Restoration Case Study: Repointing of The Aluta Mill Stone House
Project Overview
Location: Nazareth, Pennsylvania.
Building Name: Aluta Mill Stone House.
Building Type: A two-story stone residential building that exhibits Early Federal, Georgian, and Colonial Styles.
Year of Construction: Circa 1788
Historic Significance: This historic stone home has been a staple of the Nazareth area for over 200 plus years. Its unique natural stone facade reflects the craftsmanship of early local builders. The home's historical significance lies in its well-preserved masonry and representation of rural Pennsylvania architecture. The house is a private residence, holding stories of families who lived through regional historical events.
Project Background: The Aluta Mill Stone House is a prime example of rural Pennsylvanian stone masonry. Built in circa 1788, the building's exterior features traditional natural stone walls, a common material for homes of the era. Over time, the mortar holding these stones in place began to deteriorate due to natural weathering. Significant portions of the mortar had become loose or completely eroded, leading to structural vulnerabilities and aesthetic decline.
Recognizing the home's importance and need for preservation, the homeowners sought a complete restoration of the deteriorating stone facade on the front, left side, and back of the home. K.B. Masonry LLC's goal was to maintain the building's historical integrity while reinforcing its structural stability and appearance. Natural stone repointing was an essential restoration, as the building reflects Nazareth's architectural history and is a key landmark within its community.
Restoration Scope of Work
Project Selection: The homeowner chose K.B. Masonry LLC to restore this historic home. The restoration work included three primary tasks:
Task 1: Mortar Joint Inspection and Removal
Condition of The Original Elements: The mortar joints were heavily deteriorated, with large sections missing altogether. Deteriorated mortar joints left many stones at risk of shifting and exposed to further weather damage.
Restoration Process: K.B. Masonry LLC carefully removed the old, crumbling mortar by hand using different chisels to avoid damaging the original stone. This step was critical to ensure that the new mortar would bond properly.
Tools Used: To ensure precision and safety, scaffolding, chisels, water hoses, buckets, floor protection mats, P100 masks and filters, a debris disposal dump trailer, and safety gear were used throughout the removal process.
Importance of The Task: Mortar removal was a crucial first step, as the integrity of the new mortar is vital for the longevity of the stone facade.
Task 2: Repointing of Mortar Joints
Condition of The Original Elements: After K.B. Masonry LLC removed and cleaned the old mortar joints, it prepared the open joints for repointing.
Repointing Process: K.B. Masonry LLC applied fresh lime mortar using historically accurate techniques. Then, carefully performing the repointing ensures the repointing fills the joints evenly without overfilling, maintaining the home's original look. Press the mortar carefully to bond correctly with the stone and surrounding materials.
Materials Used: K.B. Masonry LLC chose lime-based mortar to match the original composition and ensure longevity. This type of mortar also prevents moisture from becoming trapped in the stone, which can cause freezing and cracking in cold weather.
Tools Used: K.B. Masonry LLC applied and smoothed the mortar into the joints using a professional mixer, buckets, hose, scaffolding, hawk, pointing detail tools, and specialty brushes.
Safety Measures: K.B. Masonry LLC correctly erected the scaffolding and was equipped with gloves, masks, and eye protection to handle the lime-based materials safely.
Importance of The Task: Repointing was essential to maintaining the home's structural integrity and aesthetic continuity. Correctly filled mortar joints protect the stone from weathering and ensure the longevity of the restoration.
Task 3: Final Cleaning of Stone Surfaces and Inspection
Condition of The Original Elements: Over the years, the stonework had accumulated dirt, moss, and other debris that masked its natural beauty and caused further deterioration. Still, after repointing, K.B. Masonry LLC thoroughly cleaned the natural stone surfaces to remove any residual dust or material from the restoration process.
Methods Used: K.B. Masonry LLC applied a gentle cleaning solution to the stone surfaces to avoid damage, followed by a low-pressure water rinse, and ensured that the cleaning process did not harm the delicate surfaces or nearby areas or remove any original stone details.
Importance of The Task: Restoring the natural stone's appearance was essential to returning the home to its original aesthetic and revealing any previously hidden structural issues.
Final Steps: K.B. Masonry LLC conducted a final inspection to ensure the repointing was even, the color was consistent, and all mortar had been correctly set.
Final Outcome
Completion
Upon completing the repointing and cleaning, K.B. Masonry LLC fully restored the home, reflecting its original historical significance, durability, and appearance. The natural beauty of the stone was enhanced, while K.B. Masonry LLC reinforced the home's structural stability. The restoration returned the home to a condition that will allow it to endure for future generations.
Significance of The Restoration
The Aluta Mill Stone House's restoration is a testament to the importance of preserving historic residential architecture. Using historically accurate materials and techniques, K.B. Masonry LLC ensured that the home would continue to serve as a lasting symbol of Nazareth's rich heritage. The project revitalized an essential home, preserving its character, durability, and appearance while enhancing the community's cultural fabric.
Project Team and Acknowledgements
Special thanks to all the employees and owners at our trusted vendors and suppliers, my wife, my kids, my assistant, and the Aluta Mill Stone House homeowners, for ensuring K.B. Masonry LLC completed this project successfully.
Conclusion
K.B. Masonry LLC is honored to have restored The Aluta Mill Stone House and contributed to its preservation. Through careful craftsmanship and attention to historical detail, K.B. Masonry LLC helped ensure this beautiful home stands as a symbol of the past and present for years to come.