Terrazzo Renewal

Transforming spaces with sustainable solutions in adaptive reuse projects
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Sponsored by National Terrazzo and Mosaic Association
By Anna Migeon

Learning Objectives:

  1. Explain the sustainable benefits of terrazzo in adaptive reuse projects, including its ability to be restored indefinitely or poured over existing substrates.
  2. Explore the technical aspects of terrazzo, including composition, design options, installation methods, and maintenance requirements for adaptive reuse applications.
  3. Discuss terrazzo’s contribution to sustainability in construction, including waste reduction, lifecycle cost savings, and environmental impact.
  4. Gain insights into the role of terrazzo in preserving architectural heritage and revitalizing historic buildings through case studies.

Credits:

HSW
1 AIA LU/HSW
ICC
0.1 ICC CEU
IACET
0.1 IACET CEU*
AIBD
1 AIBD P-CE
AAA
AAA 1 Structured Learning Hour
AANB
This course can be self-reported to the AANB, as per their CE Guidelines
AAPEI
AAPEI 1 Structured Learning Hour
MAA
MAA 1 Structured Learning Hour
NLAA
This course can be self-reported to the NLAA.
NSAA
This course can be self-reported to the NSAA
NWTAA
NWTAA 1 Structured Learning Hour
OAA
OAA 1 Learning Hour
SAA
SAA 1 Hour of Core Learning
 
This course can be self-reported to the AIBC, as per their CE Guidelines.
As an IACET Accredited Provider, BNP Media offers IACET CEUs for its learning events that comply with the ANSI/IACET Continuing Education and Training Standard.
This course is approved as a Structured Course
This course can be self-reported to the AANB, as per their CE Guidelines
Approved for structured learning
Approved for Core Learning
This course can be self-reported to the NLAA
Course may qualify for Learning Hours with NWTAA
Course eligible for OAA Learning Hours
This course is approved as a core course
This course can be self-reported for Learning Units to the Architectural Institute of British Columbia
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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.

BENEFITS OF TERRAZZO IN ADAPTIVE REUSE PROJECTS

Terrazzo offers many assets for adaptive reuse. A sustainable material, it can be customized in design and adapted to the constraints of existing spaces. Its low maintenance requirements translate to long-term cost savings, and its durability and longevity ensure a cost-effective lifecycle.

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.

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.

 

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Originally published in November 2024

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