Common Issues We Address
Cracked and Spalled Terra Cotta Units
Terra cotta is a fired clay material prized for its durability and architectural detail, but freeze-thaw cycles, moisture infiltration, and age cause units to crack, spall, and separate from the building substrate. Once the protective glaze is compromised, water penetrates the porous clay body and accelerates deterioration. AWR assesses damaged units, performs targeted repairs, and sources matched replacement units to restore both structural integrity and architectural character.
Services Include:
- Individual unit crack repair and consolidation
- Spalled unit replacement with matched terra cotta
- Glaze and surface restoration
- Mortar joint repointing at terra cotta installations
Failed Mortar Joints and Water Infiltration
Deteriorated mortar joints between terra cotta units allow water to migrate behind the cladding system, causing hidden damage to the substrate, backup masonry, and interior finishes. In coastal Mid-Atlantic environments, salt air and humidity accelerate mortar degradation significantly. AWR performs selective joint removal and repointing using mortars specifically formulated for compatibility with historic terra cotta installations — a critical distinction, as incompatible mortars can cause irreversible damage to original units.
Services Include:
- Mortar analysis and specification matching
- Selective joint removal and repointing
- Moisture infiltration investigation and remediation
- Backup masonry repair behind terra cotta
Anchor and Tie Failure
Terra cotta units are typically anchored to a backup masonry or steel frame structure using metal ties and anchors. As buildings age, these connections corrode and lose capacity, allowing units to shift, bow, or separate from the wall — creating a life-safety hazard that requires immediate attention. AWR performs anchor assessment, installs remedial anchor systems, and stabilizes displaced terra cotta to bring the facade back to a safe and structurally sound condition.
Services Include:
- Anchor and tie condition assessment
- Remedial anchor installation
- Unit stabilization and realignment
- Structural grouting behind displaced units
Sealant Failure at Transitions and Penetrations
Terra cotta installations require compatible sealant systems at all transitions, penetrations, and interfaces with dissimilar materials. Failed sealant at window perimeters, control joints, and material transitions is among the most common sources of water intrusion in terra cotta facades. AWR selects and installs sealant products specifically compatible with historic terra cotta substrates to ensure long-term performance without staining or chemical damage to original material.
Services Include:
- Expansion and control joint sealant replacement
- Window perimeter resealing
- Transition detailing at dissimilar materials
- Penetration sealing and waterproofing