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ABSTRACT
The industrial revolution of the
late 19th century produced a dramat
ic change in building construction.
The ability to economically manufac
ture steel shapes led to the develop
ment of the skeleton-frame building
system. This system enabled the exte
rior wall to be used as a nonload
bearing component of the building.
The façade could be treated as a skin
that wrapped the skeletal frame. The
skin was still needed to transfer wind
loads to the frame and provide weath
er protection, but it no longer had to
support interior floor loads. (See
Figure 1.)
INTRODUCTION
Figure 2A – The Home
See Figures 2A and 2B.
Insurance Building, Chicago,
The corrosion of exposed iron has
generally recognized as the
long been recognized as a potential
first skyscraper, was built in
problem. The incorporation of iron
1884 (Chicago Tribune
into masonry construction and subse
image from Google Images).
quent corrosion-related distress have
resulted in dramatic changes in the
construction and detailing of cladding
systems to address water infiltration
and corrosion. (See Figure 3.)
Numerous methods of limiting
corrosion have been employed Figure 1 – Skeleton-frame building under construction
throughout history, including boiling (image from www.skyscrapercity.com).
the iron in tallow, covering it with
pitch or varnish, or coating it in molten tin
or zinc (otherwise known as galvanizing).
Interestingly, research in the early 1900s
revealed that some of the substances used Figure 2B – In 1931, the Home Insurance
as pigment in coatings, such as lead, acted Building was demolished to make way for the
as inhibitors to the corrosion process. It Field Building (now the LaSalle Bank Building).
MARCH 2010 INTERFACE • 13
Figure 3 – Distress of masonry cladding resulting from corrosion of embedded steel structure.
was found that the inhibiting coatings pro systems. Although originally extolled as of mass-produced rolled steel sections in
vided protection even without a continuous inexpensive and resistant to both fire and the 1850s, two building framing systems
coat. Moisture-barrier coatings, however, rust, cast iron was a brittle material that evolved that ultimately led to modern sky
relied on the total separation of metal from lacked tensile strength. Therefore, early scrapers. The cage-building system utilized
the atmosphere. More recently, corrosion- buildings with framed structural systems steel spandrel beams to support both the
resistant materials such as stainless steel used cast-iron compression components, floor loads and the exterior wall. In a skele
and aluminum have been introduced. coupled with wrought-iron beams, which ton system, the support of the exterior
Careful attention to material selection, provided much stronger tension and flex cladding system was separated from the
detailing, and construction practices can ure. In the pursuit of enhanced capacity support of the primary building loads. Both
greatly reduce the potential for corrosion- and performance, the use of
related problems in a new building. The cast and wrought irons in
cladding systems in the majority of mason structural applications was
ry buildings built prior to 1970 were con quickly superseded by steel.
structed with corrodible metals. Proper The material properties of that
maintenance programs are critical to mini steel were more consistent
mizing the rate of corrosion of embedded than those of iron, with good
metals, but most buildings are not immune compression strength, tensile
to the eventual effects of corrosion. strength, and ductility.
Because of this consistency
INTRODUCTION OF THE CURTAIN WALL and superior performance,
Cast and wrought-iron structural com steel was used for both col
ponents had been used prior to 1800, but umn and beam members in
the limitations of these materials restricted later framed buildings.
the development of iron-framed structural Following the development Figure 4 – Early twentieth-century wall system.
CLADDING MATERIALS
Early skeletal-frame buildings utilized
numerous exterior cladding materials.
Brick, terra cotta, and stone were all used,
with economics frequently dictating both
the location and quantity of material. (See
Figure 4.)
BRICK MASONRY
Early brick walls were typically mono
lithic. Brick headers were used to tie adja
cent wythes together. The popularity of the
uniform appearance of the running bond
pattern led to alternate methods of creating
a monolithic wall. A more reliable system
that was more economical than the blind
header system was the incorporation of
steel or galvanized iron straps or wire ties Figure 5 – Terra cotta anchorage details.
during this time period tially constant and relatively low. When the
was very similar to that pH falls below four, the rate of corrosion
of ashlar terra cotta, accelerates dramatically. In masonry wall
utilizing a combination systems, mortar and cement materials ini
of keying and bent bars tially create an alkaline environment with a
and rods to tie the fac pH of approximately ten. As carbon dioxide
ing material to the back from the environment penetrates the mortar
up masonry. Individual and causes carbonation, the pH is reduced,
stones of greater thick resulting in increased corrosion (Craig,
ness keyed the stone 1995). By far the greatest cause of corro
facing into the backup sion, however, is water infiltration. (See
Figure 7 – The corrosion process.
wall. Additionally, Z- or Figures 6 and 7.)
C-shaped steel or iron
sometimes used to tie individual stone cramp anchors were installed to anchor the ATMOSPHERIC CORROSION
blocks together within a wythe or to tie stone to the backup for larger pieces. One Atmospheric corrosion is the corrosion
adjacent wythes (Lavicka, 1980). end of the cramp anchors was embedded mechanism that generally has the greatest
The thickness of stone used during the into the backup, and the other end was impact on masonry construction. Unpro
early part of the twentieth century typically inserted into a hole or slot in the top or side tected ferrous metal exposed to the environ
varied between four and eight inches, of the stone panel. ment in the presence of moisture results in
although very expensive stone may have corrosion potential between two points on
been cut as thin as two inches. The stone THE CORROSION PROCESS the surface of the metal. Variability of cor
was applied as facing to a brick or clay tile The rate of corrosion when the pH of a rosion will occur with differing electrical
backup wall. Lateral anchorage for stone material is between four and ten is essen potentials on a wet metal surface, possibly
16 • INTERFACE MARCH 2010
impact of corroding
steel. Initial material
selection now has the
potential to eliminate or
greatly reduce the prob
ability of corrosion.
Galvanized compo
nents, aluminum, and
stainless steel have all
been utilized as noncor
roding systems, but
these still have a finite
service life.
Maintenance of the
building enclosure
plays a critical role in
the rate of corrosion of
the underlying steel as
well as the extent of
distress resulting from
the accumulation of
corrosive scale.
DISTRESS CONDITIONS
Many different
types of distress condi
tions occur as a result
of the corrosion of
Figure 8 – Complete loss of lateral anchorage.
LOCALIZED CRACKING
Cracked Brick
work. Localized, cor-
rosion-related crack
ing in brickwork is
usually the result of Figure 9 – Displaced brickwork.
DISPLACED MASONRY
Although compressive stresses within
the façade (caused by moisture and thermal
expansion of the cladding, as well as
shrinkage and creep of the structural
frame) can also contribute to both localized
and overall displacements, in most cases,
corrosion of underlying steel contributes to
MARCH 2010 INTERFACE • 19
ate corrosion, cleaning and painting of the
existing steel with a corrosion-inhibiting
system (zinc, urethanes, and epoxies) can
be an effective repair (Figure 11). In some
cases, severely corroded areas can be wide
spread or directly adjacent to relatively
intact areas, requiring either localized
repairs or replacement of the piece.
To attach replacement or reinforcing
members, field welding can be an economi
cal choice; however, testing for weldability
of the existing metal and determination of
special procedures that may be required to
achieve good quality welds is critical for an
effective repair. Special care should be
taken following welding processes to ensure
that protective coatings are repaired and
that crevasses that can hold water and cre
ate a potential for future corrosion are not
created. When different metals are being
welded together, it is critical that they each
be evaluated for weldability and potential
galvanic corrosion. Field welding also poses
Figure 10 – Installation of flashing system, including end dam to protect underlying shelf a risk of fire, since the welding process can
angle at window head. inadvertently ignite interior finish materials
or materials hidden within the wall.
the displacement of masonry cladding between adjacent pieces. Where wall sys Bolting of new pieces of steel to existing
materials (Figure 9). tems require repair or reconstruction, rarely steel is the most straightforward method of
is it advisable to reuse these anchors, re repair (Figures 12A and 12B). This can be
REMEDIATION AND PREVENTION gardless of their condition. Replacement of expensive, since access necessary to install
WATER MANAGEMENT existing components with new stainless the nut at the back of the bolt often requires
Liquid water control measures are often steel anchors specifically designed for the removal of additional backup materials.
introduced with various levels of success, conditions is almost always advisable. Several new anchors that are conceptually
depending on the system design and instal- Evaluation of gravity support elements similar to pop rivets have been introduced
lation. The integrity of the mortar joints such as shelf angles and columns is usual- within the past decade to permit one-sided
between masonry units is one of the most ly more complicated and requires addition- installation and eliminate the need to
important factors in minimizing water infil al consideration. In cases of mild to moder access both sides of the member.
tration into a wall system. In addition,
flashings can provide a degree of control of
moisture penetration in masonry walls.
Without properly designed and installed
flashings (Figure 10), water that penetrates
a wall will not be diverted back to the exte
rior and can accelerate corrosion. Flashing
systems were generally not included in
exterior wall systems until the 1940s. Many
of the early systems were not effective and
may have actually exacerbated the condi
tions they were intended to mitigate.
Stainless steel, copper, and lead-coated
copper are effective and durable flashing
materials. A properly designed flashing sys
tem can both protect steel support elements
as well as direct moisture within the wall to
the exterior.
SUPPLEMENTAL LATERAL
ANCHORAGE
Supplemental lateral anchors can be installed to reestablish the required
lateral anchorage for the wall system. Numerous types of proprietary
anchors exist for this purpose. Regardless of the anchor selected, the pro
posed anchor should be tested to determine the required spacing to ade-
quately resist wind and seismic design cri 30 years. Cathodic protection systems are itage, 193, pp. 8-16.
teria. All such anchors should be of stain theoretically capable of stopping corrosion, Corrosion in Masonry-Clad Early 20th
less steel. Repair anchors may rely on adhe but they cannot reverse the corrosion Century Steel-Framed Building,
sion, friction, or bearing to achieve the nec process. Extensive evaluation of existing Technical Advice Note 20, Technical
essary structural capacity. Due to the conditions, conductivity, and continuity is Conservation Research and Edu
“blind” nature of the installation of repair necessary to determine practicality of cation Division, Historic Scotland,
anchors, variability of the substrate must installing an effective cathodic protection 1999, pp. 17-20.
be considered in developing the spacing and system. B. Craig, H andbook of Corrosion Data,
installation criteria. Some anchors will ASTM International, Materials Park,
inevitably be installed into voids or into SUMMARY OH, 1995, p.11.
inadequate substrate, rendering them inef The lessons that have been learned over Cecil Elliot, T echnics and Architecture:
fective. Contractors should be sensitized to the past 130 years regarding corrosion in The Development of Materials and
these issues and be encouraged to notify buildings are important to recognize. Systems for Buildings, The MIT
the architect or engineer should the prob Thousands of historically significant build Press, Cambridge, MA, 1993, pp.
lem be more serious than anticipated. ings will inevitably require some level of 23-73.
Techniques for installing repair anchors intervention to save. Significant pieces of C.T. Grimm, “Demolish Charleston’s
should be carefully evaluated to ensure that our architectural heritage may be lost if Brick Walls Because There Is Chlo
they do not cause spalling of the back face proper measures are not taken to address ride in the Mortar?” Journal of Ma
of the masonry. Special drills with rotary these buildings. Significant life-cycle cost terials in Civil Engineering, American
spline drives, which drill holes with minimal savings can be realized by performing regu Society of Civil Engineers, Reston,
hammering action of the bit, should be used lar maintenance on them. If both the main VA, Vol. 9, No. 3, August 1997, p.
if spalling is a potential issue. tenance and repair of these buildings are 160.
performed with the appropriate materials W. Lavicka, Masonry, Carpentry, Join
CATHODIC PROTECTION and understanding of the systems, their ery: The Art of Architecture, Engineer
The corrosion process of a metal can be service life can be greatly increased. ing and Construction in 1899, Chica
effectively halted by providing sufficient go Review Press, Chicago, IL, 1980,
electrons to the anode to reverse the reac REFERENCES p. 114.
tions at the anode and cathode (corroding J. Ashurst, N. Ashurst, Practical Building David Yeomans,
Construction Since
steel). Early construction-related applica Conservation, English Heritage Tech 1900: Material, B. T. Batsford Ltd.,
tions were used to protect subgrade piping nical Handbook, Volume 4: Metals, London, England, 1997, pp. 33-40.
in the 1920s. Prior to that, applications Gower Technical Press, English Her
were limited to marine structures. Two sys
tems exist as illustrated above. The galvan Edward Gerns, RA, LEED-AP
ic system is an obvious outgrowth of the
Edward Gerns is a principal at Wiss, Janney, Elstner
understanding of galvanic interaction
Associates, Inc. (WJE) with over 19 years of experience.
between dissimilar metals (Figure 13) and
Gerns has performed hundreds of investigations and assess
uses the natural process of the galvanic
ments and developed repairs of building façades of all vin
interaction to protect the embedded steel.
tages and sizes throughout the U.S. He has investigated and
More recently, and for larger applications,
repaired cladding materials, including terra cotta, stone,
impressed current systems are more appro
brick, curtain wall, EIFs, wood siding, and composite materi
priate (Figure 14). These electrochemical
als. He has written numerous papers related to façade
techniques, such as cathodic protection,
assessments and repairs. He is an instructor in a building
have proven effective in parking garage
diagnostics class for the Masters of Historic Preservation
installations and have been implemented on
degree at the Art Institute of Chicago.
cladding systems in Europe within the past
22 • IN T E R F A C E MARCH 2010