Fallingwater Part 2: Materials-Conservation Efforts at Frank Lloyd Wright's Masterpiece

Author(s): Pamela Jerome, Norman Weiss, Hazel Ephron

Source: APT Bulletin, Vol. 37, No. 2/3 (2006), pp. 3-11
Published by: Association for Preservation Technology International (APT)Association for Preservation
Technology International (APT)
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FallingwaterPart 2: Materials-Conservati
Efforts at Frank Lloyd Wright's Masterpiece
PAMELA JEROME, NORMAN WEISS, and HAZEL EPHRON

Following a 13-year study of building Dramaticallysited over a waterfallin a surroundingland were donated by their
behavior and conservation tech- streamknown as BearRun, Fallingwa- son, EdgarKauffmanjr. [sic], to the
ter, FrankLloyd Wright'smasterpiece,is WesternPennsylvaniaConservancyin
niques, Fallingwater's challenging an icon of twentieth-centurydesign 1963.
five-year-long restoration is nearing (Fig. 1). Voted in 1991 by the American A materials-orientedrestorationpro-
completion. Instituteof Architectsas the "best all- gram,involvingfour phases and lasting
time work of architecture,"Fallingwa- from 2001 to 2005, was the directresult
ter currentlyfunctions as a house mu- of a 13-yearinvestigationof deteriora-
seum, welcoming more than 140,000 tion mechanismsand prototypetreat-
visitors per year.Locatedin Mill Run, mentsperformedby WankAdamsSlavin
Pennsylvania,60 miles southeast of AssociatesLLP(WASA),which led to a
Pittsburgh,Fallingwaterwas originally graphicconditionsassessment,a master
the weekend home of the Pittsburgh plan, and a public peer review.1WASA,
department-storemagnate,EdgarKauf- a New York City-basedarchitectureand
mann Sr.and his wife, Liliane.The engineeringfirm,first becameinvolved
house and more than 1,600 acres of as architecturalconservatorsof Falling-
water in 1988. A detailedexamination
of the investigativework was published
in the APT Bulletinin 2001 (volume32,
no. 4).2 The presentpaper aims to de-
scribethe implementationand resultsof
the project.3
Fallingwaterconsists of a main house
and guest house, erectedin 1936-39 and
connectedby means of an enclosed
"bridge"over the driveway,which leads
to an exteriorwalkway shelteredby a
steppedconcretecanopy (Fig.2). The
complex contains approximately7,000
squarefeet, over half of which is ter-
races.The buildingsare constructedof
stuccoedreinforcedconcrete,metal lath
and stucco over structural-steelframing,
local sandstone,and steel casement
windows and doors. The stucco, based
on white cement,has always been
painted.
The main cause of materials-related
deteriorationwas moisturepenetration.
(Significantstructuralfailureswere
successfullyaddressedduringthe res-
toration by the engineeringfirmof
RobertSilmanAssociates,PC. Since
December2002 the main house has
been free of the shoringinstalledin
Fig. 1. Fallingwater,an icon of twentieth-century design, was built in 1936-39. Photographby Robert April 1997.)4 The buildingshave always
P. Ruschak. Courtesy of Western PennsylvaniaConservancy. had their chronicleaks, reportedlyin

3
4 APT BULLETIN: JOURNAL OF PRESERVATION TECHNOLOGY / 37:2-3, 2006

Terraceswere waterproofedusing an
IRMA system (inverted-roofing-mem-
braneassembly)and coveredwith a
walking surfaceof irregularflagstones,
which were extractedfrom the overbur-
den of the on-site quarry.Froma probe
of the living-roomfloor in 1999, it ap-
pearsthat terracewaterproofingran
continuouslyunderthe flagstonesof
interiorspacesadjacentto terraces.In
addition,where roofs or terracesabut
stone walls or concreteparapets,there
is no through-wallflashingor original
regletfor cap flashing.To furthercom-
plicate matters,thereis no difference
in levels betweenterracesand interior
rooms.
To combat these deficiencies,reglet-
ted coppercap flashingwas installed
on the terraceof the servants'quarters
relativelyearly on, and in 1986 regletted
lead cap flashingwas introducedto most
of the remainingterraces.However,lead
provedtoo malleableto withstandthe
foot trafficof visitors,who tend to lean
againstthe parapetwalls to have a better
view of the surroundings,resultingin
the flashingbeing knocked out of place.
Some roofs had the additionalproblem
of condensationunderthe membrane.
This condition occurredas a resultof
the lack of a thermalbreakbetweenthe
exposed slab edges (roof rolls) and the
uninsulatedinteriorceilings (the under-
sides of the slabs).
The single-ply60-mil EPDM-rubber-
ized membranesystem,which was in-
stalledat most roofs and terracesin
1987-88, began showing signs of failure
within a year.The waterproofingsystem
Fig. 2. Key plan of roof levels showing Fallingwater and the guest house. All drawings by WASA. designedby WASAprovideda built-in
Courtesy of the Western Pennsylvania Conservancy. redundancyby using threeplies of mem-
branes.The lead cap flashingwas re-
more than 50 locations. Some of these Roofs, Terraces, and Skylights moved and replacedwith new cap flash-
problemswere from the time the Kauf- ing seatedin a reglet:16-ounce copper
The roofs of Fallingwaterwere originally at terraces(as used earlieron the terrace
manns firstoccupiedthe main house in
1937.5 The distinctivegeometryof the built-up,three-plyfelt laid in hot asphalt of the servants'quarters),lead-coated
and coveredwith pea gravel.Roof edges copper at roofs abuttingconcretepara-
buildings,the extraordinaryamount of are rounded(roof rolls), an extremely
exposed roofs and terraces,and the pets, and lead where roofs (accessible
difficultdetailfor terminationof a roof- only to the maintenancestaff) abutted
environmentalconditionsgreatlycon-
tributedto these failures.These prob- ing membrane.Leadgravelstops secured stone walls.
in horizontalregletswere shown on Roofing by three differentmanufac-
lems were exacerbatedby the lack of
originaldrawings.7However,it is un- turerswas used, and all threecompanies
through-wallflashingsand the unsuc- clearwhetheror not these featureswere
cessful designfor the terminationof providedwaterproofingwarranties,a
everinstalled.(Theonly evidencefor a firstin Fallingwater'shistory.J. L.
roofingand waterproofingmembranes.6
Considerableattentionwas given to perimeterregletwas found on the roof Robinson Roofing, Inc., of Pittsburgh,
above EdgarKaufmannjr.'ssleeping Pennsylvania,certifiedin the three sys-
these issues in the previousarticlein this
alcove, but almost all of the roof rolls tems, performedthe work.
journal. have been recastover time, potentially A three-plymodified-bitumenwater-
eliminatingadditionalevidence.) proofingsystemmanufacturedby Siplast
 FALLINGWATERPART 2: MATERIALS-CONSERVATIONEFFORTS 5

Fig. 3. Axonometric detail of modified-bitumen-roofingsystem, showing Fig. 4. At the roof-rolledge, the finished base flashing was coated with an
the base flashing terminatingon the roof rolland new lead cap flashing elastomeric paint, making it virtuallyinvisible.All photographs by WASA,
inserted into a reglet. unless otherwise noted. Courtesy of Western PennsylvaniaConservancy.

was installedon the roofs.8A venting was used, thus solving the difficultissue Waterproofingof the terracesre-
base sheet was firsttorch appliedover of how to terminatethe roofingon the quiredvery accuratestone-by-stone
the primedconcreteslab.9Fiberglass roof rolls (Fig. 3).11The liquid-mem- scale drawingsof the flagstonesto en-
rigid insulationwas adheredwith as- branebase flashingwas appliedto the sure that the stones were returnedto
phalt over the base ply.10An intermedi- midpointof the roof roll and painted their originalpositions. Stone-by-stone
ate ply was then laid in asphalton top with an acrylicelastomericpaint (PPG drawingswere also generatedfor the
of this. The finishply, which was Pitt-Flex)to match the stuccoedsur- living-roomand the covered-bridge
torcheddown, has a granularsurface faces, creatinga virtuallyinvisibletermi- floors, since they were both going to be
that was flood-coatedwith hot asphalt nation (Fig.4). (In the previoussystem, lifted (Fig. 5).12The bridgefloor re-
to permitembedmentof pea gravel,per the EPDMmembraneshad been secured quiredwaterproofingbecausea natural
Wright'soriginaldesignintent. with terminationbars fastenedwith streamthat tricklesover the boulderat
Siplast'stypical base-flashingsystem impact-expansionanchors,which the north elevationis evacuatedthrough
- foil-facedin eithercopper or stainless failed.)Wherebase flashingabutted a drainin the slab. In the case of the
steel - was consideredaesthetically irregularstone walls, a mix of one part living room, however,nearlythe entire
inappropriatefor Fallingwater.Instead, TypeII gray portlandcementto two and room was dismantled(includingbuilt-in
in collaborationwith KemperSystem,a one-halfparts sand was used to parge furniture)to permitaccessto the top side
polyesterfleece-reinforced,liquid-mem- the substratesmooth. of the cantileverbeamsso that cracks
branebase flashing(KemperolV210) could be groutedpriorto post-tension-

Fig. 5. Stone-by-stone drawings were traced by hand from photo mosaics. Fig. 6. The preeminent room of the house, the livingroom, was dismantled
The tracings were digitized and then inserted to scale with a grid into the and the floor removed in order to grout the cracks in the cantilever beams
construction drawings. These provideda guide for reinstallationof each priorto post-tensioning. One of the four main cantilever beams is visible at
flagstone floor or terrace scheduled to be lifted. This detail from a drawing the center of the photograph,with concrete joists abutting it to either side.
depicts the south end of the livingroom.
6 APT BULLETIN: JOURNAL OF PRESERVATION TECHNOLOGY / 37:2-3, 2006

thetic of the terraces.Closed-cellbacker

rod (Sonofoammanufacturedby Son-
neborn)and an elastomericsealant
(Duratexmanufacturedby ChemLink)
were used at the terraceperimeters.18
Two skylights,also known as roof
monitors,had always leaked. One sky-
light is on the herb terraceof the main
house, over the guest bathroom,and
the other is on the guest-houseroof,
also over a bathroom.The formerhas
plantersin the recessat the top of the
monitor.These monitors,as well as a
planterjust above the main-houseentry,
were reroofedusing KemperolV210.
On the herb terrace,new stainless-steel
planters,paintedto match the Cherokee
red of the windows and doors, were
installed.At the guest-houseroof moni-
tor, an originalcopper drip edge, found
buriedunderthe EPDMmembrane,was
reinstated.
Fig. 7. Because the finished surface of the terraces consists of flagstones, the waterproofing is an To the east of the living room, a
IRMA (inverted-roofing-membrane assembly) system. Drainage mat was laid over the three-ply
waterproofing on the master-bedroom terrace.
glazedtrellisforms the ceiling over the
libraryarea. This skylightwas a source
of leaks despiteits reglazingin 1994.19
ing, thus eliminatingthe potentialfor drain350, manufacturedby American All but one of the four downspoutsat
substantiallifting of the living room Wick Drain)was laid over the finishply the east edge had been blocked,causing
slab duringthe structuralintervention (Fig. 7). (At some locations, protection ponding on the surfaceof the trellis.
(Fig. 6). (The slab had deflectedas much boardwas substitutedbecauseof clear- WASA'sdesign for the trellis-skylight
as seven inches as a resultof the failure ance issues.15)In addition,for the first restorationintroduceda bronzeangle
of the main cantileverbeams.) time, bilevelsumpeddrains(1610 drains clamp with a neoprenegasket (Fig. 9).20
The cantileveredterracesare sup- with perforatedstainless-steelextension The concretesurfaceswere waterproofed
ported on beamsthat rise above the collars,manufacturedby J. R. Smith) using KemperolV210. Lead-coated-
slab, allowing for continuous,stuccoed were installedratherthan the original coppercap flashinginsertedinto a reglet
soffits. Betweenthe beams a seriesof systemof coppertubes (Fig. 8).16This at the concreteparapetof the master-
concretejoists createsa systemof cof- substitutionrequiredminor cutting bedroomterracecounterflashedthe in-
fers. The cofferswere originallycovered of surroundingflagstonesso that flat stallation.Threeof the four downspout
with tongue-and-grooveredwood deck- bronzedrainstrainerscould be installed. holes were reopened;the fourthwas not
ing. This surfacehad rotted out due to The extension collarswere wrappedin becauseit is located directlyover the
condensationin some areas,and copper filterfabric (MirafiFW700) to prevent door that leads from the libraryto the
hooded vents were remediallyinstalled clogging. east living-roomterrace.
on affectedterraces,probablyin the In the past, lifting of the flagstones Small,squareskylightsthat also hold
1960s, to alleviatethe condensation.13 had caused some breakagebecausethe light fixturesin the ceiling of the covered
The new systemused marine-grade stones had been laid in a cementitious bridgesufferedfrom reoccurringleaks.
plywood as the substratefor a three-ply, mortarbed. WASAspecifiedthat the When the flagstoneroof was rewater-
rubberized-asphalt membranemanufac- flagstonesbe laid in loose, roundedsand proofed, bronzeangle clampswith neo-
tured by W. R. Grace.14Bronzeangles on filterfabric,after a preliminaryat- prenegasketswere installedat these
were introducedbelow the surfaceat tempt with pea gravelfailed. However, locations as well.
thresholdsto providea verticalelement the sand proved unsuitableas well, be-
for applicationof the base flashing. cause the shallownessof the sand layer
Concrete and Stucco
These angleswere counterflashedwith did not permitadequatebedding,and
sheet copper,which is well concealed the flagstonesrockedwhen steppedon. From 1989 to 1993 WASAexperimented
betweenthe joint at the edge of the Instead,a dry-packsand bed, consisting with various patchingtechniques.Cur-
flagstonesand the thresholds. of one part TypeII gray portlandcement rently,Fallingwater'smaintenancestaff
To permitpropersubsurfacedrainage to ten parts sand, was used.17The flag- successfullyperformsminor concrete
and to provideventilationabove the stone joints were groutedwith one part repairsusing ThoRoc HBA, a polymer-
membrane,thus preventingfrost dam- TypeII gray portlandcementto three modifiedcementitiouspatchingcom-
age, a drainagemat (%-inch-thick Amer- parts sand to match the originalaes- pound, by Degussa BuildingSystems,
 FALLINGWATERPART 2: MATERIALS-CONSERVATIONEFFORTS 7

permitthe finishedsurfaceto receivethe

typical lAinch of stucco. Existinglight-
ing fixturesrecessedinto the bottom
step were refurbishedand reinstalled.
The existing supportsfor the bottom
step were differentfrom the rest;they
consistedof back-to-backangles an-
choredinto the bedrockof the stream.
They were replacedwith stainless-steel
T-shapedstrapsof essentiallythe same
appearance(Fig. 10).
Specifyinga paint systemfor the
stainless-steelstrapsproved challenging.
The paint had to performwell in damp
conditions,as well as when submerged.
The stainless-steelcomponentswere
preparedin accordancewith the Society
for ProtectiveCoatingsstandardSSPC-
SP-5/NACENo. 1 for White Metal Blast
Cleaning,then shop primedusing 66
Hi-BuildEpoxoline (Tnemec).The sub-
mergedstainlesssteel was field primed
with an additionalcoat of 66 Hi-Build
Epoxolineand finishcoated with 290
CRU in Wright'ssignatureCherokee
red.22For nonimmersionservice,the
field primewas 1975 Endura-ShieldII
and the finishcoat, 1070 Fluronar.23

Stone
The ashlarstonework, of a highly cal-
careous sandstonequarriedfrom the
site, is in good condition.24The stone is
laid up in uneven courses, with irregular
ledges projectingbeyond the mortar
joints. The originalpointing is mostly
intact. However,rain and snow accu-
mulate on the projectingledges, allow-
Fig. 8. Detail of a bilevel sumped draininstalled on the terraces. These drains replaced the original
copper tubes, which could not be integrated properlywith the waterproofingand did not permit ing water to percolatethrough slight
subsurface drainage. separationsand hairlinecracksin the
mortar.The ledges also make it difficult
to cut out and repoint the joints. The
formerlyknown as RenderocHB. How- These stairshad been rebuiltin the fact that the stone walls extend uninter-
ever,the concretestairsto the stream late 1950s after debriscarriedby the
ruptedfrom the exterior into the inte-
were particularlytroublesome.Sup- streamduringa storm severelydamaged rior without a dampproofbarrieris also
ported on painted, flat-steelstrapsthat them.21Becausethe existing stairswere
problematic,although beginningin
are partiallyembeddedin the treads, the not original,WASA,in collaboration 1988 remedialthrough-wall lead flash-
stairs are largelyhung from the soffit of with RobertSilmanAssociates,chose to
ing has been installed beneaththe cop-
the living-roomslab. The stairs are reconstructthem using stainless-steel
ing stones at the tops of walls.
occasionallysubmergedby the stream, straps.WorcesterEisenbrandt,Inc., of Most of the north and east walls,
resultingin corrosion of the steel straps. Baltimore,Maryland,performedthis which borderthe terraceof the servants'
In 1991, underWASA'sdirection,spalls work. The new strapswere embeddedin
quartersand retainthe hillside,were
in the concretesteps were removed,and the living-roomslab. In the processof
repointedby the maintenancestaff.25In
the steel was blast-cleaned,primed, probingto revealthe existing assembly, addition,the staff has done some spot
and painted.Both trowel-appliedand an interestingdetailwas uncovered:the
repointingof defectivejoints throughout
poured-in-placerepairswere attempted, strapswere connectedto turnbuckles the complex, using a TypeS mortarcon-
but both failed due to the continuing concealedin the concrete.Formworkfor
formingto ASTM C270-06.26However,
corrosion of the embeddedsteel. recastingwas slightlyundersizedto becauseof the difficultyof cuttingthe
8 APT BULLETIN: JOURNAL OF PRESERVATION TECHNOLOGY / 37:2-3, 2006

indicatedon the drawings.Instead,there

is a French(gravel)drain.WASArecom-
mendedthat a new dampproofingmem-
branebe installed,consistingof two
plies of Bituthene4000, protectedby
Styrofoamrigid insulationsecuredwith
PL Premiumurethaneadhesive.A perfo-
ratedfooting drainwrappedin filter
fabricwas specified,which would take
uphill run-offaway from the building.
To date, these recommendationshave
not been implemented.30

Windows and Doors

Corrosiondue to Fallingwater'sdamp
environmenthas always been the main
cause of deteriorationto the original
Fig. 9. Detail of the skylight, showing fleece-reinforced liquid waterproofing over the bronze angle steel casementwindows and doors,
clamps. which were manufacturedby Hope's
Windows. John Seekircherand Co. had
restoredsome units in 1992 and com-
joints, as well as issues of authenticity,it suredand photographedpriorto disas-
was decidedthat repointingof joints sembly,and each stone was surveyedfor pleted the projectin 2003. Units were
with hairlinecrackswould not be exe- correcthorizontaland verticallocations. strippedto bare metal, and deteriorated
cuted. Instead,WASAspecifieda water Afterrebuilding,joints were pointed sections were cut out and replacedwith
new matchingZ- or T-shapedsections.
repellentto preventwater intrusion. using a TypeS mortarof two parts
Severalwater repellentswere tested in New glazing stops, made of aluminum,
cement,one part lime, and nine parts
were installed,and the glass was reput-
ProSoCo'slaboratories,and Weather sand, which approximatedthe original
SealNatural Stone Treatmentwas se- finishedappearance.A layeredwater- tied with Vulkem 116 (Mameco/
lected, as it provedthe most effective.27 proofingsystemwas used to dampproof Tremco).TnemecPoly-Ura-Prime50-
At the site discreteareasof stonework the north side of the east wall along the 330 was used to prime the steel, and
were treatedto test for changesin color two coats of Endura-ShieldSeries73
gutter.Behindthe relaidstones, some
and sheen. These test areaswere re- bedrockwas removedto increasethe (a two-part aliphaticpolyurethane)
viewed and approvedby the Pennsylva- in Cherokeered providedthe painted
gutter'sdepth.Pouredconcretewas
nia StateHistoricaland Museum Com- installedto createa smooth surfaceand finish.
mission,the state agencyhavingjuris- primedto receiveBituthene4000 mem-
diction, priorto full-scaleapplication. brane,which was also installedvertically
Cheekwalls made of the same stone along the foundationof the cheekwall.
borderthe stairsthat lead from the Hydroduct220 drainagemat was ap-
coveredbridgeto the guest house be- plied verticallyto the foundationon the
neath the steppedcanopy.These walls north side, and terminatedinto a perfo-
were in fair-to-poorcondition. Moisture ratedpipe laid on top of a gravelbed.
penetrationhad causedfrost damageto The north wall of the guest house is
the mortarand heavingof the stones. partiallybermedinto the hillside.The
The east cheek wall was particularly smell of mold is often quite noticeablein
susceptibleto these problemsbecauseof the guest house. An electricfan inserted
an inadequategutterat gradelevel that in the chimneyand a surfacetrench
was meant to divertrun-offwater from draininstalledby the maintenancestaff
the uphill area betweenthe guest house have not entirelymitigatedthis problem.
and the driveway.Two drainagepipes Wood furnishingstouchingthe north
originatingfrom the guest-housecom- wall have sustainedminor damageas a
plex, which emergefrom the groundin result.In April2000 a test pit was exca-
this area, contributeto the moisture vated at the exteriorof this wall, to
penetrationof the east cheek wall.28 verifydetailsindicatedon original Fig. 10. The stairs to the stream were a 1950s
reconstruction,which continued to deteriorate
Stone-by-stonedrawingswere pre- plumbingdrawings.29The excavation due to the corrosion of the embedded steel
paredfor the east cheek wall, which was revealedthat a bituminousdampproof-
straps. Duringthe recent restoration,the stairs
dismantledby WorcesterEisenbrandt, ing is presentbut in poor condition. No to the stream were rebuiltagain, this time using
Inc. The wall was meticulouslymea- footing drainwas found, althoughit is stainless steel.
 FALLINGWATERPART 2: MATERIALS-CONSERVATIONEFFORTS 9

The lack of a drip detail on the stuc-

coed soffitshas also causedproblems,
particularlybecausethe roundededges
of the roof rolls tend to lead water dir-
ectly to the window and door heads. In
fact, originalmetal dripslocated at the
head of some of the window and door
units are inadequate.WASAhas speci-
fied the installationof a bead of clear
silicone sealantalong the perimeterof
the stuccoedsoffitsto act as a drip edge
(999-A SiliconeBuildingand Glazing
Sealantmanufacturedby Dow Corning).
Installationof the silicone dripswill
occur afterrepainting.In some instances,
dependingon visibility,a groove may be
cut into the soffit surfaceinstead.
At locations where Wright'sdesign
called for insertingglazing into the
stoneworkwithout a frame, deterio-
rated caulkingwill be removed,surfaces
primed,and new backerrod and sealant Fig. 11. Painttesting involvedthe review of approximately120 variations,some of which are seen
installed (1200 Primerand 795 Silicone here, applied by four different manufacturerson vertical,horizontal,and rounded parapettop surfaces.
BuildingSealantmanufacturedby Dow
Corning).31
moval of the BMC 90, keepingin mind Keimpaint systems (modifiedpotassium
Paints and Coatings
that BearRun is an environmentally silicate)recommendedthe resurfacingof
protectedstream.Becausea silanewater the stucco finish, a labor-intensiveproce-
In the springof 2001 WASAbegan a repellent(ProSoCo'sSureKleanWeather durethat was deemedunacceptableand
detailed,comparativeproduct evalua- Seal SL40) was used as primerunderthe exhibitedfailuresin the samples.Only
tion in an attemptto resolve the failure BMC 90 in 1994, therewas some con- Silin'sSilith (silicone-modifiedpotassium
of ProSoCoBMC 90, a silicone emul- cernthat a new water-bornepaint system silicate)providedperformanceand ap-
sion paint that WASAhad specified could experienceadhesionfailure.34 plicationcharacteristicsthat were suit-
subsequentto some paint testing done Eachmanufacturerwas assigneda able. This systemwas also compatible
in 1990. Fallingwaterhas an unusual testing areathat includedhorizontal, with paint strippingusing only the
amount of skyward-facingstuccoed vertical,and roundedparapet-topsur- power-washing method.35WASArecom-
surfaces,which never had the benefit faces that were subdividedinto bands mendedthat preparationalso include
of a waterproofingmembrane.The where the threepaint-strippingmethods applicationand thoroughrinsingof D/2
ProSoCopaint performedvery well on had been tested (Fig. 11). Altogether, ArchitecturalAntimicrobialto remove
verticalsurfacesbut biological contami- approximately120 paint variationswere biologicalsoiling priorto painting.A
nation affectedthe horizontalsurfaces appliedin the early summerof 2002 and large-scaleapplicationof Silithwas per-
within months of application.32(Or- allowed to weatherover the winter. formedto the steppedcanopy in July
ganic debrisfrom the surrounding Samplepreparationand paint systems 2003, but it exhibitederosion and irreg-
vegetationis particularlyplentifulat variedwidely accordingto manufacturer ular discolorationby October2005. 36
Fallingwater.) and in some cases includedthe applica- In November2005 PPGbegantest-
Priorto full-scalerepaintingwith tion of a biocide. (ProSoCo'sprepara- ing eight differentexterior-paintsystems
BMC 90 in 1994, an acrylicsystemby tion of the substrateincludedtreatments on the guest-housecanopy.On both
Thoro was in use. This paint had to of D/2 ArchitecturalAntimicrobialby horizontaland verticalsurfaces,half of
be renewedon more-or-lessan annual CathedralStone Products,Inc., or their the preparedsurfaceswere treatedwith
basis, graduallyreducingvapor perme- own BioWash,and some of PPG'sprep- D/2 ArchitecturalAntimicrobialand
ability.33 arationappliedthe disinfectantMildew the remaininghalf with Mildew Check
Fourmanufacturerswere invitedto CheckMulti-PurposeWash.) Multi-PurposeWash.Two types of
participatein the 2001 paint-testingpro- WASAreviewedthe samplesin Octo- alkali-and moisture-resistantprimers
gram:ProSoCo,PPG,Keim, and Silin. ber 2002 and again in March2003. were applied.A seriesof acrylic-based
The horizontalsurfaceprojectingto the ProSoCo'sBMC II exhibitedfailures latex topcoats of variouscompositions
south of the guest-houseroof parapet similarto those of BMC 90. PPG's were then applied.They are being moni-
was selectedas the test area.Threepaint- epoxy-basedpaints were consideredtoo tored on the horizontaland verticalsur-
strippingmethodswere tested for re- glossy for Fallingwater'saesthetic.The faces, as well as the parapetroll tops.37
10 APT BULLETIN: JOURNAL OF PRESERVATION TECHNOLOGY / 37:2-3, 2006

Interiors Conclusion 2. Norman Weiss, Pamela Jerome, and Stephen

Gottlieb, "Fallingwater Part 1: Materials-
The interiorsof Fallingwaterare fin- After 13 years of buildinginvestigation Conservation Efforts at Frank Lloyd Wright's
ished with a white cement plastersimi- and the evaluationof prototype repairs, Masterpiece," APT Bulletin 32, no. 4 (2001):
44-55.
lar to the exteriorstucco. The interior Fallingwater'sfive-year,$11.5-million
surfaceshave also sustaineddamage restorationis nearingcompletion. For 3. WASA'srestoration team consisted of Hazel
relatedto moistureinfiltration.The last the firsttime in its history,the complex Ephron, partner-in-charge;Pamela Jerome,
project manager; Norman Weiss, then conser-
full-scalerepaintingoccurredin 1987- is virtuallyfree of leaks. The projecthas vation scientist; Keith Gianakopoulos, project
88 using Thorosheen(a water-based resultedin the safeguardingof an Amer- architect; and Rene Fan, Felix Fernandez, and
acrylicpaint introducedin the mid- ican icon. However, only time will tell Jorma Locci, draftspersons. Fallingwater's staff
has also been enormously helpful in this pro-
1970s). This paint is dark and highly how well this restorationaddressesthe
cess, including Lynda Waggoner, director;
textured.Recent paint analysishas site'sproblems,and some issues, such as Cara Armstrong, curator; Michele Risdal-
shown that earlierpaints were smoother the paint, are still to be resolved. Barnes, former curator; Jeff Gaul, director of
and sometimeslighterin color.38Be- maintenance; Dan Johnson and Albert Ohler,
PAMELAJEROMEis a registered architect and maintenance staff; Cecil Kifer, former mainte-
cause of multiplelayers of incompatible nance staff; and Blaney Sproul, former site
architecturalconservator. She is director of
paints (which undermicroscopicexami- preservation at WASA and an associate profes- superintendent.
nation show evidenceof delamination), sor at Columbia University's Graduate School 4. For structural problems, refer to Robert
as well as curatorialissues of interpreta- of Architecture, Planning, and Preservation.
Silman, "The Plan to Save Fallingwater,"
tion of the correctfinish, the interiors Her expertise is in masonry conservation and
Scientific American (September2000): 88-95.
waterproofing. She is a trustee of US/ICOMOS
requirepaint stripping.After several and is their liaison to APT's board. 5. Weiss, Jerome, and Gottlieb, 45.
mechanicalmethods were tested, a
small needle sealer suggestedby the NORMAN WEISSis an analytical chemist with 6. It cannot be overemphasized how problem-
40 years' experience in masonry conservation. atic Wright's deliberate choice not to install
maintenancestaff was successfullyused through-wall flashing for aesthetic reasons has
He is an associate research scholar at Columbia
in February2002 to strip the director's University's Graduate School of Architecture,
been to the waterproofing of these buildings. In
office in the servants'quartersin a test Planning, and Preservation. He was an associ- general Wright's use of different construction
ate with WASA from 1990 to 1999 and is materials that penetrate each other has compli-
program. cated an inherent design-based pathology.
PPGPermSealerVaporBarrier,a currently vice president of MCC Materials,
Inc., and senior scientist at Integrated Conser- 7. Frank Lloyd Wright, "Detail of Existing
low-moisture-transmission primer,is vation Resources, Inc.
now being used as a vapor barrierfor Roofing," undated drawing, referred to as
HAZELEPHRONis a registered architect. She drawing 3602.117 by the Frank Lloyd Wright
the ceilingsunderaffectedslabs to pre- Foundation.
vent moisturefrom migratingfrom the joined WASA in 1974, where she is now a
senior partner.She is partner-in-chargeof 8. The Siplast roofing system used was primer,
interiorto the top of the slab.39Speed- WASA'spreservation department and has PA-1125 Asphalt Primer;base ply, Paradiene
hide Interior/Exterior AcrylicLatex overseen the department'swork for 15 years. 20TS; intermediate ply, Paradiene 20EG; finish
Alkali-ResistantPrimer2-203 is then She is recognized as a waterproofing expert in ply, Paradiene 50LT. These membranes are a
the New York metropolitan area. high-quality, modified SBS asphalt, reinforced
appliedto both walls and ceilingsto with fiberglass mat.
block stains. Two coats of PurePerfor-
mance Paintfollow as the finishpaint.40 Notes 9. The underside of this type of membrane has
alternating stripes of asphalt that become tacky
Anecdotalevidenceimpliedthat the 1. Wank Adams Slavin Associates (hereafter, when heated in a torch-down application. The
interiorand the exteriorwere always WASA), "Volume I: Existing Conditions Sur- stripes of asphalt bond to the concrete slab,
paintedidenticalcolors.41However,ex- vey" (unpublished report, September30, 1999). while the adjacent unbonded stripes provide
tensive samplingand analysishas re- WASA, "Volume II: Evaluation and Recom- venting channels to move water vapor. Addi-
mendations" (unpublished report, September tionally, the ceilings below affected slabs were
vealedthat an earlyrepaintingcampaign 30, 1999). The five-hour peer review was by painted with a vapor barrieras a primer to
used a much lighter,peach-coloredoil- invitation only and occurred on April 10, 1999, further alleviate condensation.
basedpaint on the interior.It is specu- at the Carnegie Museums of Pittsburgh. The
10. WASA'sspecifications initially called for
lated that this changemay have been meeting coincided with the opening of the
exhibit Merchant Prince and Master Builder: fiberboard insulation, but the contractor con-
made becausethe interiorsurfacesnatu- Edgar J. Kaufmann and Frank Lloyd Wright.
vinced us to change this as none of the materi-
als removed from the existing roofs were dry.
rally appeardarkerthan the exteriors; After presentations by WASA and Robert
Silman Associates, the invited technical experts
thus, using a lighter-colorpaint would reviewed the proposed materials restoration
11. Kemperol V210 is a cold, fluid-applied
have given the illusion that the two resin, which, when combined with Kemperol
and structural-engineeringintervention. The
colors were the same. Fallingwater's fleece, cures to form a seamless, reinforced,
peer reviewers included Randall J. Biallas, monolithic polyester membrane system. WASA,
curatorialstaff has chosen to paint both Nicholas L. Gianopoulos, Neil Levine, John "Detail l/A-4: Iso. - Flashing Detail at Roof
interiorand exteriorthe same color. Garrett Thorpe, Bruno Thurlimann, Martin E.
Edge" (Fallingwater Phase 2 (IB) construction
Weaver,and Eric Lloyd Wright. In addition, the drawings, May 21, 2002).
Full-scaleinteriorrepainting,requiring floor was opened for questions from Western
substantialplasterpatching,takes place Pennsylvania Conservancy's board members 12. WASA, "EnlargedPlan, Drawing A-2"
periodicallyduringthe winter months and technical advisory committee, Frank Lloyd (Fallingwater Phase 3 construction drawings,
on a room-by-roombasis.42 Wright experts, and the press, in that order. May 21, 2002).
Refer to Western Pennsylvania Conservancy,
13. Weiss, Jerome, and Gottlieb, 50.
"Protecting Fallingwater for the Future: A
Private Forum" (unpublished transcript, April
10, 1999).
 FALLINGWATERPART 2: MATERIALS-CONSERVATIONEFFORTS 11

14. The W. R. Grace waterproofing system 22. Paint analysis of the windows indicated 33. WASA, "Volume 1: Fallingwater: Conserva-
consisted of a base ply of Procor Fluid-Applied that the original finish color was a Venetian red tion Analysis for Concrete and Stone Masonry"
WaterproofingMembrane (a two-part self- (Munsell 8.3 R 3/5). This shade was changed to (unpublished report, January 18, 1989), II/6.
curing rubber), followed by two plies of Wright'sCherokee red by Kaufmann jr. in 1976. Concrete surfaces had been sandblasted in
Bituthene 4000 (a peel-and-stick rubberized- The Venetian red was identified by Frank Welsh 1976, greatly damaging the original stucco.
asphalt membrane). The membranes were with Ilene Tyler of Quinn EvanslArchitects. The stucco had been patched with Thorite (a
turned up at the edges and sealed with Bitu- Quinn EvanslArchitectswith Frank S. Welsh, cementitious patching mortar) modified with
thene Mastic (a rubberized-asphalt-based "Fallingwater:Historic Finishes and Colors" Acryl 60 (an acrylic admixture).
mastic). (unpublished report, February28, 1990).
34. Row A was application of Peel Away 2
15. According to the curator, the lack of clear- 23. WASA, "ProjectManual for Fallingwater (a methylene chloride-based paint stripper,
ance at the herb terrace was further exacer- Restoration Phase 4: Stairs to Stream Recon- manufactured by Dumond Chemicals, Inc.)
bated by the fineness of the filter fabric around struction" (unpublished technical specifica- followed by pressure washing at 900 psi, then
drains, and the drains at this location were not tions, May 21, 2002). application of Peel Away 1 (an alkaline paint
sumped. These conditions allowed water to get stripper) followed by pressure washing at 900
24. X-ray diffraction performed in ProSoCo's
under the mat, causing the entire overburden to psi, and lastly application of ProSoCo's Lime-
float. In addition, the drainage mat's needle- laboratories identified the sandstone as contain- stone and Masonry Afterwash (acetic acid)
punched fabric permitted flexing, creating a ing 51.5% calcite, 47.1% quartz, and 1.3% agitated on the surface with a brush followed
microcline. ProSoCo, "Laboratory Report:
trampoline effect. This phenomenon, combined by pressure washing at 900 psi. Row B was
with the shallowness of the sand bed, caused Fallingwater Water Repellency Evaluation" pressure washing only at 900 psi; Row C was
the flagstones to rock, cracking the grout joints. (unpublished report, May 15, 2000), 2. application of Peel Away 2 followed by pres-
25. Scuppers that drain the terrace were traced sure washing at 900 psi.
16. WASA, "Detail 5/A-2: Terrace:Flashing/
Drain Details" (Fallingwater Phase 2 (IB) con- and found to dump water into the fill behind 35. WASA, "Exterior and Interior Paint Re-
struction drawings, May 21, 2002). Copper the terrace walls. During the process of rewa-
port" (unpublished report, April 15, 2005).
tubes were the original method of drainage for terproofing the terrace, the scuppers were re-
both terraces and roofs. These tubes penetrated built and pipes attached to reroute the water. 36. The large-scale application, which was
the slab but did not integrate properly with the unsuccessful, was undertaken by Fallingwater's
26. The mix consists of two parts Type IA gray maintenance staff using the product undiluted.
waterproofing system. In the case of the ter- Portland cement, one part hydrated lime, and
races, there was also no means to collect sub- eight parts ASTM C144 sand, closely matching 37. PPG's relationship with Fallingwater is
surface drainage. As a result, water around the the original. documented as early as 1951, when the exte-
perimeter of the tubes tended to freeze, damag- rior was painted with a PPG oil-based paint.
ing the tubes and the concrete structure of the 27. ProSoCo, "Laboratory Report: Fallingwa-
During 1971-72 PPG paints were again consid-
terraces. The southeast corner of the master- ter Water Repellency Evaluation" (unpublished ered and tested as a replacement for failing
bedroom terrace was recast in 1991, during report, May 15, 2000). The other products exterior paint.
WASA'sinvestigative and prototype-repair tested included Weather Seal Siloxane WB,
period. Weather Seal H40, and Sure Klean Custom 38. Integrated Conservation Resources, Inc.,
Masonry Sealer. "Paint Analysis Services:Fallingwater Bear
17. The first good rain after application damp- Run, Pennsylvania" (unpublished report, May
ens the cement and slightly solidifies the sand 28. The Western Pennsylvania Conservancy is
2001), 7-10.
so that the setting bed does not shift, but there in the process of implementing the master
is not enough cement to "glue" the flagstones landscaping plan designed by Marshall Tyler 39. Most buildings use insulation on the warm
down. The amount of cement does not signifi- Rausch of Pittsburgh, Pa.; the drainage pipes (ceiling) side to provide a thermal break, but in
cantly alter the permeability of the sand bed. will be rerouted as part of the work. this case it would severely compromise Wright's
original design.
18. WASA, "ProjectManual for Fallingwater 29. Frank Lloyd Wright, "Sheet Numbers 4
Restoration Phase 1: Guest House/Servants' and 6," unpublished drawings issued January 40. WASA, 2005. Pure Performance Paint has
Quarters and Herb Terrace" (unpublished 28, 1939, and March 14, 1939, referred to as some interesting environmental attributes in-
technical specifications, August 22, 2001); drawings VIII-21 and VIII-23, respectively, by cluding low odor, zero VOC content, and
"ProjectManual for Fallingwater Restoration Avery LibraryArchives. antimicrobial properties.
Phase 2 (IB): Main House: EK, Sr.'sTerrace,
Roof over EK, jr.'sStudy, Roof over 3rd Floor, 30. WASA, "ProjectManual for Fallingwater 41. Quinn EvanslArchitectswith Frank S. Welsh,
Restoration Phase 3: Living Room, Master Bed- 1990. The exterior finish color is Munsell 8.2
Entry Roof and Roof near Bridge to Guest YR 7.2/3.7 and was determined from historic
House" and "ProjectManual for Fallingwater room Terracesand Roofs, Enclosed Bridge,
Restoration Phase 3: Living Room, Master Cheekwalls and Foundation Waterproofing" exterior paint that survived on the soffit of the
Bedroom Terracesand Roofs, Enclosed Bridge, (unpublished technical specifications, May 21, living-room slab. Frank Welsh, with Ilene Tyler
Cheekwalls and Foundation Waterproofing" 2002). of Quinn EvanslArchitects,performed this
research.
(unpublished technical specifications, May 21, 31. Ibid. Saflex, an ultraviolet protective
2002). laminated glazing installed in 1989, is now 42. Thus far the south end of the living room
19. This reglazing was not designed by WASA. delaminating. The new sealant will be installed and the covered bridge were repainted in 2004,
upon replacement of the 1,800 square feet of the master bedroom in January 2005, and the
20. WASA, "Detail 4/A-9: Detail" (Fallingwa- glazing. guest bedroom in January 2006.
ter Phase 3 construction drawings, May 21,
32. Heidi Turner,research and development
2002).
technical analyst, to ProSoCo, Inc., dated April
21. WASA, "FallingwaterVolume 3: Concrete 11,2001.
Repairs/Coating Tests" (unpublished report,
1991), 2.