Masonry and Concrete Repair and Restoration

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1 2041 W. Carroll Chicago, IL Tel: Fax: Masonry and Concrete Repair and Restoration

2 Masonry Repair Concrete Repair & Restoration Business Information BUSINESS INFORMATION The world wants results - not explanations. If you can deliver, then you won t have to explain. If you can t deliver, explanations will not make any difference. Eugene Matthews, Inc. provides comprehensive masonry repair, restoration and related building waterproofing services to owners of commercial, industrial, institutional and fine residential structures in the greater Midwest. We have successfully completed over 4,000 projects. Eugene Matthews delivers superior workmanship along with customer centered project management. Weather induced wear and stresses, thermal expansion and contraction, material life cycles, as well as improper new construction or previous repair techniques all contribute to an ongoing need for Eugene Matthews services. Extensive knowledge of the most durable concrete and masonry repair methods and techniques, and the most effective restoration materials allows Eugene Matthews to offer customers all the services required to properly address and complete needed masonry repairs. Whether we win a job or not, our fundamental approach remains the same - we are a serious, professional and highly service oriented firm and we work every day to earn and retain our customer s business. Services Terra Cotta and Limestone Repair Brick Repair and Rebuilding Concrete Facade Repair Tuckpointing Structural Steel Repair Caulking and Sealant Repair Waterproof Coatings Critical Inspections

3 Masonry Repair Concrete Repair & Restoration 2041 W. Carroll Chicago, IL Tel: Fax:

4 Masonry Repair Concrete Repair & Restoration 55,000 lineal feet of sealant work PROJECT SUMMARIES This upscale hotel is located in Chicago s densely populated near north side. Eugene Matthews was contracted to remove and replace 55,000 lineal feet of sealant at all vertical and horizontal masonry to masonry, and masonry to metal joints. Inspections also indicated that the various granite slabs installed on the façade had cracked and needed to be replaced. Eugene Matthews worked very closely with hotel management to minimize disruptions and insure the safety of guests, employees and pedestrians on the public way abutting the structure.

5 Masonry Repair Concrete Repair & Restoration Springfield, Illinois LOOKING UP PROJECT SUMMARIES BALCONY RESTORATION SEVERE BALCONY DETERIORATION

6 PAGE TWO Masonry Repair Concrete Repair & Restoration 144 balcony project. Thousands of feet of concrete wet saw cutting with associated water contain ment and run off management. Removed 4000 square ft of deterio rated concrete. Installed 2 tons of supplemental steel. Complete replacement or nearly complete replacement of dozens of balconies Scarified all balcony surfaces and installed new waterproofing coatings. Replaced existing railings with new railing systems. Cut and installed new horizontal expansion joints at all corners of the building. Removed and replaced 6000 lineal ft of sealant at all window perimeters. Hundreds of brick replaced.

7 PAGE THREE Masonry Repair Concrete Repair & Restoration

8 Milwaukee, WI Terra Cotta Restoration Masonry Repair Concrete Repair & Restoration -Remove 4000 pieces of terra cotta from all four elevations of the south tower, from the top of the clock tower gables down to the 11th floor. -Selectively remove and crate existing pieces and ship to terra cotta fabricator to create molds and cast new terra cotta. Work with manufacturer to insure product quality. -Install new terra cotta from the 11th floor to the top of the clock tower gables.

9 PAGE TWO Masonry Repair Concrete Repair & Restoration TERRA COTTA RESTORATION REMOVAL AND REPLACEMENT

10 Masonry Repair Concrete Repair & Restoration City of Chicago Critical Facade Inspections PROJECT SUMMARIES Eugene Matthews works with owners and structural engineers throughout the inspection process. The structures pictured here are recent examples of inspection projects where Eugene Matthews provided the rigging, swing stages and experienced mechanics to operate the rigs.

11 Masonry Repair Concrete Repair & Restoration Eugene Matthews was contracted by this venerable Chicago museum to repair and waterproof 104 light wells at the roof of the building. The work required extensive brick replacement at brick piers, as well as sealant removal and replacement at all of the light well windows. Additional masonry repairs were performed at the parapet walls and included the installation of 110 lineal feet of thru wall flashing. PROJECT SUMMARIES

12 Masonry Repair Concrete Repair & Restoration BALCONY SLAB EDGE REPAIRS SLAB EDGE FAILURE PROJECT SUMMARIES PATCH PREPARATION PATCH PREPARATION This suburban Chicago condominium complex required extensive concrete slab edge repairs at 171 balconies. EMI sounded out the concrete for loose and delaminated concrete. We then saw cut the perimeter of spalled concrete. Using light duty chipping hammers we removed deteriorated concrete to the sound concrete, and to a minimum depth of ¾ behind exposed rebar. We mechanically cleaned and coated the exposed rebar with zincrich paint. EMI installed supplemental stainless steel which threaded the rods and dowels for maximum reinforcement. We formed the concrete as needed and patched with polymer modified repair mortar. AFTER

13 Masonry Repair Concrete Repair & Restoration Wood Dale, Illinois POLYURETHANE DECK COATING and RAILING REPAIR PROJECT SUMMARIES BEFORE EMI installed approximately 15,000 square feet of epoxy/urethane deck coating to the top and sides of all of the balconies. All railings were removed and reinstalled with new base plates and wedge anchors. Railings were coated with a recoatable epoxy primer and a Hi-Solids polyurethane. Additional work included the removal and replacement of sealant at all of the precast panels and window frame joints (approximately 25,000 l.f.) and the cleaning and waterproofing of all of the exposed aggregate pre-cast (40,000 s.f.). AFTER AFTER

14 Masonry Repair Concrete Repair & Restoration 2041 W. Carroll Chicago, IL Tel: Fax:

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16 Masonry Repair Concrete Repair & Restoration 2041 W. Carroll Chicago, IL Tel: Fax:

17 Masonry Repair Concrete Repair & Restoration 2041 W. Carroll Chicago, IL Tel: Fax:

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25 Masonry Repair Concrete Repair & Restoration 2041 W. Carroll Chicago, IL Tel: Fax:

26 Masonry Repair Concrete Repair & Restoration CINCINNATTI, OHIO The first phase of this project required EMI to facilitate the inspection of the building by a licensed Structural Engineer. The second phase involved the repair of areas noted in the engineer s report. This work included the rebuilding of significant areas of the façade, including the installation of new supplemental structural steel at the areas of the work. PROJECT SUMMARIES

27 Masonry Repair Concrete Repair & Restoration CINCINNATI, OHIO Eugene Matthews was retained by the owner of the building to provide a Contractor s Assessment of the condition of the exterior masonry elements of the structure. This report allowed for the Owner and the Owner s Engineer to develop a realistic budget and timeline for the work, prior to the development of general bid specifications. PROJECT SUMMARIES

28 Masonry Repair Concrete Repair & Restoration The responsibility of this facility is to supply temperature controlled oxygen to one of the largest hospitals in the Chicago Metroland area. EMI was contracted to rebuild the masonry parapet wall adjacent to oxygen lines without interrupting oxygen flow to surgical suites. EMI then applied a deck coating and waterproofing material to the chiller fan deck, chiller masonry walls and finally the exterior side of the round concrete fan shells. BEFORE POLYURETHANE DECK COATING AND WATERPROOFING MEMBRANE PROJECT PROJECT SUMMARIES BEFORE AFTER

29 Masonry Repair Concrete Repair & Restoration 6500 lineal feet of sealant work 350 square feet of spot pointing 15 swing stage moves PROJECT SUMMARIES This 4-story masonry hospital located in Barrington needed approximately 6500 lineal feet of sealant replacement on its South and East Elevations from the Ground Floor through its 4th Floor and Penthouses. All existing sealant was removed at the 2nd-4th floors at window or vent frame perimeter-to-masonry joints. EMI installed new soft cell backer rod and caulk where needed. Sealant and backer rods were also replaced at approximately 20 narrow nonmoving window panels while similar work was done at all South and East penthouses, windows, vents, doors, and expansion joints. 350 square feet of spot pointing and tuckpointing were done to complete this project.

30 Masonry Repair Concrete Repair & Restoration MULLION AND LINTEL REPLACEMENT VARIOUS LIMESTONE MAINTENANCE REPAIR PROJECTS PROJECT SUMMARIES LIMESTONE PATCHING LIMESTONE TUCKPOINTING

31 Masonry Repair Concrete Repair & Restoration Evanston, Illinois PROJECT SUMMARIES EMI removed and replaced approximately 2,700 lineal feet of sealant, backer rod & primer at rough - openings where window and sliding door framing systems directly abutted precast concrete panels, metal panels, architectural metal grilles, or brick.

32 Masonry Repair Concrete Repair & Restoration Madison, Wisconsin PROJECT SUMMARIES This notable recreational and residential facility required limestone repair at the perimeter of the building. EMI provided a sample installation of various repair mortars to determine the type, color and textural match to the existing stone. EMI then installed approximately 300 square feet of limestone patches at all spalled areas. Miscellaneous brick were also replaced at the upper stories of the alleyway elevation where water had penetrated the wall. Brick color and texture was matched with the existing brick. At the rooftop chimney, all mortar joints were ground out and re pointed. Minor patching was also performed at the chimney cap, which was then waterproofed with the application of a clear waterproof coating.

33 Masonry Repair Concrete Repair & Restoration Jacksonville, Florida PROJECT SUMMARIES Inspection and Condition Assessment EMI partnered with a New York City based engineering firm to assist this leading Hotel owner with a condition assessment of this Oceanside property. Air salinity had oxidized steel within the exposed balcony portions of the structure, but the extent of corrosion was unknown. EMI coordinated the engineering study, repair programming and cost estimates for the repairs by a review of existing drawings, determination of the structural design of the balcony system, visual inspection and sounding of all exterior elevation concrete surfaces. EMI also cored and drilled the balconies at various locations to extract powder samples for chloride content testing.

34 Masonry Repair Concrete Repair & Restoration Riverside, Illinois PROJECT SUMMARIES This historic train station, located in historically significant Riverside, Illinois, required extensive masonry repairs. Eugene Matthews removed the outer wythe of brick from the footing to the limestone sill and beltcourse the full length of various elevations. EMI removed the limestone sill and beltcourse and replaced with new limestone cut to match the existing. At the base of the walls, EMI installed through wall flashing. All brick was cleaned and reset in a sound and plumb condition. Miscellaneous grinding and tuckpointing was also performed with careful attention paid to the technical match of existing mortar.

35 Masonry Repair Concrete Repair & Restoration ROCHESTER, MINNESOTA PROJECT SUMMARIES The following services were provided for this 9-story structure: -High pressure cleaning all elevations. -Selective repointing. -Selective sealant replacement

36 Masonry Repair Concrete Repair & Restoration T his Chicago assisted living and nursing care facility required multiple masonry and waterproofing related repairs. Throughout the project, care was taken to control noise and traffic so as to minimize the impact of the work on the residents. PROJECT SUMMARIES The first phase began by addressing failing sealant and rubber membrane roof joints at the roof perimeter. EMI removed and replaced all sealant at coping head joints. Then, chimneystacks at the roof level were tuck-pointed to address progressive freeze/thaw damage. Up to 600 lineal feet of oxidized lintels were removed and replaced at multiple window openings throughout the façade. Over 300 brick were removed and replaced at the exterior of parapet walls. Finally, new expansion joints were saw cut to allow for the natural movement of the structure and to prevent additional cracked brick at the corners of the structure. The second phase of this project started with the repair of improperly installed sealant, which had lost adhesion. This required the removal, proper joint preparation and replacement of up to 1000 feet of sealant at various locations on the façade. In addition, EMI spot tuck pointed up to 1500 lineal feet of mortar joint. Finally, AC unit perimeter sealant was removed and replaced at all locations using a one part polyurethane sealant.

37 Masonry Repair Concrete Repair & Restoration PROJECT SUMMARIES COLUMBIA, MISSOURI This 15-story building required concrete repair at vertical locations. Failed areas of structural concrete were cut out, then shored and framed for repair operations. New supplemental steel was installed and then all repair areas were patched using new concrete patching materials.

38 Masonry Repair Concrete Repair & Restoration T his Seminary classroom and faculty office building was constructed in the mid 1920s. The design sought to allow for classrooms to receive maximum daytime illumination through the use of large window openings. Limestone mullions were designed to hold leaded glass windows. The vertical mullions are also integral to the structural integrity of the facade. Original construction called for the use of steel pins to hold the mullions in place. Over time, and due to the porosity of the limestone, these pins oxidized within the stone. Severe cracking and spalling ensued, which, left un-addressed, would result in multiple failures of mullion units and many damaged leaded glass windows. PROJECT SUMMARIES Eugene Matthews was selected by the Seminary to undertake these delicate repairs, all while working around multiple classroom schedules. Nearly 70 damaged mullions were restored. The windows were removed, and the window heads shored prior to the operations on the mullions. Some mullions could be patched but many others were so severly cracked that total replacement was necessary. One concern was that patching operations would create an obviously uneven and unsightly difference in color at the areas of the work. Differences in color affect many limestone structures, but these are often gradual over the length and breadth of the façade, as different elevations and pieces wear in gentle variation, relative to exposure to sun, wind, rain and pollution. EMI solved this problem by using of a unique limestone patching material that can be custom colored at the work site. Failed mullions were replaced with new cut stone and pinned with new stainless steel pins, epoxy anchored into place. Finally, the original leaded glass windows were carefully reinstalled.

39 Masonry Repair Concrete Repair & Restoration T his beloved chapel dates from the early years of the Garrett Evangelical Theological Seminary. The Romanesque design and style of construction, which incorporates stone massing and heavy timbers, is situated within a serene park like setting. While the design of this structure strives to convey a sense of historical permanence, the materials are as susceptible to weather related wear as any other. PROJECT SUMMARIES The project required great sensitivity to the nature of the as built materials. Prior to work, mortar and stone samples where analyzed to match existing as close as possible. Particular attention was paid to the constituency of the mortars. This was especially important due to the soft and porous nature of the limestone. Previous repairs had been undertaken without proper attention paid to the type of mortar installed. The result was several areas of substantial cracking and spalling of the stone. A mortar too hard and/or chemically incompatible with the surrounding stone will not allow for the natural wicking required of mortars in solid masonry walls. Over time, the stone itself becomes damaged over multiple freeze/thaw cycles as water, unable to exit through the mortar, permeates the stone. Consequently, Eugene Matthews, Inc. selected and utilized Type O mortar and a unique patching material of European origin. The inspection also revealed previous repair flaws at the roof peak where clay coping tiles had been joined with mortar rather than sealant. This common error can expose the structure to water penetration. More than another part of the structure, the roof materials undergo near daily expansion and contraction, relative to solar exposure. Sealants should be employed in this particular application due to the plasticity and flexibility this material offers over mortar, which will crack under this condition.

40 Masonry Repair Concrete Repair & Restoration PROJECT SUMMARIES Saint Louis, Missouri This downtown Saint Louis hotel required selective tuckpointing as well as extensive brick replacement at various locations over the facade. In addition to the masonry repair, sealant was removed and replaced at the rooftop copings and several areas of the concrete facade was repaired.

41 Masonry Repair Concrete Repair & Restoration PROJECT SUMMARIES Davenport, Iowa This historic 1920s office structure required a variety of repairs on the north and east elevations, including the limestone returns at the west and south elevations. EMI first had to remove all loose and spalling limestone and previous failed stone patches. Three sample limestone repair materials were installed to match the color and texture of the existing stone. Then, existing mortar from all joints within the work area were ground out with the joints then cleaned and repointed with Type O mortar installed in multiple lifts. Finally, all windows were recaulked at the window frame to limestone joints.

42 Masonry Repair Concrete Repair & Restoration PROJECT SUMMARIES This precast constructed seven story suburban Chicago hotel required sealant removal and replacement at all precast to precast exterior wall joints, precast to aluminum window frame joints, as well as at the window frame to frame mullion joints. Various areas of the precast were also patched utilizing a polymer modified repair mortar. Finally, the seventh floor precast panels were cleaned and power washed.

43 Masonry Repair Concrete Repair & Restoration PROJECT SUMMARIES This hospital complex contains several stand-alone structures. A 10-story bridge connects two of the buildings, allowing for pedestrian traffic between the two structures. The bridge structure is exposed to substantial thermal expansion and contraction stresses. Over time, vertical structural tile columns became damaged, allowing water to penetrate beyond the masonry fabric of the structure and to affect underlying structural steel. Eugene Matthews was engaged to: Install a suspended scaffold to inspect the bridge for any loose structural tile. Remove structural tile, where necessary. Mechanically clean and paint the exposed steel with a rust inhibiting paint. Install wall ties as needed. Install through wall flashing at each floor. Rebuild the columns with brick in a sound and plumb condition. Install silicone sealant at the vertical brick to masonry or window frame joints. Grind out and install silicone sealant at the cracks in the structural tile. This project required close coordination with hospital staff to accomadate the flow of patient, staff and visitor traffic at the hospital.

44 Masonry Repair Concrete Repair & Restoration BEFORE BEFORE This suburban Chicago banking facility was experiencing significant water infiltration at the window headers. Improper previous flashing was at the root of the problem. Over time, the underlying structural steel began to oxidize, creating the need to replace oxidized steel and to properly through-wall flash the affected areas. Brick courses above the headers were removed, steel cleaned and or replaced, and new through wall flashing installed. Cast stone was then installed in the area above the window headers. The original brick was cleaned and reinstalled at areas where brick had cracked. New expansion joints were also cut into the structure to allow for natural, thermal driven structural movement. PROJECT SUMMARIES AFTER AFTER AFTER

45 SMALL REPAIR AND MAINTENANCE PROJECTS EXAMPLES Masonry Repair Concrete Repair & Restoration STEP CRACK REPAIRS BRICKWORK ON A PLANTER BOX E X P A PARAPET AND COPING STONE REBUILD GARBAGE ENCLOSURE BLOCKWORK REPAIRS R EP N SI O N J A I R S PRE-CAST CAULKING O I N T BRICKWORK AT A DRIVE THRU

46 SMALL REPAIR AND MAINTENANCE PROJECTS BRICKWORK AT A DOCK EXAMPLES Masonry Repair Concrete Repair & Restoration BRICK RETAINING WALL REPAIRS PRE-CAST CAULKING PARAPET AND COPING STONE REBUILD INFILL OVERHEAD DOOR WITH BLOCK LINTEL AND BRICKWORK AT A OVERHEAD DOOR BLOCKWORK AND BRICKWORK E X P A N SI O N J R E P A I R S INTERIOR BLOCKWORK O I N T

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52 SAFETY Masonry Repair Concrete Repair & Restoration 2006 Also a Recipient of 2005 ASA Safety Award

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