Thayer Academy, through CBI Consulting Inc.(CBI), engaged Atlantic Restoration Corp. (ARC) under a quasi design build approach to perform comprehensive façade repairs consisting of masonry pointing and rebuilding, sealant replacement, wood replacement, and flashing repairs to the Main Building of the academy.
The Main Building was erected in 1877. In 1922 masonry deterioration and an unfortunate lightening strike, which destroyed the eight story entry tower, required a tower reconstruction and veneer replacement of 20% of the brick surface. Following a partial restoration in 2002, Thayer Academy engaged CBI to undertake a review of the Main Building at the end of 2011. This review revealed deteriorated masonry, poorly executed repairs, failing carpentry around windows and roof trim. With that information, CBI created a work scope to address those deficient items increase the durability of the building's façade.
The project presented numerous challenges, one of which was the cutting and pointing of the needle joints. The joint widths ranged in size from 1/8" to as small as 1/32". This condition required special techniques and tools (developed by CBI and ARC during a mock-up phase) in order to achieve proper cutting depth and pointing. The base project expanded by 30% because of unforeseen conditions, yet had to be completed within 11 weeks to meet the school summer schedule. As the job expanded, Thayer, ARC, and CBI cooperated in working a 7 day week. This project was completed at the end of August on time.