Photo courtesy of FotoGrafix Viken Djarferian

As part of an adaptive reuse of Chicago's 106-year-old Cook County Hospital, led by Skidmore, Owings & Merrill and Koo Architecture, the terrazzo contractor preserved and restored the original cement terrazzo tiles, carefully matching and complementing them with poured-in-place epoxy terrazzo. Simulated grout joints were cut to replicate the original design.

INTRODUCTION TO TERRAZZO AND ADAPTIVE REUSE

Repurposing buildings is more than simple nostalgia; it’s smart sustainability. Adaptive reuse leverages the value of existing structures, revitalizing old, neglected, or underused built assets as functional environments, thus avoiding the costs and environmental impact of demolition and rebuilding.

Terrazzo exemplifies this philosophy with its capacity to be restored and layered over existing surfaces and create precise color matches to existing design elements. Specifying terrazzo means embracing a legacy of durability, versatility, and environmental responsibility, ensuring that the old becomes new again, beautifully and elegantly.

By retrofitting and updating structures, adaptive reuse restores prime real estate to productive, attractive spaces, optimizing its performance while playing a crucial role in urban revitalization. This approach aligns with sustainable development principles and is both financially advantageous and environmentally responsible. Renovating and adapting buildings for new uses brings value to the community, creating spaces that meet contemporary needs while preserving historical and architectural heritage.

INTRODUCTION TO TERRAZZO

A. What is Terrazzo?

Terrazzo is a composite material traditionally made of a cement binder, but more commonly today, a resinous matrix mixed with aggregates of natural stone, recycled glass, mother-of-pearl, or other natural or synthetic material. The design-flexible epoxy system, thinner and lighter than the cement system with a sand cushion, has become the system of choice for most installations.

Unlike manufactured products, terrazzo is installed using the in-situ method, where raw materials are combined and poured directly onto the floor, with flexibility and versatility to create custom designs. Once cured, the surface is ground to a smooth, hard finish. Terrazzo can also be applied to walls, ceilings, stairs, curbs, panels, and countertops, whether applied by hand on-site or as precast elements, offering a durable and versatile surface.

Divider strips—typically made of zinc, aluminum, brass, plastic, or even another color of terrazzo—are used to separate colors and create patterns. For more intricate designs, strips can be waterjet-cut, while epoxy terrazzo can be poured without divider strips for seamless, free-form patterning.

Terrazzo supports human health, safety, and welfare by being a durable, low-maintenance material that promotes better air quality due to its non-porous, VOC-free composition. Its slip-resistant surface enhances safety in high-traffic areas, while its longevity reduces the need for replacements, eliminating disruption in work, travel, and learning environments and contributing to sustainable, healthier environments.

B. History and Evolution of Terrazzo

Terrazzo techniques are rooted in traditional Old-World craftsmanship. For centuries, terrazzo in various renditions has been used for flooring and wall surfaces, with origins tracing back to ancient Egypt and Rome. Its current iteration first took shape in Venice, as marble workers reinterpreted mosaic artistry, placing marble remnants in a mortar base or spreading marble chips into cement, followed by grinding and polishing.

The in-situ method of pouring terrazzo in place exemplifies this hand-crafted tradition. These techniques maintain their historical roots alongside modern design innovations and advanced installation technology.

Italian immigrants introduced terrazzo to the United States in the 1890s, and it gained popularity in the 1920s as technological advancements reduced costs and improved quality. Designers were drawn to its design flexibility and compatibility with Art Deco styles. The introduction of divider strips in 1924 reduced cracking while enhancing design versatility. During this period, the development of electric grinding machines also significantly improved efficiency, reducing installation costs and time.

As terrazzo’s popularity and affordability increased, the industry flourished. The National Terrazzo and Mosaic Association (NTMA) was established in 1923. Today, the NTMA, headquartered in Fredericksburg, Texas, is a full-service, non-profit trade association that has led the industry through continuous advancements over the past century and continues to set national standards for all terrazzo systems. NTMA members are qualified, approved contractors. The NTMA supplies comprehensive specifications, color plates, and general information to architects and designers, also serving as an authoritative third-party resource as needed for all parties in a project at no cost. Personalized guidance and assistance from the association’s technical director is offered free of charge.

From Industrial Roots to Modern Elegance: Palladiana Terrazzo Transforms NYC Lobby into Meeting Space

Photo courtesy of Michael Blackburn

Large-aggregate terrazzo with brass accents transforms this New York City lobby at Hudson Square into a dynamic meeting space.

Once a bustling manufacturing district, New York City’s Hudson Square has evolved into a vibrant hub for technology and media companies. Architecture Plus Information (A+I) in New York City was commissioned to reimagine the lobby at 225 Varick Street, an industrial structure built in 1926. The space has been beautifully transformed with large-aggregate Palladiana and Venetian terrazzo inlaid with brass accents, providing a stunning backdrop for the 12 floors of loft-style office spaces with expansive city views. Here, tenants and guests are invited to take a moment to pause amidst their busy day. “Terrazzo is at once incredibly durable, incredibly varied, and beautiful,” said Jennifer Wichtowski, an associate at A+I. "It has a timeless character but can be given a modern edge, making it highly versatile and flexible.”

Crafted from hand-fractured marble pavers, the installation elevates the aesthetic while complementing exposed columns and concrete. Remarkable artisanal craftsmanship is showcased in the textured curves of the space-defining features that demarcate lobby circulation and social space. “Rather than creating simple pass-throughs for morning and evening traffic, A+I designed productive spaces that act as social activators, enhancing the value of the buildings in which they are placed,” Ms. Wichtowski added. The precast terrazzo steps are all handmade, with book-matched marble treads and nosings. Designed to render the tread as a two-inch thick slab, the innovative installation was produced with a 3/8-inch thin-set epoxy terrazzo system. Richly textured Venetian aggregate, size one to three, is troweled between the pieces of marble.

BENEFITS OF TERRAZZO IN ADAPTIVE REUSE PROJECTS

A. Sustainability and Environmental Impact of Terrazzo

“Terrazzo offers many fiscally and environmentally friendly assets,” explained Robyn Toth, principal and owner at TCA Architects in Crownsville, Maryland. Terrazzo is a hard, seamless flooring with a permanent finish that lasts for decades, conserving resources over time. Epoxy resin contains no Portland cement. Its nonporous finish is impervious to moisture and microbial growth.

Terrazzo systems routinely incorporate local and recycled materials, from reclaimed glass and local stone aggregates to repurposed marble or other elements from remodeled interiors. Recycled concrete has been creatively used for aggregate. Terrazzo is VOC-free, contributing to a healthier indoor environment. It is formulated without formaldehyde or harmful chemicals, ensuring minimal to no outgassing before, during, or after installation. Additionally, terrazzo requires no paints, coatings, adhesives, or sealants that could release volatile organic compounds. Terrazzo can be installed in occupied spaces without adversely affecting occupants, reflecting its minimal impact on indoor air quality.

Terrazzo is a resilient building material that can be restored and repaired indefinitely to conserve historic and new installations without total replacement, thereby reducing landfill waste. Extending the life of an existing terrazzo surface conserves resources exponentially. It avoids the considerable costs of demolition, clean-up, removal of old materials, time, energy use, and the mess of demolition and pouring a new concrete slab.

Furthermore, terrazzo can be installed over different floor systems with nominal substrate correction, thus avoiding the considerable costs, waste, and mess of demolition. Leaving the old floor in place is also an environmental advantage, saving tons of waste from going to landfills.

TJ SAMSON HEALTH PAVILION: ABANDONED WALMART FINDS NEW PURPOSE AS HEALTH CENTER

Photo courtesy of David Laudadio

An abandoned Walmart was repurposed as TJ Samson Health Pavilion. Epoxy terrazzo was chosen for its versatility and low maintenance.

When a hospital sought to expand its outpatient county services, it reinvested in the community by converting a vacant Walmart building into a hub for centrally located, 24-hour healthcare services, which was transformative for the area. Terrazzo was selected for its design versatility, resilience, and ease of maintenance, which made it ideal for an antiseptic facility with continual use. Fostering an engaging atmosphere, the terrazzo patterns assist patients in wayfinding through the facility and establish comfortable enclaves for patient service. The 126,000-square-foot pavilion integrated over 26,000 square feet of epoxy terrazzo in a four-color radial pattern, finished to a high polish. Two-color atrium steps were built of poured-in-place terrazzo. The installation spans new and existing concrete slabs with existing Walker ducts. Much of the terrazzo was poured over extremely poor existing slab conditions, with extensive cracking. Epoxy and sand floor fill were used to prepare the concrete for the terrazzo installation, ensuring a durable and seamless finish. The project was led by Stengel Hill Architecture.

B. Lifecycle Advantages

1. Permanent vs. Replaced Floors

“Owners can get caught up in first costs,” explained Ms. Toth. “Walk them through 20 years of operating and maintenance costs, and terrazzo becomes a much stronger candidate.” The bulk of the savings come from maintenance costs drastically lower than many flooring materials and eliminating flooring replacements for the life of the facility. Terrazzo’s cost benefits have made it the preferred flooring of many public schools, state universities, and government buildings.

Lifecycle costs for a permanent, seamless, custom-designed, low-maintenance terrazzo floor are leveled with just one carpet or vinyl replacement. Terrazzo also avoids the immense costs and downtime associated with floor replacement, even in the highest-traffic areas. Removal and disposal of replaced flooring are other expenses and environmental impacts to consider. High-traffic environments may have to replace carpet or vinyl as often as every five years, triggering costly planning, disruption, and waste. A material that lasts conserves resources long-term.

2. Maintenance and Care of Terrazzo

A terrazzo floor requires only sweeping and damp mopping with a pH-balanced cleaner with no harsh chemicals. As soon as terrazzo is installed, its considerable maintenance savings begin to balance out the initial costs, which may be higher than some other options.

Comparing terrazzo’s maintenance costs with those for VCT, for example, it can be estimated that for a 100,000-square-foot terrazzo floor, the maintenance per year is $56,000, with a 30-year total cost of $2.9 million.1 For VCT, maintenance is estimated at $135,000 annually and a total 30-year expenditure of $4.3M.

Installation costs of terrazzo and VCT break even at around 12.5 years, around the end of a typical VCT floor’s usefulness. From the point when a VCT requires replacement, a terrazzo floor’s savings accelerate and continue to bear return the longer a terrazzo floor is in service.

Terrazzo maintenance advantages:

• Solid-surface terrazzo maintains its condition and looks good longer than softer synthetic materials.
• Simple, minimal, cost-effective maintenance schedule saves on labor, chemicals, and water.
• Resistant to abuse, heavy loads, and high traffic.
• A seamless, non-absorbent, nonporous surface free of grout joints resists microbial growth and moisture accumulation, resulting in a consistently cleaner floor.
• An integral cove base around walls and columns can provide a tough, protective transition to vertical surfaces and prevent dirt build-up.