Completed Projects: F.M. Kirby Center

Project Background
Masonry Preservation Services’ F.M. Kirby Center project started as a way to remedy specific deterioration problems that were the result of more than 50 years of exposure to the elements and two earlier attempts at rehabilitation which proved to be inadequate.

Work on the Kirby Center began with a physical survey of the structure, in which MPS cut out sections of the building's façade in order to expose portions of the infrastructure. An envelope inspection revealed that the original terra cotta façade had no provisions for thru-wall flashings. (Fig. 1)
This condition allowed water to penetrate and accumulate inside the façade. As the structure aged, both the steel and masonry components progressively deteriorated (Fig. 2). This condition led to more severe moisture intrusion. On warm, dry days, heat on the outside of the building drew moisture trapped inside the base layer of the terra cotta tiles toward the outside of the façade. This "wicking" phenomenon led to the exfoliation of the glazing layer, like paint peeling from a poorly ventilated house.
MPS’s inspection also revealed that attempts to rehabilitate the structure in the 1970s, and later in 1994, actually made the problems worse by effectively "painting over" a set of relentless natural events.
Upon extensive facility review, MPS recommended a comprehensive restoration program for all of the building's terra cotta, including removal, replication, and reinstallation of the center tower's terra cotta cladding and replacement of portions of its structural steel frame. Budget constraints, however, dictated that a somewhat less authentic, but cosmetically compatible, system of repair be developed.

In response to financial considerations, MPS developed a dual repair/replacement approach which eliminated the need for replication of original materials. The original terra cotta tile at the building’s center tower and crown was replaced by Glass Fiber Reinforced Concrete (GFRC), which emulated the look of the original tiles. Epoxy paint from the 1994 effort was removed entirely and restored with a proprietary patching and coating system formulated to match the appearance of the original terra cotta. (Fig. 3)
In order to allow uninterrupted use of the Kirby Center during renovations, an extensive scaffolding system was erected to allow workers full access to the building façade while permitting continuous access to the building itself by theatergoers. (Fig. 4)
Due to the architectural significance of the structure, photographic and written documentation of all terra cotta façade components was compiled before demolition began. Following documentation, the upper parapet and the center tower were dismantled. (Fig. 5)
Restoration work included the manual sounding and removal of de-bonded glaze on hundreds of terra cotta panels (Fig. 6). Once the panels were completely free of deteriorated material, surface preparation, patching, coloring, and highlighting were all performed by hand to achieve the original appearance of the mottled terra cotta finish. (Fig. 7)
Although the original scope of work included some structural repair, once the crown and central tower were dismantled, it was clear that extensive repair would be necessary to bring the building back to a state of structural integrity. Final restoration work included the complete replacement of the central tower's framing and the installation of a new roof and secondary level decks.

Additional Project Notes
For its work on the F.M. Kirby Center, MPS received an Honorable Mention award from the International Concrete Repair Institute (ICRI). The project was one of more than 30 entries from around the world competing in the ICRI’s Special Projects Category in its 1998 awards competition for outstanding concrete repair.

For more information on Masonry Preservation Services, contact us today or call 800-772-3573.