Despite what we learned from the three little pigs, as they grow older, even the hardiest of brick buildings will require repair and restoration. The strict requirements of some historic districts have given way to lots of new tricks for dyeing and distressing new brick and mortar to closely resemble the older surrounding masonry.
Bob and Chris once again meet up with Cas Stachelberg from Higgins and Quasebarth to talk more about the fa�ade restoration. Higgins and Quasebarth is a New York City firm focused on the preservation and rehabilitation of historic properties. Stachelberg sizes up the restoration work by first describing the original high quality brick from the building's original use as a residence. The masonry works transitions to a more common brick with large mortar joints that was added when the building was converted to commercial use. Moving along the facade, Stachelberg points out the bluestone stairs, which were likely added during the building's commercial conversion. In disrepair, the stairs are now delaminating from decades of exposure to New York weather. The restoration expert also notes the brownstone sill on the other side of the building, which he believes was the building's original entrance.
Bob meets with Allan Cox from Nawkaw Corporation, on the front of the New York restoration project to discuss the bricks. The bricks were aged and roughed up with a grinder prior to installation to give them an antique appearance. This process also de-glosses the surface of the brick so pigments can be added. After three attempts, the New York City Landmarks Commission approved the pigments added to the brick. To further conform to the Commission's requests, sand dust must be sprayed into the finish to refract additional light.
Bob points out the newly clean beams that were sandblasted to remove more than a century of industrial grease and grime. The exposed surfaces in the interior will become an integral part of the new interior design. Vila points out that the sandblasting which was done on the interior brick would do irreparable damage if it were done on the exterior bricks as it creates a porous surface that would not withstand the weather.
Bob meets up with Professor Tom Visser from the University of Vermont to learn more about the antique year old brick used in the Burtch-Udall house in Quechee. The wall was built in the 1820s with bricks made on site. The brick is a high quality sand-struck brick. It's laid in a standard bond pattern with headers and then nine courses of stretchers. The wall is two courses of brick thick. The bricks were laid using a lime and sand mortar. Looking closely, one can still see the original tooling that was done. The bricks have never been re-pointed and never been cleaned and are still in excellent condition after nearly two centuries.
Bob visits the Sumner Mansion with UVM professor Tom Visser to learn more about the proper restoration and preservation procedures for an antique brick home. The original early 1800s brick has been sandblasted - removing the outside fire skin of the brick to reveal the soft inner core - leaving the brick permanently damaged. The only option now it to re-point it up and re-paint it. Care should be taken with masonry sealers as they can often trap moisture in the wall and lead to accelerate spalling of the bricks. If you have paint on old brick walls, your best option is to use a commercial paint remover such as a caustic soda, a Peel-Away type product, or even a solvent-based stripper. As for repairing the mortar, very often people patch and re-point using a Portland Cement mortar. This is not a good choice as it stands out like a sore thumb and is too hard for the bricks - putting stress on them and causing them to fail. To select the right mortar to use, loosen a sampling of the original mortar with a mason's chisel, crush it with a geologist's mortar and pestle, and then dissolve the lime binder with household distilled white vinegar. What will settle in the bottom of your jar is the sand from which the mortar was originally made. You can then take the sand to a mason and match its color and texture and make up new lime and sand mortar to match the original.
Bob takes a field trip to East Windsor Hill, Connecticut, where the bricks for this project were made. He walks through the process the brick ingredients follow and learns about the various machines involved.
