Bringing an International Architectural Landmark Back to its Original Splendor

Project Background

• One of Frank Lloyd Wright’s most famous architectural statements, Fallingwater is visited by more than 150,000 people a year
• Decades of water penetration, freeze-thaw cycles, and moisture migration had caused widespread exterior structural deterioration, including severe cracking in many areas and high concentrations of efflorescence at the concrete
• Cracks and calcium carbonate staining patterns indicated a water intrusion pattern that jeopardized the structure’s stucco and underlying concrete and reinforcing steel within the signature cantilevered terrace areas
• MPS was contacted by Wank Adams Slavin Associates Architecture to assist in the pilot phase testing, constructability, and implementation of repair procedures

Project Challenges

• The home’s main terraces were in need of comprehensive repair, including the faithful reconstruction of deteriorated stucco and concrete; ultimately the cantilevers were structurally supported by a post-tensioned reinforcing solution
• Water had caused some concrete sections to deteriorate to a point where they were no longer structurally sound
• Delicate repair intervention prototypes needed to be implemented with a keen eye toward the historical fabric of the structure, original materials, and Wright’s design intent

Project Approach

• Deteriorated stucco and wall coatings were carefully stripped off and analyzed, and new stucco and coatings were applied to determine the most effective approach
• Once deteriorated concrete was removed, reinforcing steel was coated with a protective coating, stainless steel anchors were drilled into the concrete, and slurry coat and repair material were applied to the concrete repair areas to recreate original profiles
• A system of stainless steel wire was woven through the eyes of the anchors to provide support for the new repair material
• Plunge pool and adjoining vertical walls in the area were repaired using shotcrete application and the placement of a new deck
• Stone chimney mortar joints were repointed using a delicate mortar joint cutout procedure and new historically accurate mortar