Centenary United
Methodist Church
Scope of Work
Full architectural services
Restoring the exterior masonry of the church.
Location
Beatrice, NE
History
The Centenary United Methodist Church was built in 1929.
Designed by Dougher, Rich and Woodburn Architects
Completion
Phase 1 is complete.
Phase 2 is complete.
Phase 3 is currently active
Phase 1
Phase 1 – The Challenge
Our team faced numerous distinctive difficulties at the Centenary United Methodist Church in Beatrice, Nebraska. The degradation of the tower and specifically at the southwest spire was a particular concern and one of the most critical issues to be resolved.
Repairs made after the lightning strike in the early 1990s were insufficient to stop the significant movement that followed. The tower as it stood prior to any recent renovation has portions that are misaligned, shifted and in some areas even dislodged. Displaced stones jeopardize the structural integrity of the spire.
Both churchgoers and the lower levels of the building are clearly in danger from the possibility of falling components. among those broken pieces are many tiny finals and crockets. To prevent further falling pieces, the disassembly of the southwest spire occurred under the observation of qualified professionals to determine which stones needed to be replaced and to recommend measures for restoring the existing masonry.
Notes:
A significant structural problem was also presented at the west gable wall where the choir sits. On either side, there is a symmetrical breaking in the stones causing misalignment due to an outward displacement. Again, a qualified professional was brought in for evaluation and correction of an issue with the initial structural design.
Some parts of the façade in other areas have less critical issues again with difficulties in resolution. In contrast to how the stone naturally evolved, many of the stones at the building corners were laid with their sediment layers oriented vertically and therefore show signs of delamination.
Some stones were experiencing severe surface erosion and spalling to the point where surfaces had retreated past the mortar’s edge. Warm, wet sections of the building that are shielded from sunshine support the growth of black lichen. When lichen dries and is swept away by rain, the lichen areas leave black lines on the stones below.
In mortar joint gaps that require re-pointing, the type of mortar will be changed replacing a cool-gray mortar as applied with a warm-gray mortal like the original mortar type.
Phase 1 – The Strategy
Berggren Architects provided the Centenary United Methodist Church with a comprehensive report which included six major tasks to under take in order of priority.
While some of the tower repairs can be made in-situ, other sections, including the entire southwest spire, must be taken down, disassembled, and the stone pieces reset. Disassembling the spire provides a valuable opportunity to investigate potential design flaws within all four spires.
Traditional Dutchman patches will be used where possible for areas of missing stone. The small corner pinnacles will be redesigned to be re-pinned in the method recommended by the stone fabricator. They will also be pinned further from the edge, lessening the potential for fracture and falling incidents.
Notes:
We have identified the structural deficiency of the gable wall to be the internal steel structure. The ends of the gable are supported by two columns which were designed without sufficient lateral support for their height.
Wherever visible, areas of missing stone will be replaced using a Dutchman patch, while areas of damaged stone will be repaired with stone epoxy. For small holes, fractures in still-solid stone, and delamination in remote locations, lime putty will be used.
Areas of slick, dark-gray mortar will be re-pointed with mortar matching the original. The lichen, identified as a purely cosmetic issue, may be removed with a chemical cleaner. The reconstruction of the front steps and completion of the storm sewer will occur around this phase.
Other restoration tasks include improving the wood fascia behind the gutters and repairing the deteriorating interior plaster walls.
Phase 1 – The Results
The results of phase 1 include new pinnacles on the bell tower, installation of identical stone to the tower and the installations of new bat screens.
Phase 2
Phase 2 – The Challenge
Phase 2 of Centenary United Methodist Church addressed an interesting issuing with the west gable wall.
The gable wall’s stone veneer, over the last century, has developed significant cracks that are, notably, symmetrical. Through research we found the parallel vertical cracks in the stone veneer that are located near the other edge of steel columns buried in the wall. The cracks occurred because the support for the veneer differs on either side of the columns. To the right, the masonry is carried on the steel frame buried in the wall, to the left, the masonry is bearing on the foundation.
Phase 2 – The Strategy
Our design remedy combined many small details, including a movement joint through masonry, adding a steel bent plate onto the steel column, and more. The plate supports the masonry veneer and prevents it from siding down the existing diagonal supporting steel.
A copper joint cover was then added to allow for the differential movement of the masonry supported by the steel structure that is supported by the foundation and held in place by the stone veneer. The new stone veneer was then placed on top.
Phase 2 – The Results
The stonework and cap stone are now in excellent condition. The new copper has begun to weather and blend into the existing copper gutters and flashing on the church. The copper flashing is well fastened and weather-tight.
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