Corrosion of steel within ‘vintage’ buildings circa 1880s to 1930s pose a health and safety risk to the public in major urban centers. Projecting masonry elements pose a particular concern when the underlying steel appurtenances and anchorage begin to corrode. Failed masonry has fallen from buildings, leading to death in worst case scenarios. While some signs of masonry cracking or displacement are usually visible prior to failure, the level of degradation of the embedded steel is not. With the equipment available to test these unforeseen conditions, methodologies exist to understand unobservable conditions to assist in condition state ratings of embedded steel. In many cities, building owners are being faced with large expenditures to strip and replace terra cotta or stone elements where the underlying steel is in fair condition.

This paper discusses a field-testing program where two full building elevations' terra cotta clad steel appurtenances were evaluated for corrosion. The testing program assessed all steel components which projected from the structure with a bespoke, in-depth, testing program geared towards the development of condition state ratings for the elements of the facade. In addition, this novel approach provided valuable insight to more appropriate means of testing glazed brick and terra cotta assemblies, both of which can provide dubious results with surface mounted testing.

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