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Masonry Work in the Cellar

Masons remove concrete

A significant aspect of the Mansion Revitalization Project involves repairing sections of the Mansion’s masonry. The brick and stone foundation walls and chimney bases in the cellar provide the strong underpinning upon which the Mansion stands. As with the home’s framing, some necessary interventions in past decades, using "modern" materials, have proven to be unsympathetic to the original fabric of the house, slowly causing unintended damage. 

While the Archaeology team completed excavations in the cellar, the Preservation team began conducting in-depth assessments of the stonework and masonry in preparation for the work to come.

Assessing the West Wall

The cellar’s west wall, a critical structural component for the Mansion, has been largely inaccessible since the installation of HVAC ductwork in 1998. With the removal of that ductwork, as part of the Mansion Revitalization Project, Mount Vernon’s Preservation team was able to assess the wall’s condition.

Moisture infiltration, in the form of rain or groundwater, has been an issue in the Mansion cellar since Washington’s time. Washington designed a system of underfloor drains to manage moisture from rain and groundwater that worked well into the modern era until necessary structural reinforcements to the Mansion’s framing in the late 19th and early 20th century obstructed portions of the system. Over many years, moisture and humidity in the cellar have damaged some original materials, particularly soft Aquia sandstone blocks used in the original foundations.

For this reason, the Preservation team was eager to evaluate the condition of the west wall, some of which is comprised of original Aquia sandstone. During their assessment, the team identified surviving 18th-century materials, as well as areas that had undergone previous repairs or replacements. By thoroughly documenting the wall’s condition, the Preservation team can create a comprehensive restoration plan for this critical support element. Restoration efforts will begin on the west wall following the installation of external shoring.

west wall archaeology
Project archaeologist Nick Beard works along the west wall of the cellar, a critical structural component for the Mansion that has been largely inaccessible since 1998. (MVLA)

Initial Restoration Efforts

In the meantime, preparatory masonry work has begun in other parts of the cellar as well. 

Masonry Probes

The Preservation team conducted masonry probes to understand the extent of deterioration within the cellar. By doing so, the team can determine whether particular stones require replacement or if a stone veneer is a viable restoration option. Understanding the depth of deterioration allows the Preservation team to develop an informed repair plan.

In some cases, the probing process is akin to taking dendrochronological samples, where the probe penetrates the stone to gauge its condition and depth. The team also collected mortar samples, which will aid in understanding the overall integrity and composition of the masonry.

The Preservation team also probed the brick and mortar around the Mansion’s north and south chimney stacks, located in the cellar. This will allow experts to assess the depth of the modern brick and mortar and determine how much of the original material remains.

The Veneering Process

With that information in hand, historic masonry specialists with Dominion Traditional Building Group began applying sandstone veneers to partially deteriorated stones in the cellar passageway. The process of veneering involves attaching a thinner piece of stone to the front of the existing stone, thereby maintaining aesthetic continuity while ensuring structural integrity.

Mortar and Brick Removal

Historically, mortar is sacrificial material, intended to deteriorate over time to protect the masonry. Modern hard mortars such as Portland cement, when combined with porous 18th-century materials, can lead to unintended damage, as the moisture penetrates the stone or brick instead of the mortar.

Experts with Dominion Traditional Building Group began removing modern cement from the brick wall along the passage. Eventually, the cement will be replaced with a soft, lime mortar, like that used in the original construction. They also began removing some modern brick and concrete around the Mansion’s north and south chimney stacks.

Masons repair a stone wall in the Mansion cellar. (MVLA)

Modern concrete is cut away in the cellar. (MVLA)

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