Restoring a Frank Lloyd Wright Residence

Restoring a Frank Lloyd
Wright Residence
William Waterston, RRC, AIA
Wiss, Janney, Elstner Associates, Inc.
271 Old Stoddard Road, Nelson, NH 03457
(781) 576-9098 | waterston@aol.com
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ABSTRACT
SPEAKER
William Waterston, RRC, AIA
Wiss, Janney, Elstner Associates, Inc., Nelson, NH
William Waterston is a recently retired associate principal at Wiss, Janney, Elstner
Associates, Inc. in Boston, Massachusetts. He continues to work as an affiliated consultant.
He is both a registered architect and a Registered Roof Consultant focused on solving waterproofing
and roofing challenges in new and existing buildings. Waterston is the author of
several articles on roofing material choices and roofing practices. He has presented at various
venues, including IIBEC and Construction Specifications Institute (CSI) meetings, conventions,
and symposia. He is an Emeritus Member of IIBEC, AIA, and CSI.
In the 1950s, American architect Frank Lloyd Wright developed a building system using concrete block components
that could be assembled into a home, which he described as “Usonian Automatic.” In 1955, Wright designed
such a home for Dr. Toufic Kalil and his wife, who built their home in Manchester, NH, with the assistance of a local
contractor.
Wiss, Janney, Elstner Associates, Inc. (WJE) was selected by the heirs of the Toufic Kalil House to assess the
existing conditions in preparation for selling the home. After WJE’s initial meeting, a landscape contractor demolished
a site wall with his truck.
Based on our observations of existing conditions and research of historic documents, WJE developed repair
documents to replicate the severely damaged site wall. The company also developed roofing repair and replacement
documents to replace the leaking roofing system installed in 2003. Documents from the Frank Lloyd Wright Archives
housed at the Avery Library of Columbia University supplemented the Kalil family’s personal papers.
The personal family records revealed names of products used for the original roofing system that differed from
those in the project specifications. Little information was found about these products. The challenges of the existing
conditions of the concrete roof deck and low flashing heights demanded creative approaches to the roofing replacement
material and assembly.
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Wiss, Janney, Elstner Associates, Inc.
(WJE) was approached in 2018 to provide
a condition assessment of the Toufic H.
Kalil House (Kalil House) in Manchester,
New Hampshire, by the heirs of Dr. Toufic
H. and Mildred Kalil. The private residence
is one of seven homes designed by
Frank Lloyd Wright, with construction
beginning in 1955, using a style and
materials described by Wright as “Usonian
Automatic.” The heirs wanted help in
determining the condition of the home
and what needed to be done to ready the
house for sale. Following the condition
assessment, WJE provided design and construction
services for roofing replacement
and concrete repairs. From historical documents
saved and collected by Dr. Kalil and
through our investigations, an intriguing
story emerged of a homeowner dealing with
roof leaks and contractors experimenting
with emerging roofing products.
Kalil House is located in the North End
area of Manchester and is on the same
street as another home designed by Frank
Lloyd Wright for Dr. Isador and Lucille
Zimmerman in 1952. Dr. Zimmerman and
Dr. Kalil worked together at a local hospital.
The Kalils admired the home of the
Zimmermans so much that they bought
a large lot just down the street. Mrs. Kalil
penned a letter to Wright on July 1, 1954,
asking him to design a home for them.
On July 5, 1954, Eugene Masselink wrote
on behalf of Wright that he would like to
build a house for the Kalils. He requested
a topological survey of the property and
their requirements for the home, along
with their budget. On August 28, 1954,
Dr. Kalil sent the survey, photographs of
the site, and a list of requested amenities
for their new house. The Kalils met Wright
in New York City (he was working on
the Guggenheim Museum at the time) in
October 1954 to discuss the design of their
home. Initial design drawings prepared by
Wright were sent to the Kalils on January
29, 1955.
Kalil House is L-shaped in plan with
the main entrance to the house through
the attached carport and at the intersection
of the double-
height living room
(tower, Figure1, Figure
2, and Figure 3), and
one-story wing. There
is a notable central
fireplace and hearth.
Throughout the house,
there are single-pane,
fixed- and aluminumframed
awning windows
set within precast
concrete units. At the
time of our condition
assessment, the roofing
at the high and
low roofs consisted
of low-slope ethylene
propylene diene monomer
(EPDM) rubber
membrane and metal
roof edge flashing
with scuppers. Many
of the original finishes
and furnishings
designed by Wright
as part of the original
plans remained in the
house. There is a small
one-story guesthouse
behind the main house
of similar construction.
The interior of the
guesthouse was left
in an unfinished state
and was used for storage
by the Kalils.
USONIAN AUTOMATIC
In 1954, when Frank Lloyd Wright was
designing the Kalil House, he was 88 years
old and had designed over 700 buildings
throughout his professional career. The
Kalil home would be one of a handful of
projects he designed before passing away
just four years later. Wright’s Usonian
houses were small houses for middle-class
Americans, which were moderate in cost
and stylishly built from local materials and
labor. Usonian Automatic—which Wright
used to design the Kalil House—was the
evolution of Usonian. Usonian Automatics
are distinguished from Usonian houses by
the exclusive use of concrete blocks in the
former.
Usonian houses were typically one-story
homes with a distinctive horizontal connection
between indoor and outdoor. “These
houses were generally without [a] basement
or attic and were built on radiant-heated
concrete slab[s]. All the exterior walls,
some of the interior walls, as well as the
ceiling and roof were built of these custom-
designed concrete blocks. Even the
Restoring a Frank Lloyd
Wright Residence
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Figure 1 – Kalil House showing solid and perforated blocks
at the rear entrance.
windows were made of perforated concrete blocks into which fixed glass or operable metal sashes were placed. These blocks were in the same one-by-two-foot and two-by-two-foot module as the solid wall blocks.”1
The first concrete-block Usonian house, known as the Millard House and “La Miniatura,” was built in 1923 for Alice Millard in Pasadena, California, and is constructed of textile concrete block. Wright utilized this type of concrete block for three other homes: Ennis House, Samuel Freeman House, and Storer House, all built in southern California in 1923. The so-called “textile homes” have been described as a revolutionary system of decorative molded concrete blocks, “distinguished by their method of construction.”2 Wright biographer Meryle Secrest offers a description of this type of construction and the challenges that become inherent to Usonian and Usonian Automatic houses:
“Working with his son Lloyd, Wright had hammered out a variation on the design of the humble and inexpensive concrete block, which was easy to manufacture, easy to assemble and apparently easy to maintain: he called it the textile block system. It could be made in a variety of patterns, sizes and surfaces, and link together with a method of horizontal and vertical steel rods that he and his son invented. The result was wonderfully solid and imposing inside and out, with an overtone of theatricality that seemed natural, if not required, for the Los Angeles of the 1920s, but the method was not as trouble free as it looked. Recent study has established that the small Freeman house alone required over eleven-thousand blocks and that the intricate patterns of the blocks, cast in dry, porous concrete did not usually come out cleanly on the first pass through the mold. As many as four stampings might be necessary before the results could be called satisfactory. In addition, far more patterns had been used than had first been thought (there were more than forty), and each block had to cure for twenty-eight days before it could be used. That was not the end of the matter. The material used meant that the resulting block, seemingly so solid, was actually very fragile and extremely vulnerable to chipping and crumbling.”
“These disadvantages, along with the obvious problems of flat roofs – and Wright began to make extensive use of them in his designs – are evident nowadays, but even in his day Wright was on the defensive about them and eager to prove he had cured their draw-backs.”3
Following World War II, and as the United States was experiencing a suburban housing boom infused with a do-it-yourself mentality, there was pressure to find economical alternatives for traditional building materials and methods. It was at this time that Wright’s Usonian designs began to transform what would become the lexicon of the typical American middle-class suburban ranch-style home with the incorporation of the carport, a centralized kitchen, and a larger common living space.4 In the 1950s, Wright began designing Usonian Automatic homes as his offering to middle-class Americans for simple modular concrete block homes that he believed homeowners could fabricate and construct themselves. In practice though, these homes required “great care….in construction to ensure that block joints occurred on module, otherwise an incremental error soon built-up, and the necessary fine tolerance was difficult to achieve in homemade blocks.”5 Wright designed a total of eight Usonian Automatics, with seven eventually being built. At the time the Kalil House was under construction in 1955, two other Usonian Automatic homes had been built: one in Phoenix for the Adelmans and another in Paradise Valley, Arizona, for Arthur Pieper. Mr. Pieper had been a student of Wright’s at the School of Architecture at Taliesin, and he constructed the home himself.
Like the Kalil House, other Usonian Automatic homes were constructed of precast concrete blocks with an integral steel reinforcement system, which, when assembled, had practically no allowances for construction tolerances in the walls and roofs. Wright’s hope to design a home with materials made by the homeowner and constructed by the same could not be achieved. Fabrication of the precast concrete blocks and assembly of these homes required a high level of skill from an experienced mason. Construction stories of many of the Usonian Automatics are rife with complications during construction; experimentation with emerging building materials that eventually would not stand the test of time; and leaks, which are a theme common to many of Wright’s buildings, from modest homes to world-famous museums. The Kalil House was not exempt from this trend.
TOUFIC H. KALIL HOUSE
ROOFING HISTORY
Early in the condition assessment of the Kalil House, the Kalil heirs provided WJE with a trove of historical documents saved by Dr. Kalil. Many of these documents were original records, including correspondence, drawings, and sketches between Dr. Kalil, Wright, and the local construction team, and other ephemera. These documents offer a descriptive narrative of the construction of the house and issues of roof leaks encountered during and immediately following construction.
Armed with construction drawings and specifications issued in July 1955, Dr. Kalil approached Donte Donati, a local contractor and concrete block supplier, to build his home. “Donati declined the Kalils’ offer to build the house, but two young men overheard the conversation between the Kalils and Donati. Camillo Palermo and his partner were experienced carpenters and metalworkers recently returned from military service in the Korean War, and they were looking for work. They struck up a conversation with Dr. Kalil and offered their services. Fortunately for the Kalils, these two craftsmen had both the talent and the enthusiasm to build their Usonian Automatic.”6
Camillo Palermo built the forms out of metal, and Donati allowed him to make the blocks under pressure to speed up production. Dr. Kalil reported to Wright in a letter dated January 31, 1956, that the foundations and footing [for the house] were laid before the start of cold weather and that 70 concrete blocks were being manufactured per day. About this same time, Morton Delson was assigned as the Wright representative on site.
An article entitled “My Story of Building Dr. Kalil’s House in Manchester, NH,” written by Paul Beaudoin as told to him by his father-in-law John Martineau in January 2007, describes the construction environment at the Kalil House:
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My name is John Martineau. As a young man I was learning the masonry trade and was employed by Carmen Palermo. I joined a fellow classmate, Louie LaTullipe, who was already employed as an apprentice. During 1955, the contractor was contacted by Dr. Kalil to build a new type of concrete house, in Manchester, NH, designed by Frank Lloyd Wright. The style of this house was called Usonian. We worked on this house for two years.
Mr. Palermo was the type of contractor that had a very “can-do” attitude. As he started to take his measurements, he quickly realized that because of the accumulated tolerances, the blocks were going to quickly make the walls too long. Also, none of the horizontal or vertical joints were going to line up.
An engineer was making monthly visits to check on the progress. After obtaining approval from the engineer, a jig was made to shave all of the blocks down to a more accurate working dimension. Mr. Palermo devised a jig that consisted of two engines with giant grinding wheels that sat on either side of a roller conveyor. Each block had to be passed through twice for all four sides to be ground evenly.
As the walls were being built, all of the electrical wiring had to be run at the same time. Now Mr. Palermo was not an electrician, but he knew enough about wiring to get it done. He stated that “if we couldn’t figure it out, we could go to the public library and find out how.” The wiring was a very long process. Each wire had to be brought up through the wall as the wall was being built.
The roof took an unbelievable amount of labor to complete. Each of the blocks had to be kept square to each other, proper height from the floor, and perfectly level. Each of the blocks had to be supported until each of the two rods was inserted. Each of the blocks weighed between 180 and 220 pounds, depending if they were solid or with an imbedded pattern.
Each of these blocks was wheeled up a ramp to the roof. One guy would balance the wheel-
barrel and the other would pull the wheel-barrel by rope.
The roof also had a cooling feature that allowed the roof to be flooded to keep the house cool in the summer. The corners of the roof had a drain plug to retain the water, but allow an overflow to drain. After the blocks of the roof were completed, a fiberglass blanket was laid down for waterproofing. This was a new type of material that was being used, for the time.
In my opinion, the house was not very economical or very practical.7
This article provides a quite detailed first-hand account of the construction. A photo from that period survives with Mrs. Kalil on the roof of the carport before the lightweight concrete slab is poured (Figure 2). Note that the reinforcing bars extend above the concrete roof blocks in areas where the span is greatest.
We learn from his story that the roofing is quite different from the specification from Wright, which called for a four-ply coal-tar-pitch built-up roofing system with copper flashings and components. Through review of historical documents, we did not discover how the roofing installed on the home became what we learned to be “Celastic and BBX” roofing materials. The documents provided to WJE outline the various issues and challenges encountered by Dr. Kalil related to leaks and the roofing. The documents provide little in the way of specifics of what we discovered through the course of assessment and repair; however, they do tell the story of multiple failed roofing applications and the responses to the owner. Documents pertinent to leaks and roofing are listed in Appendix A.
Documents show that the roofing materials, Celastic and BBX, were shipped to the site on December 3, 1956. Celastic was packaged as 5-yard rolls. Activator BBX was packaged as 5-gallon pails. Calahan & Horsey, the distributor of the material, inquired about the weather, deck condition, and other details. Dr. Kalil responded that snow or rain was predicted for the next day and that only the BBX had arrived. It is not clear when the material was installed in 1957. More materials were shipped and invoiced in September 1957, and in November, more Celastic was invoiced.
Little was found in our search for information about Celastic or BBX. We did find a patent application in 1960 for a method for forming laminated objects which refers to Celastic. The patent describes Celastic as “sheet material preferred for use in accordance with this invention is a fabric of the general nature of canvas which has been impregnated with a plastic emulsion containing colloidal clay so that medium-weight canvas is formed to a sheet approximately 1/8 in. in thickness. A commercial form of the material is sold under the trademark ‘Celastic.’”8
Cracking of the roofing was reported during the winter of 1957-1958 by Dr. Kalil. During the period from January to July 1958, several letters were sent. Horsey, Robson & Company (HRC) reported that they had reviewed previous applications of their products and found no cracking. They proposed to inspect the installation. After the inspection, HRC provided new material that Palermo was to install. They agreed that repair was needed with materials shipped on May 26, 1958. Robson, of HRC, was able to find sources of leaks in the roof of the house and sealed them with “Liquid Tape,” concrete, and wood sealer. Robson expressed that a complete repair of the leaks would require
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Figure 2 – Interior view of the living room.
resealing almost the entire roof. Robson
advised Dr. Kalil that if leaks continued,
then Mr. Palermo should put a few sheets
of tar paper over the affected areas.
On July 16, 1958, Dr. Kalil received a
quote from Geo. W. Horne to replace the
roofing and install a new tar and gravel
roof. A few weeks later, on July 27, 1958,
HRC described a new plan for the Kalil
House roof, noting that “bad weather has
made it difficult to make plans for installation
and adhere [tar paper]…and most
importantly, HRC can no longer manufacture
the Celastic and BBX due to lack
of raw material supply.” BBX-Plastic roof
sealer was to be used instead and was
to be applied with a brush or roller. HRC
noted that “Palermo can finish it himself
after a tutorial from HRC.”
Delson wrote on September 18, 1958,
that a mastic underlay had been applied to
the roof, and Horsey Set would be applied
above it as waterproofing and decking.
Horsey Set would be applied in a red color.
If any cracks appeared in the roofing, then
HRC would immediately make arrangements
for repairs.
At this point in roofing repairs, HRC
claimed no responsibility for leaks and
installation since the materials were
installed without anyone from HRC present.
They wanted to continue working
on the Kalil House. Robson claimed the
surface was “soaked.” He suggested the
addition of Horsey Set, which is installed
directly on the concrete surface. HRC
wanted Dr. Kalil to sign the terms and conditions
of the Horsey Set installation. On
October 2, 1958, HRC felt that the weather
had reached a point where installation of
Horsey Set would have to wait until after
winter.
In a letter dated October 2, 1958,
Delson disputed the description of the roofing
installation made by HRC in their letter
of September 22, 1958. Delson believed
that HRC did not intend to send someone
to supervise the installation of Celastic and
BBX, and that the method of application
described to him by a company representative
was simple. The application method,
according to HRC, involved installing concrete
and wood sealer in a specified pattern
on the dry roof surface. The surface was
then to be sealed with BBX, following which
Celastic was to be applied. Finally, the
roof was covered in a layer of paint. It was
recommended to Delson that the insulating
concrete roof slab be covered with a thin
coat of “cement” prior to roofing installation,
as the original surface was not intended
to be covered in Celastic. Delson did not
believe that the concrete topping had continued
to crack, but he did state that there
were existing hairline
cracks in the concrete.
Delson stated that, as far
as he knew, there had
not been new cracking in
the concrete topping and
there had never been any
cracking in the underlying
insulating slab. Delson
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During our investigation, we observed
some evidence of the materials
described in correspondence, as well
as unexpected conditions.
Figure 4 – Mildred Kalil on roof
blocks. Note the reinforcing bars
extending above the surface.
(Courtesy of the Kalil Estate.)
Figure 3 – Exterior view of the home.
requested that the installation of Horsey Set proceed immediately.
Two letters went back and forth between HRC and Dr. Kalil. One requested Dr. Kalil sign the terms and conditions and one requested that HRC commence the Horsey Set installation. Several more messages were exchanged. Dr. Kalil did not sign and explained why. HRC stated that they would withdraw their offer. On October 24, 1958, Dr. Kalil would not sign for the reasons given in his earlier letter. HRC was shipping material to arrive by November 6, 1958. Horsey Set should not be installed below 60 degrees.
On July 19, 1960, Palermo received a proposal from A.J. Murphy & Sons to install a three-ply tar and gravel roof, with colored gravel to be supplied by the owner.
In a letter written to Wesley Peters (a representative from the office of Frank Lloyd Wright) dated June 7, 1962, Dr. Kalil recounted his experience during the construction of the house as follows. The Celastic roof did not survive the first winter. Horsey Set was installed, but then did not survive the following winter. At this point neither HRC, nor Wright wanted to take responsibility for the roof, and Dr. Kalil was left with a leaking roof. Dr. Kalil had a difficult time finding workers who would install a new roof and eventually hired an out-of-town roofer to install a tar and gravel roof. The roofer could not use proper flashing because there was no space after the two previous roof installations. Due to the poor flashing, the roof leaked around its perimeter and where there were joints between levels. Local roofers had no solution to this problem. Dr. Kalil applied caulking compound himself to remedy the situation and planned to contact the Barrett or Koppers company for assistance with better repairs. Dr. Kalil noted staining on walls and ceiling blocks, which he planned to have refinished after the leaks were fixed. Original wiring in the ceiling and roof were replaced due to wet wires shorting and burning out. Dr. Kalil also mentioned that the fireplace did not work.
There is record of an invoice for repairs in December 1963, on a tar and gravel roof. The next record of roofing replacement is from June 2007, when 60-mil EPDM roofing was installed by Olympic Roofing, and repairs were made in June of 2013. This was the roofing system observed by WJE at the start of our condition assessment that was ultimately replaced.
ROOFING CONDITION ASSESSMENT
When we conducted our first site visit to the house for the condition assessment, the Kalil heirs reported a history of leaks consistent with the documents retained by Dr. Kalil from the 1950s and ‘60s. During our investigation, we observed some evidence of the materials described in correspondence, as well as unexpected conditions. The roof was covered in black EPDM with pyramid-shaped mounds all over the roof rising above the surface (Figure 5). At the main (lower) roof, the perimeter edge metal consisted of a copper drip edge that extended over the roof edge. The tower roof above the central kitchen and fireplace was similar. Drains were located at the perimeter and consisted of simple copper square tubes. The tower roof had scuppers with extensions installed by the Kalil heirs—
presumably to stop water from splashing on the windows below (Figures 5 and 6). The guesthouse studio (Figure 7) roof had similar details and mounded roofing.
The assembly of the concrete units into the roof, walls, and windows presented challenges. The edge of the roof was on the same plane as the joint for the unit with fixed glass or the sill of the operable window. Previous roofing installations had adhered the EPDM flashing directly to the concrete, the glass, and the aluminum frame (Figure 6).
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Figure 6 – Roofing and sill of operable windows are on the same plane. Note the owner-added scupper extensions.
Figure 5 – The mounds or pyramids raise the roofing above recessed light fixtures.
During our investigation, by using infrared scanning and inspection openings, we found that much of the roofing assembly was wet. At the inspection openings, we determined that the assembly included a 2-in.-thick polyisocyanurate insulation board fastened to the concrete with the EPDM adhered to the insulation. The insulation was cut to adjust to a rise in the concrete deck. The mounds that rise about the roof surface correspond to the recessed ceiling light fixtures (Figure 7).
The light fixtures are simple, with a brass plate supporting a hand-blown glass ball. A standard lightbulb is positioned above the plate and ball with its socket mounted to an electrical box (Figure 8). The fixture box was encased in concrete at the roof, which was the reason for the mounds in the concrete roof deck. At the time of our condition assessment, approximately half of the light fixtures were not functional.
The concrete surface below the roofing sloped at the rising wall, so the deck was uneven at the perimeter, preventing a square-edged insulation board from lining up directly with the rising wall. We discovered a red coating or sheet directly applied to the concrete in some locations (Figure 9) and suspected that these were remnants of the Celastic or Horsey Set materials applied in 1957 and 1958. We also discovered a copper flashing at the joint between the roof blocks and the rising wall blocks of the tower that extended out toward the field of the roof. This detail is not included in original drawings and is not mentioned in correspondence from construction (Figure 10).
ROOFING REPLACEMENT
We easily determined that the existing roofing system was beyond its useful service life, and with roofing replacement there would be an opportunity to correct flashing details and improve drainage from the roofs. We reviewed various roofing alternatives within our firm and with the client, including liquid-applied membranes, modified bitumen, or single-ply membranes. These systems were considered with insulation above the membrane and below the membrane. Both configurations were challenged to provide adequate slope and drainage due to the uneven deck, low
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Figure 10 – Copper flashing between
roof deck block and rising wall block
was exposed during inspection opening.
Figure 9 – The red material seen at the inspection opening is likely the Horsey Set or Celastic.
Figure 7 – Exterior view of the guesthouse.
Figure 8 – Interior view of the recessed light fixture.
flashing heights, and perimeter drains. We also struggled to balance the desire to retain the historic appearance of the house at the roof perimeter while also addressing original design issues that contributed to improper drainage and leaks.
We were also challenged with accommodating current energy code requirements for roof insulation. Given the unique and historical nature of the house, the local building department allowed a variance to code requirements for roof insulation. The original roof was not insulated. While leaving a roof uninsulated in New England is not typical, we determined that removing the insulation to improve flashing heights and drainage from the roof would be less detrimental to the structure than installing insulation with complicated flashing details, leaving the potential for leaks.
After review with the heirs, we designed a replacement roofing system that consisted of a modified-bitumen membrane, coverboard, and vapor retarder directly applied to the concrete roof deck. We relied on liquid flashings (polymethyl methacrylate – PMMA) at the base of rising walls and penetrations. For roof edges, we use liquid flashing in conjunction with new copper edge flashing. We also eliminated the upper (tower) roof scuppers by sloping the roof to a single scupper at the rear of the tower that drained to a new collector box and downspout that exited to the main roof surface. This modification to the tower roof did mean raising the edge.
We solicited bids from qualified roofing contractors and coordinated our specification with the roofing material manufacturers. The first selected contractor worked with us on initial submittals and performed more inspection openings. During the bidding phase, we determined that a torch-
applied cap sheet with red granules was available in sufficient quantity to restore the roof to its original intended color. The red-colored cap sheet was also a close color match to the interior floor, carport, and outdoor patios. After some delay, the initial contractor declined to perform the work. Unfortunately, this used up critical summer working conditions, but a second contractor was approached and successfully performed the work.
During roofing replacement, we assisted the Kalil heirs in coordinating roofing work with repairs to the electrical wiring embedded in the roof deck for the recessed ceiling lights. During tear off of the existing roofing (Figure 11 and Figure 12), the electrician was on site. With the roofing removed, we discovered junction boxes set flush with the surface of the deck (Figure 13). The electrician pulled new wiring and re-established circuits to restore power to all of the ceiling light fixtures. While we
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Figure 13 – A junction box was found buried in the concrete roof deck.
Figure 11 – Upper roof tear off.
Figure 12 – The electrical boxes
are above recessed light fixtures.
anticipated the need for a coverboard once the roof deck was exposed, we determined that the modified-bitumen assembly could be directly adhered to the concrete deck. To accommodate the concrete mounds above recessed ceiling lights, the torch-applied vapor barrier was cut and patched. The smaller guesthouse/studio that is somewhat hidden from street view provided a location for trial applications. For the upper tower roof, a combination of lightweight insulating fill and tapered insulation was used to reconfigure the drainage pattern of this roof. New copper flashings at roof edges, coated with liquid flashing along the skyward-facing edge and caps, were installed. Some of the most challenging flashing details were at the base of the rising walls of the tower, where aluminum-framed windows and fixed-glass windows were within a few inches of the main roof. To provide as much drainage and positive slope as possible, the base of the rising wall was treated with liquid flashings that coated the concrete frame of the fixed windows and the aluminum frame of the operable windows, which had been previously fixed in a closed position (Figure 14).
COMPLETED ROOFING
The results of the roofing replacement were successful and became a selling point for the home. The red granulated cap sheet is an added benefit reflecting an element of the original design (Figures 15 through 17).
CLOSING
The home was placed on the market and offered at $850,000. There was a great deal of interest from a number of people locally and internationally. When the offers were considered, the one by the Currier Museum
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Figure 16 – View from carport roof
of completed work on main roof.
Figure 14 – PMMA flashing was applied at the base of the wall and at operable window frames.
Figure 15 – Liquid flashing at base of tower rising wall, new collector box, and scupper.
of Art was accepted. The Museum now owns two Frank Lloyd Wright homes which will be open to the public by tour only.
FOOTNOTES
1. Hurd, M. K. “Usonian Automatic: Wright’s Concrete Masonry.” Concrete in Housing. #C881028. The Aberdeen Group. 1988.
2. Heinz, Thomas A. The Vision of Frank Lloyd Wright. Regency House Publishing, Ltd. 2005.
3. Secrest, Meryle. Frank Lloyd Wright, A Biography. The University of Chicago Press. 1992.
4. Hurd, M. K. “Usonian Automatic: Wright’s Concrete Masonry.” Concrete in Housing. #C881028. The Aberdeen Group. 1988.
5. Secrest, Meryle. Frank Lloyd Wright, A Biography. p.533. The University of Chicago Press. 1992.
6. Komanecky, Michael. The Currier Bulletin. p.13. 1994.
7. Beaudoin, Paul. My Story of Building Dr. Kalil’s House in Manchester, NH. Steinrag.com. January 2007.
8. Method for Forming Laminated Objects, United States Patent Office 2,955,642. Patented October 11, 1960.
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Figure 17 – Liquid flashing at base of rising wall above carport roof and new copper roof edge flashing.
SUMMARY OF CONTENTS CITATION
Eugene Masselink (EM) writes on behalf of Frank Lloyd Wright (FLW), who would like to build a Eugene Masselink to Dr. Kalil,
house for the Kalils. EM requests the Kalils’ requirements and budget for the house. EM informs letter, July 5, 1954
the Kalils that he will need a topographical survey and photographs of the building lot.
A letter from Dr. Kalil that accompanies the delivery of topographical studies, pictures of the lot, Dr. Kalil to Frank Lloyd Wright,
and personal data. The letter includes a short description of the surrounding properties and letter, August 28, 1954
a list of requested amenities for the new home.
A letter confirming that FLW received the August 28,1954, letter from Dr. Kalil. Eugene Masselink to Dr. Kalil,
letter, September 4, 1954
The correspondence references a letter of “the 16th,” which is not included in the collection Eugene Masselink to Dr. Kalil,
of original documents. EM informs Dr. Kalil that he may make an appointment to meet letter, October 7, 1954
with FLW the following week.
A letter to inform that the plans for the Kalil House have been mailed. Eugene Masselink to Dr. Kalil,
letter, January 29, 1955
The letter outlines the terms of service and costs for employing FLW as the architect for the Frank Lloyd Wright to Dr. Kalil,
house. Included in the letter is an invoice for five percent of the proposed cost of the house invoice, January 29, 1955
to cover preliminary architectural services.
Dr. Kalil expresses that he is happy with the design of the house and thanks FLW for a recent Dr. Kalil to Frank Lloyd Wright,
meeting. The letter accompanies a summary of items which were discussed in the meeting. letter, March 2, 1955
Dr. Kalil lists items discussed during a recent meeting about the new house. The list includes Dr. Kalil, notes, March 2, 1955
ceiling heights, window configurations, an incinerator, utility sink, outdoor storage space,
and bathrooms.
A letter accompanying a check to pay for preliminary design. Dr. Kalil to Eugene Masselink,
letter, March 2, 1955
EM acknowledges that FLW received a check for his services, along with Dr. Kalil’s list of items Eugene Masselink to Dr. Kalil,
to be accommodated in the house design. letter, April 7, 1955
A telegram stating that drawings have been completed. Eugene Masselink to Dr. Kalil,
telegram, June 28, 1955
A letter requesting confirmation that Dr. Kalil received the latest working drawing set. Eugene Masselink to Dr. Kalil,
letter, July 11, 1955
A letter outlining the terms of service and costs for employing FLW as the architect for the Frank Lloyd Wright to Dr. Kalil,
house. Included in the letter is an invoice for four percent of the proposed cost of the house, invoice, July 11, 1955
to pay for the working drawings.
A letter informing Dr. Kalil of FLW’s availability for a meeting. FLW requests payment for the Eugene Masselink to Dr. Kalil,
working drawing set. letter, September 10, 1955
EM confirms that FLW received payment for the working drawings. Also included in the letter Eugene Masselink to Dr. Kalil,
is FLW’s availability for a meeting with Dr. Kalil. letter, October 7, 1955
Dr. Kalil writes to inform FLW that the footings and foundation of the house were laid before the Dr. Kalil to Frank Lloyd Wright,
start of cold weather and that 70 concrete blocks are being manufactured per day. Morton and letter, January 31, 1956
a concrete block manufacturer have been coordinating the concrete block production. Dr. Kalil
inquires about whether the concrete floor in the house will be comfortably warm in the winter.
Dr. Kalil requests copies of original sketches from FLW. Morton Delson needs the sketches Dr. Kalil to Eugene Masselink,
in order to answer questions he has about the project. letter, February 1, 1956
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APPENDIX A. CHRONOLOGICAL LISTING OF DOCUMENTS
SUMMARY OF CONTENTS CITATION
FLW informs Dr. Kalil that the sketches will be sent soon and that Dr. Kalil’s concerns about Eugene Masselink to Dr. Kalil,
heating are being addressed. letter, February 22, 1956
A letter accompanying a deposit for dies. The letter requests prompt delivery of the Rayco Construction Company
purchased dies. to Dr. Kalil, letter, May 26, 1956
An invoice for the installation of 71 small windows and 1 big window, all made A.W. Therrien Company to Dr. Kalil,
of 0.040-gauge aluminum. invoice, August 28, 1956
An invoice for lead-coated copper counter flashings. A.W. Therrien Company to Dr. Kalil,
invoice, August 28, 1956
An invoice for 19 linear feet of lead-coated copper flashings. A.W. Therrien Company to Dr. Kalil,
invoice, October 24, 1956
Calahan & Horsey inquire about the weather, deck condition, paint rollers, and the arrival Calahan & Horsey to Dr. Kalil,
of Celastic and BBX. Dr. Kalil notes on the letter that snow or rain is predicted for the next day, letter, December 3, 1956
two-thirds is dry, there are paint rollers available, and that only the BBX has arrived.
An invoice for ten 25-yard rolls of Celastic #32 and thirteen 5-gallon cans of Activator BBX. Calahan & Horsey to Dr. Kalil,
invoice, December 5, 1956
An invoice for three 25-yard rolls of Celastic #32 and twelve 5-gallon cans of Activator BBX. Calahan & Horsey to Dr. Kalil,
invoice, September 5, 1957
An invoice for two 25-yard rolls of Celastic #32 and four 5-gallon Cans of Activator BBX. Calahan & Horsey to Dr. Kalil,
invoice, September 5, 1957
A statement of charges owing. Horsey, Robson & Company to
Dr. Kalil, invoice, November 1, 1957
An invoice for 31/3 linear yards of Celastic #32. Horsey, Robson & Company to
Dr. Kalil, invoice, November 19, 1957
HRC has reviewed past applications of Celastic and BBX which are 8 to 10 years old. Horsey, Robson & Company to
The company claims they have not found any cracking in their roofing unless there has been Morton Delson, letter,
an excessive amount of movement in the substrate. HRC would like a visual inspection report January 31, 1958
of the surface below the installed Celastic and BBX on the Kalil House.
A letter following an inspection of the roof of the Kalil House. HRC will redo the application of Horsey, Robson & Company to
Celastic and BBX products because of an unexplained failure. HRC would like to wait for good Dr. Kalil, letter, April 16, 1958
weather to let the concrete dry out before beginning reinstallation.
A letter to reiterate to Palermo that he will supply labor for reinstallation of roofing materials Horsey, Robson & Company to
while HRC will supply the material—both are to be at no extra cost to Dr. Kalil. Mr. Palermo, letter, May 6, 1958
A letter informs Dr. Kalil that the roofing for the house needs to be redone. The areas that Horsey, Robson & Company to
need to be recoated will be determined soon and the materials will be shipped to Dr. Kalil. Dr. Kalil, letter, May 16, 1958
A.C. Horn has sent samples and application instructions for their Colorundum Sealer Clear, A.C. Horn Companies to Dr. Kalil,
Colorundum Sealer Reducer, and Colorundum Dressing, which are to be tested for use on the letter, May 23, 1958
floor of the house.
HRC informs Dr. Kalil that replacement quantities of Celastic and BBX have been shipped, Horsey, Robson & Company to
to be used for repairs on the roof. Dr. Kalil, letter, May 26, 1958
HRC apologizes for construction delay due to wet weather. Horsey, Robson & Company to
Mr. Palermo, Dr. Kalil, letter,
June 12, 1958
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SUMMARY OF CONTENTS CITATION
Robson, of HRC, was able to find sources of leaks in the roof of the house and sealed them Horsey, Robson & Company to
with Liquid Tape, concrete, and wood sealer. Robson expresses that a complete repair Dr. Kalil, letter, July 11, 1958
of the leaks would require resealing almost the entire roof. Robson advises Dr. Kalil that if
leaks continue then Palermo should put a few sheets of tar paper over the affected areas.
Details are included for how to return Celastic and BBX to HRC.
A letter responding to inquiry from Dr. Kalil regarding a tar and gravel roof for the house. Geo. W. Horne Company to Dr. Kalil,
Geo. W. Horne recommends removing plastic material that covers parts of the roof and then proposal, July 16, 1958
installing a tar and gravel roof. The letter outlines the application process for the tar, felt,
and flashing. Geo. W. Horne proposes to leave the already-installed lead-coated copper
flashings but does not recommend them.
There is a new plan for the Kalil House roof. Firstly, the bad weather has made it difficult to Horsey, Robson & Company to
make plans for installation and adhere to them. Secondly, and most importantly, HRC can no Morton Delson, letter, July 27, 1958
longer manufacture the Celastic and BBX due to lack of raw material supply. BBX-Plastic roof
sealer will be used instead. BBX-Plastic Roof sealer is applied with a brush or roller and
Palermo can finish it himself after a tutorial from HRC.
A mastic underlay has been applied to the roof, and Horsey Set will be applied overtop as Morton Delson to Horsey, Robson &
waterproofing and decking. Horsey Set will be applied in a red color. If any cracks appear in Company, letter, September 18, 1958
the roofing, then HRC will immediately make arrangements for repairs.
HRC states that Celastic and BBX were applied without anyone from HRC present or aware, Horsey, Robson & Company to
contrary to HRC’s mandate that the products must be installed under HRC’s supervision. Morton Delson, letter,
HRC claims no responsibility for the roofing failure but would like to continue working with September 22, 1958
the Kalil house and FLW. HRC claims there was a thin topping applied to “soaked insulating
concrete,” which continued to crack. Therefore, when Celastic and BBX were applied they could
not handle the movement of the concrete. HRC states that the roof is full of cracks and new
ones are continually appearing. They will not guarantee a roofing system until the roof is no
longer cracking. Another suggested product is Horsey Set, which is installed directly on the
concrete surface.
A letter to request Dr. Kalil’s signature, accepting the terms and conditions of installing Horsey, Robson & Company to
Horsey Set. Dr. Kalil, letter, October 2, 1958
A confirmation that HRC received a 9/18/1958 letter from Dr. Kalil regarding the terms Horsey, Robson & Company to
and conditions of Horsey Set installation. HRC has not yet received a response to their Morton Delson, letter,
9/22/1958 letter and feels that the weather has reached a point where installation of October 2, 1958
Horsey Set will have to wait until after winter.
Morton does not agree with the circumstances around the roofing installation which were Morton Delson to Horsey, Robson &
described by HRC in their 9/22/1958 letter. Morton believes that HRC did not intend to send Company, letter, October 6, 1958
someone to supervise the installation of Celastic and BBX and that the method of application
described to him by a company representative was simple. The application method, according
to HRC, involved installing concrete and wood sealer in a specified pattern on the dry roof
surface. The surface was then to be sealed with BBX, following which Celastic was to be
applied. Finally, the roof was covered in a layer of paint. It was recommended to Morton that
the insulating concrete roof slab be covered with a thin coat of “cement” prior to roofing
installation, as the original surface was not intended to be covered in Celastic. Morton does
not believe that this concrete topping has continued to crack but does state that there are
existing hairline cracks in the concrete and in the Horsey Set. The hairline cracks appeared
in the Horsey Set two weeks after application and that more had appeared ten days after that.
Note: Morton Delson refers to Horsey Set already having been on the roof, but also
references that Horsey Set has not yet been applied and that the mastic underlay has
been installed for three weeks, awaiting the Horsey Set installation. It is possible that
Morton is meaning to say Celastic and BBX, not Horsey Set, when referring to previously
installed roofing. Morton states that, as far as he knows, there has not been new cracking in
the concrete topping and there has never been any cracking in the underlying insulating slab.
Morton requests that the installation of Horsey Set proceed immediately.
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SUMMARY OF CONTENTS CITATION
HRC confirms they have received Morton’s 10/7/1958 letter. HRC requests prompt Horsey, Robson & Company to
approval and a signature from Dr. Kalil for their terms and conditions for the installation Morton Delson, letter,
of Horsey Set so that the product can be installed immediately, before the weather worsens. October 7, 1958
Dr. Kalil requests that the installation of Horsey Set proceed but does not include a signed Dr. Kalil to Horsey, Robson &
copy of document of terms and conditions. Company, letter, October 8, 1958
HRC requests that Dr. Kalil sign the letter of terms and conditions before proceeding with Horsey, Robson & Company to
Horsey Set installation. Dr. Kalil, letter, October 10, 1958
Dr. Kalil does not sign the terms and conditions document and includes reasoning behind Horsey, Robson & Company to
his decision. Firstly, Dr. Kalil states he cannot assure that the roof will no longer crack, and Dr. Kalil, letter, October 15, 1958
refers HRC to FLW. Secondly, there is a disagreement as to who holds responsibility for any
issues. Finally, HRC stated they would provide supervision of the installation of Horsey Set at
a time suitable to them. Dr. Kalil states that the house must have a roof before winter and
inquires whether HRC is referring to the coming spring as their preferred time for the project.
Dr. Kalil will not hold HRC responsible for damages due to roof cracking after the installation Dr. Kalil to Horsey, Robson &
of Horsey Set. Company, letter, October 20, 1958
HRC requests that Dr. Kalil sign the terms and conditions. If Dr. Kalil does not, then HRC Horsey, Robson & Company to
will withdraw their offer. HRC requests this be done immediately because there cannot be Dr. Kalil, letter, October 22, 1958
any more delays in installation because of worsening weather.
Dr. Kalil cannot sign the terms and conditions due to the three points he disagrees with Dr. Kalil to Horsey, Robson &
(as described in 10/15/1958 letter). Company, letter, October 24, 1958
HRC is shipping Horsey Set, which will arrive by 11/6/1958. It will be difficult to coordinate Horsey, Robson & Company to
installation of roofing due to both weather and availability of personnel. Horsey Set should not Dr. Kalil, letter, October 31, 1958
be applied in temperatures below 60 degrees Fahrenheit.
An invoice for cutting grooves in blocks, caulking and sealing the tower (two coats), three Palermo to Dr. Kalil, invoice,
gallons of sealer, and one tube caulking compound. April 16, 1959
A.J. Murphy proposes to install a three-ply tar and gravel roof mopped to the cement deck, A.J. Murphy & Sons to Mr. Palermo,
using no metal flashings. A price is given for adding two layers of 1/2-in. insulation, if proposal, July 19, 1960
desired. If Dr. Kalil would like, he may supply his own colored roof gravel. About six tons
of gravel will be needed for the roof.
FLW requests payment for his services for the completed house. Eugene Masselink to Dr. Kalil,
invoice, August 1, 1961
FLW inquires about the final cost of the house. Dr. Kalil has paid the 10 percent of the original William Wesley Peters to Dr. Kalil,
price of $25,000, but as per their contract, owes FLW 10 percent worth of any additional letter, May 26, 1962
costs for the house. FLW acknowledges that Dr. Kalil had to endure much more cost than
expected in relation to the roof completion and FLW offers to share in any “unusual expenses.”
Dr. Kalil recounts his experience during the construction of the house as follows. The Celastic Dr. Kalil to William Wesley Peters,
roof did not survive the first winter. Horsey Set was installed, but then did not survive the letter, June 7, 1962
following winter. At this point neither HRC nor FLW wanted to take responsibility for the roof,
and Dr. Kalil was left with a leaking roof. Dr. Kalil had a difficult time finding workers who
would install a new roof and eventually hired an out-of-town roofer to install a tar and gravel
roof. The roofer could not use proper flashing because there was no space after the two
previous roof installations. Due to the poor flashing, the roof now leaks around its perimeter
and where there are joints between levels. Local roofers have no solution to this problem.
Dr. Kalil applies caulking compound himself to remedy the situation and plans to contact
the Barrett or Koppers company for assistance for better repairs. There is staining on the wall
and ceiling blocks, which Dr. Kalil plans to have refinished after the leaks are fixed. Original
wiring in the ceiling and roof were replaced due to wet wires shorting and burning out.
Dr. Kalil also mentions that the fireplace does not work.
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SUMMARY OF CONTENTS CITATION
Delson believed that the roof was no longer leaking and that the cold roofing application by Morton Delson to Dr. Kalil, letter,
Colonial Paint Co. fixed any issues. July 24, 1962
The office of FLW was surprised to hear about the roofing issues as they had received no William Wesley Peters to Dr. Kalil,
indication that they continued. Delson told FLW that Dr. Kalil had a Colonial Paint Co. cold- letter, September 7, 1962
process roof installed and guaranteed, with success. FLW restates they were not aware of any
issues beyond the HRC roofing product failures. FLW feels they should have been informed
about the issues as opposed to having Dr. Kalil feel like FLW had abandoned him as a client.
FLW inquires about the current state of the roof and if they can help in fixing it for the winter.
Dr. Kalil states that the Colonial Paint Co. cold-process-applied roof was not guaranteed. Dr. Kalil to William Wesley Peters,
On the contrary, the company would only agree to install the roof on the condition that they letter, September 21, 1962
not be held responsible for its outcome. By the time of the installation it was late fall and there
was no time to look at alternative solutions. Dr. Kalil has very negative feelings towards this
roof and feels it is a mess and has no chance of working with the underlying compromised
systems. Dr. Kalil informs FLW that work on the roof has already started, but it is not clear
if this work is for the Colonial Paint roof or for a new fix. It seems that the Colonial Paint
roof was applied in a previous year.
An invoice from a roofing contractor, including labor for temporary repairs and roofing cement John W. Joy & Sons to Dr. Kalil,
(Dec. 1963), repairing tar and gravel roof, installing aluminum flashings, repairing copper invoice, June 15, 1964
flashings (June 1964). Items used for June repairs include aluminum flashing, copper flashing,
roofing cement, roofing asphalt, roofing gravel, Parker nails, lumber, and caulking components.
The FLW Foundation is updating its catalogue of FLW’s buildings and requests information Bruce Brooks Pfeiffer to Dr. Kalil,
and a photo of the house from Dr. Kalil. letter, July 18, 1967
Morse thanks Fred and John for one of the extra concrete blocks that he took from the Leonard J. Morse-Fortier to Fred Kalil
property. While inspecting the extra blocks, Morse discovered that there were a variety of and John Kalil, letter, May 24, 1991
blocks that were cast, including one with conduit cast into the block, which may have been
used at various parts of the house. Morse references efflorescence on the concrete and asks
who to contact for further information about how to restore the concrete. The house retains
structural integrity; however, Morse is unsure about the shear strength of the window walls
and suggests a test for providing more information. Morse references Steven Kroeter of
ARCHETYPE Associates in Brooklyn, NY, and Bruce Brooks Pfeiffer of the Frank Lloyd Wright
Archives Taliesin West in Scottsdale, AZ, for more expertise.
Storrer requests verification/information to compete his documentation of the as-built plans William Allin Storrer to Mrs. Kalil,
of FLW buildings. letter, August 1, 1992
Zimmer requests permission to photograph the Kalil house again. D.F. Zimmer to John Kalil, letter,
August 11, 2006
An estimate for a rubber roof installation, including: going over rubber roof on house in Olympic Painting and Roofing to
various areas, installing 1/2-in. fiberboard with adhesive, installing 0.060 fully adhered John Kalil, quote and invoice,
EPDM rubber roofing (installed in six sections on roof), one-year warranty on workmanship, June 7, 2007
installing 3-in. seam tape on all seams, installing L-Stock drip edge on flat roof perimeter,
installing 6-in. cover tape on all aluminum L-Stock, and covering 30 ceiling lights.
An invoice for roof repair, which includes cleaning the roof, repairing downspout flashings The Melanson Company to
and holes, and installing a chimney screen. John Kalil, invoice with images
of roof, June 25, 2013
108 | Waterston 2020 IIBEbeC BuildINg ENClosure Symposium | November 9, 10, 12, 16, 17, 19, 2020