Reynolds Building, Winston-Salem, NC
Structural Façade Reconstruction
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Fig. 1
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Fig. 5
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Fig. 7
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Fig. 8
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Project Background
Far from just standing in the shadow of its younger, bigger brother, the Reynolds Building in Winston-Salem is as a lasting tribute to early 20th century American architecture. Its art deco design was conceived by New York architectural firm Shreve & Lamb and was a prototype for the Empire State Building.
The 22-story tower, with attached ten-story office wings on its north and east elevations, is constructed of Indiana limestone with brick and structural clay tile backup.
The Problem: During a June 1995 structural condition survey, spalling and displacement of limestone components were noted at the low-rise office wing's upper floor and parapets (Fig. 1)
Project Challenges
- A study was initiated to disassemble a portion of the limestone parapet to confirm the severity of hidden deterioration. Several conditions complicated the project, including heavily congested rooftop mechanical assemblies located on the low-rise wings (Fig. 2) and the size and weight of limestone components requiring removal, some of which exceeded 1.5 tons.
- Occupied adjacent structures had to remain in service during the lifting of limestone components.
Project Scope
- Working in concert with Sutton-Kennerly & Associates, Greensboro, North Carolina, Masonry Preservation Services designed a structural steel lifting assembly attached to alternating limestone parapet components to serve as a hoisting frame for limestone disassembly and rebuilding. An elaborate scaffolding system was also erected to provide a separate structural platform to support cantilevered outrigger beams and counterweights required for swing-stage scaffolding placement directly over the hoisting frame (Fig. 3).
- Fourteen pieces of limestone were removed to reveal the underlying conditions (Fig. 4). Oxide jacking was identified on heavily corroded lintels and anchors, the cause of limestone displacement and spalling (Fig. 5).
- In addition to the oxide jacking, most limestone panels were missing top and/or bottom anchors or the anchors were severely corroded.
Project Approach & Solutions
- MPS began rebuilding the ten-story low-rise limestone parapets in autumn 1997.
- Additional work on the low-rise and high-rise below the tenth-story level included repointing, spall repair, and lead-coated copper spandrel repair. Under a separate contract the original windows were also replaced.
- MPS redesigned the rooftop scaffolding to accommodate both limestone hoisting and swing-stage outriggers. Even with the complexity of erecting this structure around the rooftop mechanical equipment (Fig. 6), the project was completed in just seven and a half months (Fig. 7).
- The resulting repair included provisions for thru-wall flashing and anchorage of all limestone components in accordance with building codes without any change in the building's exterior appearance (Fig. 8).
Additional Project Notes
Based on MPS’s performance, the project's size and scope were extended to complete the remaining upper tower and cleaning of the entire original structure. Today, the Reynolds Building's 70-year-old masonry façade stands as a tribute to the durability of masonry and the commitment of R.J. Reynolds to its landmark building.
For more information on Masonry Preservation Services, contact us today or call 800-772-3573. |
