A Modern Makeover – A Failed, Tired Masonry Façade Gets a New High-Performance Look

This topic was initially presented at the 2020 BES. 

This presentation will provide a case study of a medical research/office facility that, at nearly 35 years old, needed major exterior repairs. This mid-1980s building was constructed with thought given to energy conservation and durability by using continuous thermal insulation in the wall assembly and a durable masonry cladding system. Unfortunately, defects in the original design and construction created an exterior wall assembly that developed cracks in the exterior masonry and deterioration of the supporting steel members, and the building lacked an air barrier and leaked air badly, defeating the original energy conservation considerations. The lack of vertical masonry control joints led to widespread cracking and corrosion of supporting steel relief angles. The assessment of the masonry defects discovered that the wall assemblies lacked a weather barrier and an air barrier. Large air leaks were discovered during the cladding assessment, creating another challenge in developing restoration concepts.

The assessment resulted in three options. All steps—from the initial assessment of the building through the various design concepts and options—will review the construction challenges for the new lightweight metal panel over-cladding system, designed with a modern appearance to align with the owner’s corporate image and to coordinate with other research facilities.

Timothy A. Mills, PE, LEED AP, CIT II

TAM Consultants, Inc. | Newport News, VA

Timothy Mills graduated with a bachelor of science degree in engineering from Brooklyn Polytechnic Institute of New York in 1983. Prior to forming TAM Consultants in 2002, Mills worked at a number of multidiscipline design and inspection firms. He has published numerous articles, presented at conferences and symposia, and completed nearly 1,500 residential home and commercial building inspections and 300 energy audits. He is an instructor for ABAA training courses that educate and certify contractors in the proper installation of air barriers, and is a certified ABAA Auditor for their quality assurance program, as well as a Certified Level II Infrared Thermographer.