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The Tile Files: Loesch House Terra Cotta Roof
A log home in a historic ravian German village presents a veteran restorer with a terra cotta challenge. by Chris Mayo
Bethania, N.C., settled in the mid-1700s by Moravian (a Christian religion) Germans, ranks as one of the best-preserved historic locales in the United States. The town is a rare example of the agricultural patterns of a German “open field” agricultural village. The Bethania Town Lot also illustrates Moravian community planning and development. Documents dating back to as early as the 1750s provide a picture of hard work, perseverance, communal cooperation and fine craftsmanship. Bethania was registered as a National Historic Landmark in 2001.
Within the boundaries of the town, a multitude of houses, churches and stores have been preserved and restored. The “Loesch House” is a log home which was one of the earliest built within the district.
Chronicles reveal that the large Loesch family was active in nearly every aspect of the community: church, politics and business. By conducting a quick Internet search, one can find several references to the Loesches’ fine clock and watch crafting, silver and gold smithing, farming and construction.
Bob Adams bought the Loesch house in the mid-1980s with an eye on restoring the home to its original form, and he began restoration in 1989. Having spent most of his adult life involved in antiques and restoration, he describes himself as a student of historical restoration. His passion for the subject is apparent when he speaks about it. “I wanted a log home and I wanted to restore this particular house the right way,” he says.
After more than 35 years in the restoration business, he has met some of the best, and he’s learned that it is prudent to call on the best when one is undertaking a new project. The most common mistake people make in restoration, he claims, is that they think they know what they’re doing even if they’ve never done it before, or they try to match a look without matching the types of materials used to achieve that look.
Adams started the restoration project on the first story — replacing structural members where needed, matching paints and floorboards and trim. After finishing the lower floor, he moved to the second floor, utilizing the same basic techniques. The pitch of the roof had been lowered by a previous owner, and the original terra cotta shingles were replaced with more conventional shingling. Adams, with his dedication to detail and passion for “true” restoration, chose to wait to begin the roof until it could be done right. He began searching for experts who would be able to do the job. A fire to the upper story of the house in 2006 forced his hand. The roof was damaged to the point that it had to be replaced. Some of the original roof tiles were stored in the attic when Adams bought the house, and fortunately they survived the fire.
Lab results and common sense suggested the original roof tiles had been molded from local clays. The challenge from that point was, naturally, to find the right people to copy them, people who subscribed to Adams’ diligent approach to restoration. He found some artisans not far from home that fit the bill — Star Tile Works LLC, formerly Star Kilns Inc., located in Star, N.C. A longtime family operation, Star Tile Works had built a reputation for quality and attention to detail.
Speaking with the CEO of Star Tile Works, Derek Krouse, it is easy to see what attracted Adams to them. “We created the company as a means to bring traditional craftsmanship to the trades,” he says. “Since my father started the company years ago, we have always tried to do everything the old way.”
The challenge with the terra cotta tiles for Adams’ house lay in the various colors in the samples he provided — “from dark red to white to several in between those two extremes,” says Krouse. Agreeing that the clay had been from local sources, he began to take samples for test tiles from local clay deposits. Not completely satisfied, he ventured further afield for more samples. They then mixed the clays to the appropriate colors and textures, extruded the mixes into sheets, cut and textured the raw tiles by hand, and fired them in their kiln. “They created a perfect match,” claimed Adams. “Beautiful work.”
The original tiles were slotted and fitted on lathing in the roof system. Adams’ roofer recommended a change — use titanium underlayment and nail the tiles to that. Adams was initially resistant to any deviations, but the roofer pointed out that copper underlayment was common when the house had been built. Adams ultimately agreed and has been happy with the results. “The titanium really holds the nails well,” he says. “This roof is going to last a long time.”
When Adams bought the Loesch house, he knew it would take a while to complete the restoration. More than 25 years later, he’s finally finished. He admits it took far longer than he originally thought, but he is adamant that it was worth it.
“When I first bought the house, I was the new owner,” he says. “Over the years of studying the history and doing the restoration, I’ve transformed from owner to custodian.”
