Revised: Case Study-Pabst Brewery Company Complex

History

Located at: 807 West Juneau Avenue, Milwaukee, Milwaukee County
Architects: Charles Hoffman and Otto Strack
Dates of contributing buildings: 1858-1953

"The Pabst Brewery was the principal production facility for one of the largest brewers in the world. Founded in 1844 by Jacob Best and his sons, the brewery originally produced ale, porter and whiskey in addition to the lager beer for which it ultimately became famous. Former steamship captain, Frederick Pabst entered the business in 1864 following his marriage to the daughter of Phillip Best, who inherited the business from his father. Two years later, Captain Pabst became company president and, by 1868, the brewery was the largest in Milwaukee. In 1874, it had become the largest in the nation brewing 114,162 barrels of beer. Late nineteenth century mechanical and scientific advancements - many of which were either pioneered or refined at the brewery - improved the consistency of beer and helped increase production. These included better carbonation techniques, the use of strains of yeast more suited to brewing, and the introduction of numerous devices such as barley washers, improved filters, hop extractors and bottling equipment. On March 18, 1889, the business was renamed in honor of Captain Pabst who had overseen an increase in production from fewer than 5,000 barrels in 1864 to over 500,000 barrels by 1889. In 1892, aided by aggressive promotion and a wide distribution network, the brewery became the first to produce over one million barrels of beer in a single year and stood as the largest lager brewery in the world. One of its most popular beers was its "Select" brand, which, with a blue silk ribbon tied to each bottle, served as the precursor of Pabst's trademark "Blue Ribbon" beer. These staggering production increases necessitated the construction of numerous specialized industrial buildings at the brewery, including a brewhouse, malt house and bottling works. Many of these buildings feature elements like battlements and crenellated towers, which reflect the German origins of Captain Pabst and, generally, the Germanic character of late nineteenth century Milwaukee. The Pabst Brewing Company Brewery Complex occupies 18.4 acres near downtown Milwaukee. The architectural style of the historic buildings is Late Victorian, Modern Movement. And the areas of significance for listing the complex on the National Register were Architecture and Industry. They are constructed of Cream City brick. Many of the buildings have multi-lite wood sash windows. However, the Manufacture ring building and the Keg House have industrial steel sash windows. The buildings have been vacant since 1996." (from the National Register nomination)

The complex is located in the northwest corner of downtown Milwaukee, Wisconsin. The property is immediately east of Interstate 43, the main north-south corridor.

Historically, site planning was approached based on natural factors. Proximity to waterways and rail lines was vital. Brewery complexes were often sited over cave systems to allow inexpensive storage of beer in the cooler caves. Historic properties offer little opportunity to modify building siting. Large building complexes were constructed according to the business operation. When the business operation changed existing buildings were modified, added to or demolished. And new buildings were constructed to accommodate the business operation.

The Pabst Brewery is located in Milwaukee, Wisconsin off of the banks of Lake Michigan. It is also close the Milwaukee & Horicon Rail Road.

Similarly the Lemp Brewery was located near the Mississippi River and the Missouri-Kansas-Texas (reporting mark MKT) Rail Line. Additionally, the Lemp Brewery in St. Louis, Missouri was planned and constructed over the Cherokee Cave System.

Dealing with a large-scale complex, such as the Pabst Brewery which has 26 buildings on 20 acres of land, presents concerns with the development approach.

A project of this size works best being developed in phases, and possibly by a team of developers. Therefore, it is vital that an overall master plan be formulated to provide consistency throughout the complex redevelopment.

The scale of the Lemp Brewery is comparable to the Pabst Brewery with 27 buildings on 14 acres of land as part of the historic complex. Therefore, it will be best to redevelop this site in phases.

A feasibility study was performed to determine the structural integrity of each buildings, the condition of significant architectural features and compatible adaptive reuse strategies for the individual buildings and complex. The exterior brick facades were in good condition but required repointing in many areas, approximately 30 – 40% overall. Many of the wood windows were deteriorated beyond repair and all required lead abatement. The steel sash windows contained asbestos putty also requiring abatement. The steel sash windows had also rusted in many areas, mostly at the sills. The Brew House contains a three-story rectangular atrium running essentially the full length of the building. The building contains a mezzanine space above the second floor. The ground floor space offers two sets of repeating masonry archways. The First German Methodist Church is brick bearing walls with no columns. The sanctuary is completely open and the choir loft on the third level is still intact.

Brick –

Brick mortar joints are deteriorated and the brick will require cleaning. Historically, brick mortar was mixed from materials available locally. Conversely, modern repointing mortar is usually premixed at a factory to insure consistency. The key factor is to consider the entire wall system. If contemporary practices are enforced this may lead to brick spalling and compromise of the wall system. Therefore, the mortar must be mixed using the same recipe as the original mix. This can be determined by having the original mortar analyzed. This will permit the entire wall system to function as originally designed. The repointing mortar will match the original mix and the joints will be tooled to match the existing joints. The Lemp Brewery Complex in St. Louis is also brick masonry construction. Many areas will required repointing, repair or replacement.

Windows –

Windows are one of the most character defining features of historic buildings. So their rehabilitation or in-kind replacement is vital to maintaining that character. Original windows will be removed and replaced with windows of the same material that will replicates the profiles, sightlines muntin patterns as the original windows.

I’ve discovered that if the original windows can be repaired this is the most feasible rehabilitation approach. These windows are built using slow growth lumber, which, means they are more resistant to moisture deteriorating the wood than new windows. Whichever treatment is selected an ongoing maintenance program must be implemented to ensure the life of the windows.

Many of the Lemp’s windows are totally missing. In addition, the windows in buildings closest to the interstate will require noise abatement. Overall the windows will require analysis for lead paint for wood windows, and asbestos putty for steel windows.

Building Services –

Historic buildings typically have outdated infrastructure. Unsightly vents, exhaust vents and electrical, water and waste service, and roof drainage may detract from the character of the buildings. Unsightly exhaust vents, electrical service and roof drainage features will be removed and relocated to enhance the historic character of the buildings. The electrical service can be buried underground, and exhaust vents can be completely removed or relocated, if required, to less visible areas. Roof drainage will be repaired and replace as required to match the original. Exhaust vents, above ground electrical service and deteriorated roof drainage features are a concern at the Lemp Brewery Complex. The city of St. Louis and the local utility company will have major roles in upgrading and relocating the infrastructure.

Many of the buildings at the Pabst Brewery site contain industrial steel sash windows. Upgrading the thermal efficiency of the steel sash windows will be vital for the successful reuse of the Pabst Complex. The putty glaze in these windows could contain asbestos. The environmental hazards have been abateted using Brownfield credits to allow redevelopment for prospective developers. The windows were replaced with thermally insulated aluminum windows that matched the profiles of the existing windows. Buildings 11 and 12 at the Lemp have industrial steel sash windows that will require the same investigation as those at the Pabst Brewery.

The Brew House contains an original three-story rectangular atrium that provides day light to the central portion of the building. This is an existing sustainable feature that will be utilized in the rehabilitation of this building. Building 1 at the Lemp Brewery site utilized roof monitors and atrium space to allow natural light and ventilation to reach embedded areas of the building. This was necessary due to the building’s large floor plate.

The Keg House and Manufacturing & Cold Storage Buildings will be adequate for residential or “live-work” units. The Bottling Building is suitable for commercial space. The Boiler House can best be used for office or retail space, in addition to the Research Lab and Paint Shop. The Grain Silos will be adequate for reuse as a restaurant. The Brew House and Mill House can be used for mixed-use development. The First German Methodist Church is suitable for a variety of commercial uses. The Malt Elevator and Malt House are adequate for mixed-use development such as retail, residential and office space.

CHALLENGES:

Human Aspects –

Challenges for the architectural team were:

- creating environments to connect users

- create natural features (daylighting, landscape)

- promote opportunities for walking and biking

- provide better indoor air quality

- increase natural daylight

Existing Sustainable Strategies –

Identifying existing sustainable strategies.

Determining if and how rehabilitation can occur.

RESPONSE:

Human Aspects –

Created planned landscaped areas that are visually connected to interior spaces.

Designed walking/biking paths to promote healthier transportation modes.

Night flushing of buildings, mixed-mode HVAC.

Integrated daylighting with electrical lighting.

Existing Sustainable Strategies –

The Pabst Brewery site is near mass transit lines

There may be opportunity to partner with transit authority to provide better access to bus and light rail from this site

APPLICATION:

Human Aspects –

Treatment between exterior skin of buildings and outdoor public spaces should allow for a connection to the environment

Existing Sustainable Strategies –

The Lemp Complex is near existing bus routes

The site is situated between the affluent South County area and the CBD. The Lemp redevelopment will be a vital link along future mass transit lines

Proximity to Cherokee Street neighborhood will allow community intergration

Opportunity to enhance open public spaces

Site design is limited because existing buildings can’t be relocated. Must consider existing traffic patterns within the complex (between buildings). Existing infrastructure is deteriorated/outdated. This presents concerns that are not present when ‘new’ construction requires new infrastructure. Site design & planning utilized spaces that historically were not used (i.e. roof) to create amenities to draw closer to the environment. Create a buffer zone to allow for walkable/bikable paths and to introduce landscaped areas. Create large public areas to encourage public gatherings and social contact. The Lemp site provides opportunities for public spaces. Rooftop amenities can easily be implemented based on structural stability of buildings.

Great amount of site water runoff is due to large amounts of paved areas. This puts a strain on the storm sewer system. Introduction of porous pavement materials allows more rainwater retention.

Bioswales were introduced to reduce water runoff, supply water for site landscaping, and provide relief for the storm sewer system. These treatments can be implemented in the rehabilitation of the Lemp Brewery.

Energy - stabilize greenhouse gases, improve building envelope, provide daylighting, integrate building systems, and provide renewable energy

Many historic materials contained hazardous chemicals.

Construction waste accounts for roughly 35% of US landfill volume

• Construction Waste per year

– Demolition 48% (65 mil. tons)

– Renovation 44% (60 mil. tons)

– New construction 8% (11 mil. tons)

Hazardous materials must be mitigated using Brownfield’s. Materials such as asbestos and lead paint have specific removal procedures that must be followed.

Many times features/materials may be repaired and reused. This reduces the amount of waste going to landfills. New materials should contain low VOC’s.

Due to historic construction methods, indoor environmental quality was seldom addressed adequately to provide healthy indoor experiences.

Indoor environmental quality must be improved to today’s standards, while not compromising historic character. HVAC systems will be designed to provide adequate air quality will be introduced.

Thermal comfort will be improved with windows using thermal insulated glazing.

Ventilation is addressed by allowing operable windows.

Electric lighting, daylighting, views and ergonomics will also be improved with upgraded systems and furniture. These will be concerns and strategies for the Lemp Brewery redevelopment. Additionally, double or triple paned glazing will also provide noise control.

Breathing life back into a large building complex can be difficult and success could hinge on the reuse of the buildings. Reuse of the buildings is important, however, what goes on between the buildings is also vital. How users move from place to place within the complex could determine the success or failure of the entire redevelopment. The reuse strategy is to provide mixed-use opportunities, adopting the idea of a city within. The experience users have will be enhanced through the use of landscaped features, such as, “active living walls”, planted areas and outdoor courtyards. Walkways will be planned to provide a safe, inviting environment for those that use outdoor spaces. Courtyards and gardens will allow areas for relaxation and rejuvenation. The Pabst and the Lemp Brewerys share similar challenges concerning design for social sustainability.