Replicating and reconstructing old building materials requires deep research of its time

Old and historic buildings have charm, style, and class that persevere across time. They also have all the quirks and idiosyncrasies you’d expect, like outdated electrical systems, defunct valves and openings for heating and cooling mechanisms, and all sorts of unknowns embedded in the walls and floors.

Renovating or reusing existing buildings to match their historic significance requires extensive research into the building materials used of its time. Solid panes of thick glass, intricate brickwork, stone flooring, and beautiful crown moulding and woodwork are hard to find and replace in today’s marketplace.

Sometimes materials are hard to find and use for good reason. For instance, modern buildings use double-paned windows that seal tight around the building envelope in ways old sills and frames may not support. Replacing them may sacrifice the aesthetic a little, but overall helps protect historic buildings for future generations.

Similarly, removing outdated and harmful substances like asbestos, lead paint, and inefficient mechanical, electrical, and plumbing systems means we can save natural resources and combine modern science and engineering with classic historical value. But doing so requires a lot of planning.

Historic preservation meets traditional craftsmanship

When historic buildings need to be rebuilt without access to the original materials, we use a process known as “reconstruction” or “replication.” Replication involves recreating the appearance and structural elements of the original building using alternative materials and historical records as references. While it is ideal to use original materials, there are several situations where it’s impossible:

Building materials just aren’t used any longer, or existing materials have decayed or been damaged.
The cost of original building materials could just be too high. Supply and demand have changed over 100 years. Limestone, for instance, is much harder to use today because we’ve used so much of it.
Properties in historic sites or historic districts may have preservation concerns, like using certain colors of paint that match the original structure or time when it was built.
Safety and building code requirements may (rightly) require we use new construction techniques for fire safety or structural strength. In many parts of the U.S., state and local governments may require flood, fire, wind, snow, and earthquake protection features.

Luckily, there are ways engineers like our team at R.E. Dimond can work within these constraints to reconstruct or at least imitate the original building materials used in many existing buildings. To do that we review and conduct:

Documentation and research: Detailed historical records, including photographs, drawings, and written descriptions, are studied to understand the original design, materials, and construction techniques.
Site surveys: Archaeological investigations and surveys of the site may uncover remnants of the original materials or provide valuable insights into the building’s construction.
Comparative analysis: If there are similar buildings from the same period or style in the vicinity, their materials and construction methods can be studied to inform the reconstruction process.
Traditional craftsmanship: Skilled artisans and craftsmen experienced in time-honored construction techniques can sometimes be found to replicate the original building elements using alternative materials. This is common with glass and sometimes brick, but costs can rise rapidly depending on the project scope.
Modern substitutes: When suitable alternatives are available, modern materials with similar properties and appearance can recreate the original building’s features. For instance, synthetic stone or concrete may replace natural stone, or timber substitutes may replace traditionally historic wooden elements.
Historical accuracy vs. functionality: Depending on the purpose of the reconstructed building, compromises may be made between historical accuracy and modern functionality. For instance, modern wiring, plumbing, and insulation may be incorporated while preserving the building’s external appearance.
Documentation of the reconstruction process: Reconstructed buildings are often accompanied by detailed documentation that distinguishes the original fabric from the newly constructed elements. This helps future preservation efforts and ensures transparency for visitors.

Navigating laws and regulations for building material replication and historic buildings

Building preservation is a complex process. We work closely with building owners to navigate their best options. Sometimes the buildings are well-preserved and the historical evidence is still plainly visible, hanging on or around the building ready for restoration. Other times the historic status of a building, particularly if it’s on the National Register of Historic Places or sits in an historic district, requires more technical assistance.

Buildings on the National Register of Historic Places typically have to involve local, state, and federal preservation agencies depending on its significance. We also have to thoroughly document the building’s existing condition, materials used, materials replicated, and much more. This helps future building restoration efforts.

We faced this exact challenge during the revitalization of the Stutz Building in Indianapolis, where nearly a century of incomplete records meant our engineers had to survey, document, and re-map entire wings of the building’s mechanical and plumbing systems from scratch before any new design work could begin.

The most common materials we work to replicate include:

Brick and masonry, either matched in size, color, and texture to generally available bricks or preserving the existing bricks. Sometimes we can use “faux” exteriors on existing walls to give it a uniform look.
Metalwork around grates, rails, columns, and decorative elements. Sometimes we’ll fabricate new pieces, or try to restore the original elements.
Roofing materials, which have changed a lot over time. We can often find modern alternatives that match the style, shape, color, and texture with improved durability and longevity.
Glass and glazing, which can sometimes require hand-blowing new glass, painting stained glass, or replacing the historic materials entirely depending on the new construction reuse needs.
Plasterwork can be replicated using specialized techniques to cast moldings, cornices, or decorative motifs.
Floors with intricate tiles, patterns, or mosaics can be replaced with new materials that mimic the appearance and original historic character.
Woodwork, with particular emphasis on non-structural elements like stair banisters, rails, and cabinets, can be recreated by skilled craftsmen to join or recreate designs. Sometimes just sanding and re-staining is all that’s needed to restore the original appearance.

Historic structures like the Eagles Theatre link us to our past and future

Historic preservation matters to our communities. It links us to our past and connects us to our future. We do this work because significant economic benefits come from restoring historic buildings, too. Preservation values buildings that are actually used, too, like the historic Eagles Theatre in Wabash.

Originally built in 1906, the Eagles Theatre underwent an extensive renovation completed in 2020. With the help of krM Architecture, we helped add screens, convert spaces into new use, installed a new, modern kitchen, and more.

Once the initial historic preservation project was completed, we moved to ongoing maintenance and monitoring. We help clients establish a maintenance plan that preserves the building’s high historical value.

Get started on your historic building with R.E. Dimond and Associates

We love local history and combining new materials with age-old craftsmanship to preserve historic properties.

For a closer look at how we balance modern MEPT systems with historic character across a full building, see our overview of MEPT engineering in historic preservation.

Get started on the next chapter of your historic building’s long history by speaking to one of our engineers. We can help evaluate the historical integrity and building structure to give you actionable next steps. We can even help you navigate permitting requirements, too.