Streetsboro, OH – Faced with the possibility of moving its’ deteriorating 230,000 square-foot tobacco curing and processing complex in 2009, the Lancaster Leaf Tobacco Company, Inc. embarked on an $11.5 million expansion and restoration project to modernize its’ tobacco-processing operation and save nearly 120 jobs. A subsidiary of Universal Corporation, Lancaster Leaf’s revitalization advancements are poised to make it one of North America’s largest processors of dark, air-cured tobacco and stimulate job growth in the regions’ future.
SUSPECT SUPER STRUCTURE
As part of this renovation, many of the early 1900’s tobacco warehouse structures at the Pitney Road complex are being preserved vs. replaced, including the recent structural restoration of a 5-story warehouse on the southwest corner of the campus. Notably, a 40’ x 50’ section on the east elevation of the warehouse had collapsed in the summer of 2011. Immediately, a detailed inspection was done on the remaining masonry façade by Caretti Restoration & Preservation Services, Inc. (Camp Hill, PA), to determine the best implement of repair for the severe structural issues.
The inspection revealed that a triple wythe of bricks was coming apart and the header courses that tied the walls together were not intact. In addition to the building’s age, deterioration occurred because it was a concrete superstructure with brick infill that expands when it gets wet and pulls the concrete apart vs. a steel-based superstructure.
SYNERGISTIC SYSTEM SOLUTION
To avoid the costly and time consuming replacement and reinstallation of the damaged concrete superstructure, Caretti Restoration’s GM/VP, Bob Gensel, enlisted leading industrial masonry repair reinforcement system manufacturer Helifix®, Inc. to implement a strategic combination of their precision engineered Crack Stitch and DryFix systems in early October of 2011.
Helifix’s Crack Stitch system was utilized predominantly for repairing vertical cracks on the building’s corners to solve key structural concerns and also for aesthetics. Helifix’s Dryfix remedial pinning and tying system was used for tying the wythes of bricks together to the walls and also for repair of the corroding, loose, and missing steel shelf angles supporting the brick veneer for all damaged areas of the warehouse’s 5 stories.1 2 3 next >>