to kneading of clay before it was set in mold
7 Cross section of early extruded brick Horizontal lines from extrusion process
8 Mortar A cushion/seal between bricks/bearing surface Bonding agent/surface enhancer A mixture of cement, sand & lime Sacrificial
9 HISTORIC MASONRY
10 Mass Wall Multiple wythes of brick Load bearing Thermal mass
11 Mass Wall Sheds most moisture Absorbs some moisture Moisture dissipated by movement of heat and by evaporation Soft bricks/soft joints No provision for expansion
12 CONTEMPORARY MASONRY
13 Screen Wall Single wythe of brick with backup material Non load bearing Expansion joints
14 Screen Wall Assumes water will penetrate wall Provides for water intrusion Provides for water escape
15 COMMON ISSUES
16 Moisture penetrates walls Freeze thaw action
17 Moisture penetrates walls Surface spalling
18 Moisture trapped in walls Efflorescence- deposit of salts
19 Moisture trapped in walls Rising damp
20 Mortar harder than brick Brick erodes, mortar remains
21 Movement Vertical and horizontal displacement
22 PROPER TREATMENTS
23 Secretary of the Interior s Standards National Standards & Guidelines
24 Cleaning Sample test panel, mildest treatment Typically done before repointing or replacement
25 Cleaning Medium bristle brush and non-ionic detergent Rinse thoroughly
26 Cleaning Sand blasting not recommended
27 Repointing Carefully remove deteriorated mortar Replace only deteriorated mortar
28 Repointing Replace with mortar softer than the brick Match original mortar color and joint type
29 Repointing Match composition, color and joint type of original
30 Repointing Incorrect color mortar and wider joints
31 Brick replacement Very difficult to match new brick to old Difficult to match new mortar color to old
32 Brick replacement Restoration of façade with reclaimed and recycled brick
33 CONDITION ASSESSMENT & METHODOLOGY
34 Assessing an Existing Masonry Building Existing Condition Survey / Laser Scan Photographic Documentation Sounding Inner Wall Sampling Laboratory tests Chemical Analysis Petrographic Examination Brick Absorption Tests Brick & Prism Compression Test
35 EXISTING CONDITION SERVEY with a Laser Scanner Highly portable laser scanning equipment. Scanner and tripod Battery and computer 3D laser scanning technology provides a snap shot in time, an archive of information that does not change.
36 Laser Scan
37 Photographic Documentation
38 Sounding & Inner Wall Sampling Energy absorption vs. rebound Solid wall- ping sound Hollow wall - thud sound Deteriorated wall muted thud Visual survey of inner wall Are the bricks solid? Is the mortar solid? Are there gaps in mortar? Is the wall wet? Retrieve samples for lab test.
39 Laboratory Tests: Chemical Analysis of Masonry Mortar Finding the proper mortar match for repairs ASTM C 1324 is a combination of test procedures for microscopic examination and chemical analysis of mortar to determine components of masonry mortar and quantities of components. In other words, reverse engineering of mortar.
40 Laboratory Tests: Petrographic Examination & Absorption Tests A polarizing light microscope is used to view the sample and help analyze the mortar. Brick samples are heating and boiled to analyze their absorption rates
41 Laboratory Tests: Brick & Prism Compressive Strength Matching the existing brick strength is important to the future integrity of the entire wall. Similar to the brick compressive test, this test analyzes a portion of the masonry wall including the mortar.
42 PROJECT OVERVIEW
43 Significance Local significance industry/commerce Link to agricultural industry Coming of age of livestock feed industry Best remaining example of pre WWII livestock
44 Character Defining Features Large main block flanked by set back wings Dominance of primary facade
45 Character Defining Features Repetitive segmented & corbeled semicircular arches Large window openings, banding, corbeled parapets
46 Character Defining Features Large interior space
47 History Constructed as US Sugar Beet Co. Sold at auction May 1924 / fall 1929
48 History James Garver Feed & Storage 1975 Garver Feed & Supply Co.
49 History Madison Landmark 1994 Business closed October 1997.
50 Preservation Principles National Park Service Standards Cogent link to the past Stabilization
51 STRUCTURAL & ENVELOPE EXISTING CONDITION
52 Typical Building Envelope findings Rising damp Deteriorated sills Freeze thaw damage Gaps within mortar bed Failing roofing Non-weather tight openings Deteriorated parapets Spalling masonry Failing mortar
53 Rising damp Masonry wall acts like a sponge leading to faliiling mortar and spalled brick. (A) (B) Also note the distinctive tide mark. (B) (A)
54 Rising damp Failed roofing causes rising damp issues on the interior. Failing mortar & spalled brick.(a) Also note the distinctive tide mark. (B) (B) (A)
55 Deteriorated sills Typical sill condition Loose mortar (A) (A) (B) Fractured brick (B)
56 Freeze thaw damage First two interior brick courses experience freeze thaw. One full brick (2-2/3 ) concealed within solid ice. (A) (B) (A) Snow is 14 inches at deepest point.(b)
57 Freeze thaw damage Exposed window sill.(a) (B) (A) Exposed top of wall.(b)
58 Deteriorated parapets
59 Spalling masonry Fracturing concrete band.(a) (A) (B) Spalled brick.(b)
60 Failing mortar
61 Gaps within mortar bed
62 Failing roofing
63 Non-weather tight openings
64 Atypical Building Envelope findings Excessive water damage Vegetation within walls
65 Excessive water damage AREA F AREA H
66 Vegetation within walls
67 Typical Structural Findings Wood Roof Deterioration Concrete Roof Deterioration
68 Deteriorated Wood Framing Sheathing Joists Nailers Steel framing supporting the wood framing in most cases was found to be OK
69 Deteriorated Concrete Spalled sections of concrete Holes on Concrete Roof
70 Atypical Structural findings Detrimental Movements Structural Masonry Cracks Bad Lintels Stability Issues Unknown Conditions
71 Detrimental Movements Bowing Bulging Movement related to settlements Movement related to thermal changes
72 Structural Cracks Cracks at Lintels Wall Separation Cracks related to possible settlements
73 Bad Lintels Steel Masonry
74 Stability Issues Tall walls with openings Lack of connection to floor or roof structure
75 Unknown Conditions Significant amount of concealed and inaccessible areas What will we find during repairs, stabilization, and construction?
76 SUMMARIES OF STABILIZATION
77 Stabilization strategies for Structural Issues Roofs, Wood and Concrete Detrimental Movements Structural Masonry Cracks Bad Lintels Stability Issues, Diaphragms, Walls, Columns, Trusses Unknown Conditions D, F, G, H
78 Masonry walls EXTERIOR INTERIOR
79 COST ESTIMATE DEVELOPMENT
80 Estimating Process and Tools Scopes of Work Defined Detailed Quantity Surveys Unusual Conditions Identified Subcontractor Input Segregation by Building Area
81 Cost Evaluation and Considerations Historical Cost Database Subcontractor Input Unit Prices Established Total Project Cost
82 SUMMARY
83 Have a good understanding of the extent of deterioration and therefore probable costs All solvable stabilization issues Implementation could be phased to accommodate budget Stabilization should create opportunities for those interested in the adaptive reuse
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