In-Kind Terra Cotta Replacement in the 21st Century

Architectural terra cotta was the most popular building material in America between 1890 and 1930. As an era of innovation, the characteristics of terra cotta and appropriate construction methods were not fully understood. With building construction halted during the Great Depression and changing architectural styles, demand for terra cotta dropped to a low, and the industry fell into decline, nearly disappearing completely. As terra cotta buildings began to age and deteriorate, the industry no longer existed to provide material replacement as needed. Various alternative materials were explored and used for reasons of availability and cost. However, performance and appearance of some of these materials was deemed unsatisfactory and the continued need for more appropriate replacement materials has led to a recent revitalization of the terra cotta industry. Currently three major manufacturers produce architectural terra cotta for replacement material in historic structures: Boston Valley Terra Cotta, Gladding McBean, and Shaws of Darwen. Each of these companies uses different fabrication processes ranging from traditional hand pressing or slip casting methods, to mechanical methods o