Completed Projects: Harbor Court Complex

Project Background
The development of Baltimore’s Inner Harbor area was the key to the city’s revitalization in the 1980s. At the heart of Inner Harbor, an area home to Class A office buildings, high-end retail spaces, The National Aquarium, and Camden Yards, is the Harbor Court Complex.

Built in 1986, Harbor Court encompasses an entire city block on the west side of Inner Harbor. Harbor Court includes a 30-story condominium and office building; an eight-story hotel; and a parking garage topped with a tennis court, health club, and garden area.

The Problem: Cracked and spalled bricks led Harbor Court's owner to contact the Greensboro, North Carolina, engineering firm of Sutton-Kennerly & Associates to evaluate the problem and design a fix.

SKA then brought in Masonry Preservation Services to assist in a condition survey. MPS performed the rigging and demolition required for SKA to assess the complex’s structural framing and brick veneer systems.

Loose and missing shelf angles
Misalignment of framing and veneer system resulting in unacceptable stresses within the assembly
Insufficient ties to secure the brick veneer to the structural framework at high wind loads

SKA designed a prototype repair to be performed on the major structures of the complex where severe brick cracking and displacement had been noted during the condition survey.
Prototype repair provided a deeper understanding of conditions throughout the structures and allowed the development of a comprehensive repair design.
With feedback from MPS, SKA was able to evaluate whether their project design could be effectively performed.
Upon completion of prototype repair, SKA developed project documents for the entire complex.
MPS is awarded a contract for repairs to the hotel, parking garage, and one half of the condominium building.

Because of the insufficient number of existing masonry ties holding the brick veneer to the structural frame, 20,000 retrofit ties were installed before any other deficiencies were corrected.
In order to determine the exact locations of the existing ties, exterior walls were surveyed with an electronic metal probe.
Tie locations were reviewed by SKA to determine where additional ties were required.
MPS utilized a probe to find the location of steel studs at the locations where the new ties were to be installed.
Once a stud was located, a hole was drilled into the steel stud. A retrofit anchor was inserted into the pre-drilled hole.

Once the retrofit ties were installed, MPS began the removal of brick at each floor line and properly supported the remaining brick with shoring (Fig. 3). Any defects (loose or missing bolts, missing shelf angles, cracked or broken brick) were then corrected.
At the outside corners of the building, an elaborate system of new steel framing was welded and bolted onto the existing structural frame. MPS utilized a 75-ton hydraulic "ironworker" to notch, punch, and shear the steel angles and plates.
Other repairs, including the installation of new through-wall flashing, repointing, and re-caulking, were performed.
Extensive testing of replacement bricks, mortar, and sealants was conducted to ensure that the repairs would last and also blend in with the existing façade.

Additional Project Notes
Based on MPS’s performance on this project, MPS was awarded additional work on remaining portions of the tower façade, project work that had been previously awarded to another firm.

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