A mighty fortress

Masonry Construction, Jan, 2005 by Diana Granitto

When Christian Brothers College (CBC) High School relocated to a new campus, the school wanted a facility that would honor the heritage of the 150 year-old St. Louis institution. The new complex needed to integrate traditional elements into a design for the future.

Design concept

"We wanted the students, faculty, and alumni to fee at home in the new building, said Jim Conrad, project manager at Mackey Mitchell Associates. architects for the 240,000-square-foot facility. "We didn't try to replicate the old structure, but to use some of the same imagery."

The most striking feature borrowed from the old school's design was the strong &&& gothic entry guarded by twin torrets rendered in an octagon shape, the new building's historic look was reinforced with traditional elements such as red brick trimmed with limestone. One piece--an original rose window--was moved from the previous facility.

Managing the scale of the imposing structure was a critical design consideration, "There's about a half-mile of building facade." said John Gunther, project designer and principal of Mackey Mitchell. "'Masonry makes it easier to impart cadence and rhythm, to create visual interest." For example, the limestone base. gables, and window trim play across the 300-foot-long academic wing overlooking the road. Other masonry elements used to break up the expanse include brick patterning and spandrels recessed between brick columns.

The H-shaped footprint also helps to reduce the scale by forming shorter walls and creating two outdoor courtyards. The structure appears as one large building, but building codes demanded breaking it into five contiguous compartments separated by firewalls. At three-stories high, two of the firewalls had to be built of concrete block. Acoustical concrete block was used in the theater and gymnasium, and clay brick masonry pavers lead up to the entry.

The facade uses a rich, vibrant red brick reminiscent of traditional tones "but not so dark and somber." said Gunther. "We must have looked at 10 or 15 samples in the sunlight, and we chose a shade that strikes a nice balance between traditional and contemporary."

Construction challenges

The sample panels prepared by Grant Masonry used different brick and mortar combinations to help the architect achieve the desired look. This step was essential before committing to the 500,000 face brick used on the project, In addition to the brick, Grant's crew of 30 installed 200,000 block. 700 cubic feet of limestone, and all of the pavers. The masonry portion of the project totaled $3.5 million.

"The most difficult aspect was the schedule because the school had to be open by the end of August" said Brian Grant. president of Grant Masonry. "'Constructing a project that size, with four wings, required working through the winter. We had 11 months for our part of the project, so everything had to work just right--the trades ahead of us had finish on time and the suppliers had to produce and deliver when required."

Construction of the tall, complex turrets took place during the coldest conditions. "We totally enclosed the scaffolding and worksite to keep on track," Grant said. "There was a lot of detail and ornate stonework." Craftsmen were protected by temporary plastic barriers as they meticulously placed the specially shaped brick and stone surrounds to form the octagonal towers and crafted the crenellated stone summits.

Grant Masonry also performed sitework and modified walls to remodel existing buildings on the 25-acre property, which had been donated by a CBC alumnus. A 10,000-square-foot home became offices and a residence for the Brothers. A stable was transformed into concession stands, team rooms, and bath rooms serving the school's new sports stadium. The finishing touch was to color the brick to blend with the new facility (see sidebar), and then CBC moved onto a new campus designed for its next 150 years and beyond.

Dyeing to March

Constructed of red brick with a slurry coating, the existing 30-year-old buildings on the CBC High School property did not match the new facility. The remedy was a color correction process using a water-based solution that adheres to the pores of the brick and permanently bonds with the clay substrate.

"The process starts with the same dry pigments that are used in the brick-making process," said Brad Clear, director of operations for Masonry Cosmetics, which performed the brick coloring on the CBC project. The fine particles are dissolved in water, and unlike a paint or stain, the solution does not seal the surface or impede evaporation. "None of the natural physical properties of the brick are affected," Clear explained. "Even the color variations in the original brick remain as variations in the new color."

To determine the appropriate color range, different shades were tested on a small area of one of the buildings to be treated. Three red hues were chosen to emulate the color scheme of the new structure.

Applying the colors solution's a painstaking process. The applicator Chooses the shade for each brick and brushes the solution on one brick at a time to avoid staining the mortar joints "You create the color range as you go, said Clear. "Up close you see the different colors in each brick like the dots in a Cezanne painting From a distance you see the painting as a whole."