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There are a lot of arguments on this subject. In
stone or brick construction where units are under
compressive stress and replacements are easily
available, the replacement is a viable option. It is
relatively easy to replace a few bricks or stones
after finding a good match and using compatible
mortars.
In Terra Cotta cladding, it is a different story.
The replacement of units that cannot be anchored
in a conventional or original way poses several
problems.
A. New units matching the existing are not
easily obtained and take time to make
them. It is not economically feasible for
a manufacturer to stop production to
cast and fire a few units.
B. Usually, they cannot be installed and
anchored with the conventional system.
They require pinning and often grouting
of the cells, which then changes the
structural consistency of the wall.
C. After all the drilling, patching and
blending, you no longer have a new
unit.
In cases where the installation of new units
creates more problems than it solves, the repair
provides a better and more economical result.
Consolidation
The process of injecting fluid grouting into
stones or masonry units by continued pressure to
eliminate voids and reinforce weak or unstable
areas.
This is a costly and complex procedure that
requires studies that cannot be covered here.