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A New Era for Terra Cotta

How Technology is Changing the Game


By Michael Kramer, Midwest Territory Manager, Gladding, McBean

When it comes to preserving historic buildings, capturing accurate details on-site has always been a critical part of the job, especially for materials like terra cotta.

Known for its charm and historical value, terra cotta is often found in intricate designs that require extreme precision to replicate. Over the past 20 years, technological advancements have begun to shake up the terra cotta industry, making restoration projects faster, more accurate, and more efficient.

PHOTOS: GLADDING, MCBEAN

Gone are the days when fieldwork relied solely on tape measures and paper sketches. Today, digital scanning tools like photogrammetry and Lidar are the norm, revolutionizing how teams collect and use data to replicate terra cotta pieces. However, the road to adopting these technologies wasn’t exactly smooth. High costs, complicated software, and the need for specialized expertise held many firms back. But now, the industry is seeing some big changes, and it’s all thanks to these once out-of-reach tools.


The Old Way: Fieldwork with Tape Measures and Sketches

Back in the early 2000s, when the tech boom was just getting started, measuring, and documenting architectural details in the field was a slow, painstaking process. A single misstep—a quarter inch off here, a missing detail there—could derail an entire project. It wasn't unusual for surveyors to ask for multiple pallets of terra cotta fragments just to ensure they had everything needed to replicate a building’s intricate designs (photo below.)


ALL PHOTOS: GLADDING, MCBEAN

Typical documentation in the field.


After hours spent measuring, sketching, and taking photographs on-site, all that information had to be translated into digital drawings back in the office. Each hour of fieldwork usually required at least three to four hours of follow-up documentation. It was exhausting, and there was always the looming possibility of an error that could cost time and money.

Fast forward a few years, and the landscape started to shift. The introduction of digital tools like photogrammetry and Lidar opened new possibilities, though the initial high price tags and complex learning curves kept many firms from jumping on board.


Photogrammetry: The Game-Changer

In the last decade, photogrammetry has emerged as a real game-changer. This technology uses regular photos to create 3D models, and the best part - You can do it with just your phone. For Gladding, McBean, this was a dream come true. Suddenly, you didn’t need to rely on expensive, complex equipment to get highly detailed measurements. Photogrammetry not only improved the accuracy of data collection but also dramatically sped up the process.

Before photogrammetry, we needed multiple fragments from a building to ensure accurate replication. Now, with this new tech, the demand for physical samples dropped by around 75%. That meant less time spent collecting and shipping fragments and more time getting down to the actual restoration work.

What used to take weeks now took days, and the accuracy was through the roof.

The 3D models produced by photogrammetry were so precise, with tolerances down to 0.1mm, that it exceeded even the strictest industry requirements (photos below.)



Left: An array of images taken of a representative fragment for creating a 3D model using photogrammetry. Right: A screenshot of a 3D model.


Enter Lidar: Taking Things to the Next Level

After the success of photogrammetry, Lidar (Light Detection and Ranging) was the next natural step. Lidar uses lasers to map out areas in incredible detail, creating highly accurate 3D models of buildings and their features. While this tech had been around for a while, it was only recently that it became affordable and user-friendly enough for smaller firms to adopt.

Handheld Lidar scanners, designed for rugged environments, soon found their way into the field. These devices were perfect for capturing data from hard-to-reach places, like when surveyors had to work from scaffolding or lifts. With Lidar, it became much easier to get a full picture of a building’s terra cotta features without needing as many physical samples as possible.

With both photogrammetry and Lidar in their toolkit, we were able to gather data faster and more accurately than ever before. But gathering data was just the first step. The real challenge was turning that data into something useful for the drafting and production teams (photo below.)


A member of the Gladding, McBean Drafting and Survey Team operating a handheld scanner at a jobsite.


Turning Data into Action: The Shift to 3D Models

Once Gladding, McBean’s field team had all the data from their scans, they needed to turn it into something the drafting and production departments could actually use. This meant developing a workflow that could convert a bunch of images into 3D point clouds and fully meshed models in a matter of minutes.

These models were used to create shop drawings, which are the blueprints for terra cotta production. By refining this process, teams were able to produce extremely detailed, accurate drawings much faster than before, helping to keep projects on track and within budget (photo below.)


The 3D model created directly from the scans gathered in the field.


CNC Modeling: Automating the Hard Work

While photogrammetry and Lidar were transforming the way fieldwork was done, CNC (Computer Numerical Control) machines were about to revolutionize production. CNC technology allows for the automated production of complex designs using 3D models. For Gladding, McBean, as a company that had always relied heavily on hand-sculpting, this was a big deal.

CNC machines can crank out precise terra cotta models at a fraction of the time it takes to sculpt them by hand. While hand-sculpting is still an art form, and some details still require that human touch, CNC machines are taking care of the bulk of the work, freeing up skilled artisans to focus on the more intricate parts of the job.

There were some growing pains along the way. The first few CNC models didn’t always match the quality of hand-sculpted pieces, so the Gladding, McBean production team had to spend time fine-tuning the process. But once they got the hang of it, the machines were able to produce models that were virtually indistinguishable from hand-sculpted ones (photos above right.)



Left: Initial test run output showing the evolution and refinement of our use of CNC. The model on the far right proved that this process could provide ornate modeling that is production ready. Right: Examples of plaster models created using CNC and used for production.


Collaboration is Key

One of the biggest reasons these new technologies have been so successful is collaboration, both within the industry and with external partners. Take, for example, Gladding, McBean’s partnership with the University of Wisconsin-Milwaukee School of Architecture and Urban Planning (UWM-SARUP). This collaboration helped bridge the gap between academia and industry, giving students and professionals alike the chance to learn from one another.

UWM-SARUP students brought a wealth of knowledge about the latest scanning technologies, and Gladding, McBean offered students real-world experience in terra cotta production. The partnership worked so well that one of UWM-SARUP’s top students was recruited to head up the manufacturer’s in-house scanning lab.

This collaboration didn’t just benefit the students; it also helped the Gladding, McBean production team back at the plant. Field teams were trained on how to use the new scanning tools, and soon the whole company was up to speed on photogrammetry and Lidar. Thanks to this partnership, Gladding, McBean was able to streamline its processes and reduce project lead times, saving both time and money.


Looking Ahead: What’s Next for Terra Cotta Restoration?

The terra cotta industry has come a long way in the past couple of decades. From slow, manual measurements to cutting-edge 3D scanning and CNC production, the entire process has been transformed. And while the technology has advanced rapidly, it’s clear that we’re only scratching the surface of what’s possible.

Looking ahead, there’s plenty of room for further innovation. As 3D scanning and CNC technology continue to improve, production times will likely get even shorter, and the accuracy of terra cotta models will keep getting better. Gladding, McBean is also exploring how to use these technologies to cut lead times even further, helping to keep costs down and projects on schedule. One thing is sure: the future of terra cotta restoration is bright. By embracing new technologies and collaborating with partners from all corners of the field, the industry is finding new ways to preserve our architectural heritage while keeping pace with modern demands.


Conclusion: Blending Tradition with Innovation

The terra cotta industry is in the middle of a major evolution, blending traditional craftsmanship with cutting-edge technology. The introduction of photogrammetry, Lidar, and CNC machines has made it possible to replicate historic architectural details with more speed and accuracy than ever before.

This new era of terra cotta restoration doesn’t replace the artistry of hand-sculpting but complements it. By automating the more repetitive tasks, CNC technology allows Gladding, McBean's artisans to focus on what they do best—bring historic designs back to life with an unmatched level of detail.

This transformation for Gladding, McBean began in earnest no more than two years ago. To paraphrase an adage -- Change happens slowly, then all at once. This perfectly describes the journey this 150-year-old company has made. Yes, this technology has been around for ages, slowly growing and evolving, but Gladding, McBean has been a patient observer. In a highly regulated industry, innovation often comes with significant operational risk, making swift adaptation a gamble that couldn't be afforded. Looking back, those pressures were a good thing. Jumping into these changes too early would have caused unnecessary disruptions. Then, all at once, with the right team in place and careful strategy, Gladding, McBean transformed its vision into reality.

In the end, the future of terra cotta restoration looks bright. With the right blend of tradition and innovation, the industry is well-equipped to meet the demands of modern restoration projects while preserving the architectural beauty of the past.🀰


"With the right blend of tradition and innovation, the industry is well-equipped to meet the demands of modern restoration projects while preserving the architectural beauty of the past.”

Michael Kramer, Midwest Territory Manager, Gladding, McBean


With over twenty years of experience, Michael Kramer serves as the Midwest Territory Manager for Gladding, McBean, specializing in historic preservation and architectural restoration. His hands-on work with structures across Chicago, the Midwest, and the nation has shaped his distinctive approach to project demands, streamlining documentation processes and increasing efficiency. A dedicated advocate for the use of terra cotta, Michael is passionate about preserving its legacy while promoting its integration into contemporary building design.

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