United States Penitentiary at Lewisburg, Lewisburg, PA
Smokestack Tower Masonry Restoration
Project Background
Nestled in scenic Central Pennsylvania, the United States Penitentiary (USP) at Lewisburg is a high-security facility housing male inmates. Construction began at USP Lewisburg in 1931; it opened uncompleted in the fall of 1932. USP Lewisburg is one of only a handful of federal penitentiaries in the country.
Constructed by the abundant supply of craftsmen during the depression, USP Lewisburg was intended to be unique in function and form. The facility’s masonry structures were designed by architect Alfred Hopkins, who modeled the prison after the Palazzo Pubblico in Siena, Italy. The Italian Renaissance-style buildings are rich in corbels, gothic arches, and ornate brick and terra cotta construction. The center of the prison complex is punctuated by a 200-foot-tall masonry tower concealing a once-active smokestack; the tower is adorned with open-arched balconies and topped with two tiers of battlements. We owe the distinct architectural style of the prison to the enlightened thinking of the 1930s Bureau of Prisons, which endeavored to apply correctional principles that would rehabilitate the inmate instead of isolating him in a dismal environment.
Prior to Masonry Preservation Services' arrival on-site, a preliminary debris netting system was installed at a portion of the tower, but was incapable of providing the protection required. Thereafter, Masonry Preservation Services (MPS) provided rigging and swing-stage support for engineers to perform a condition assessment of the tower. The results of the evaluation indicated that several areas of masonry above the balcony level had deteriorated and rotated out of plane. Embedded steel supports at the corbels and arches had oxide-jacked the brick masonry out of position, causing masonry spalls, cracks, and the increased likelihood of falling debris. An initial attempt at light-duty debris netting was implemented, but it was soon realized that a more robust containment system was required. MPS then installed a structural netting containment system intended to limit masonry from falling to the roofs below. As a few years of Pennsylvania winters passed and the deterioration of the masonry accelerated, restoration or demolition of the upper portion of the tower was imminent. Fortunately the Federal Bureau of Prisons decided to restore the historically significant tower, and MPS was awarded the restoration work.
The Problem
Over 70 years of exposure to the elements and minimal maintenance has caused deterioration of masonry and embedded steel components. These deterioration mechanisms have rotated and displaced multiple areas of masonry at the upper portion of the tower, particularly at corbelled arches. Additionally, many other areas of deterioration continued to develop at the tower interior and exterior. As time passed, the likelihood of masonry fragments dislodging from the tower increased and action was required.
Project Challenges
- Perform repairs at a fully operational penitentiary 200 feet above mission-critical dining operations.
- The tower is situated in the center of the prison complex and is surrounded by other building on all sides, leaving no area of the tower dropping directly down to grade.
- Obtain custom-shape brick in various sizes to match the existing masonry in size, color, and texture.
- Complete detailed and ornate restoration work critical to the tower in a limited and confined work area.
Project Scope
Complete a myriad of repairs at the upper portion of the tower to restore its aesthetics and masonry integrity. The scope of repairs at the upper 70 feet of the tower generally includes:
- Rebuilding of the brick corbels, arches, and battlements above the balcony level
- Rebuilding of the terra cotta balconies
- Structural steel replacement
- Overall brick repointing
- Terra cotta battlement coping repair
- Cast stone balcony column replacement
- Steel tower stair replacement and painting
- Concrete balcony slab replacement and modifications
- Roof membrane installation
- Waterproofing coating application at smokestack cap
Project Approach
- Perform quality, long-term masonry repairs that are consistent with historical standards and guidelines.
- Utilize a combination of historic and modern materials and methods to restore and extend the service life of the tower.
- Implement a phased repair plan to allow access to the various work zones while allowing a work environment sufficient for craftsmen to perform quality restoration work.
- Do not impact normal penitentiary operations during the course of the project.
Due to site and security limitations, erection of conventional scaffold from grade up to the work area was not possible. Holes were cut into the 20-inch-thick masonry walls near the balcony level for steel beams to be needled through the structure. These beams form the take-off point for the scaffolding that encompasses the upper portion of the tower. Brand Scaffold then completed the installation with six decked levels of scaffold that allows full perimeter access to the tower masonry.
For more information on Masonry Preservation Services, contact us today or call 800-772-3573. |
