Washington Pavillion
A historic landmark in Sioux Falls, the Washington Pavilion required a full restoration of its deteriorating terracotta cornice and rooftop balustrades. The project called for a solution that preserved the building’s classic appearance while solving ongoing safety and water-damage issues. Using fiberglass replicas with faux joints and a two-tone finish, we recreated the look of the original terracotta while delivering a durable, long-lasting system that safeguards the building for future generations.
Project Overview
Client Background
The building owner and design team sought a durable, historically faithful replacement for failing terracotta cornice and rooftop balustrade systems on a major civic venue in Sioux Falls. Preservation and public safety were top priorities.
Objective
Replicate the original terracotta appearance while eliminating chronic deterioration and water-intrusion risks, delivering a long-life, low-maintenance solution that reads as authentic from street and rooftop levels.
Scope
Full perimeter replacement of cornice and balustrade/railing systems in fiberglass-reinforced polymer (FRP).
Thousands of unique pieces across multiple mold families; numerous custom posts. Including corner/zig-zag conditions, some up to ~17 ft tall.
Color and jointing strategy engineered to visually match historic terracotta.
Key Details
Location: Sioux Falls, South Dakota
Building Type: Performing arts & science center (former historic high school)
Historic Material: Terracotta (severely deteriorated, patch-repaired)
Replacement Material: FRP with gel-coat finish; aluminum channels/anchorage per engineering
Visual Strategy: Faux joints and two-tone speckled finish to emulate multi-piece terracotta courses and weathered chroma
Logistics: ~35–40 truckloads shipped; two on-site phases spanning 2023–2024
Design Approach and Execution
Design philosophy
Strict historical replication with modern performance.
Faux joints: In-mold inlays create rhythmic “breaks” so 8-ft FRP runs present as many smaller terracotta blocks.
Two-tone finish: Approved speckled/duotone palette replicates the building’s primary field color with secondary flecks, matching aged terracotta.
Execution
Survey & Documentation
Drone survey of the entire perimeter to capture piece rhythms and joint locations.
Cataloged and received 10–15 original terracotta samples; identified protected (unfaded) reference color.
Meticulous shop drawings mapping thousands of joints and profiles.
Engineering & Approvals
Primary engineering by Larson Engineering; designs conservatively over-engineered, then value-checked with city engineering to eliminate unnecessary tie-backs and through-wall tubes—maintaining safety while restoring buildability and timelines.
Fabrication
One-to-one profile replication in FRP; gel-coat color system with approved mock-ups.
Baluster profile variance resolved by creating a faithful “average” of 6–7 historic shapes observed in original molds.
Installation Support
Staggered course layout to visually hide vertical seams.
Rapid iteration during field conditions (cardboard markups to revised molds) to keep schedule.
At the Washington Pavilion in Sioux Falls, we replaced the failing terracotta cornice and rooftop balustrades with historically accurate fiberglass replicas. The original pieces were crumbling and causing water damage, but now the building has a seamless new system that looks true to its history while being durable, weather-resistant, and safe for decades to come.
Results and Acknowledgments
Outcome
Historically authentic façade reading with crisp profiles, convincing terracotta segmentation, and a durable FRP envelope that ends chronic spalling and leaks.
Safer rooftop perimeters; cleaner water management; dramatically improved, unified color presentation versus patchwork repairs.
Completed over two phases (late-2023 through late-2024) with continuous production and just-in-time deliveries.
Credits and Collaboration
Design, fabrication, and program leadership: Architectural Mall
Structural/attachment engineering: Larson Engineering
Owner/Design Team: Washington Pavilion & City of Sioux Falls stakeholders
