Structural and Fireproofing y CONCRETE TILE 19 10 Concrete Stone and Sand Company Youngstown, Ohio j A NY useful article having the two attributes of quality and reasonable price is sure to meet with the approval of a discerning public. Concrete structural tile has not been an exception. Wherever tests and demonstrations of economy and practicability, herein explained, have been given, the people have been favorably impressed and the product quickly adopted for the uses to which its peculiar qualifications es¬ pecially fit it. Throughout the catalogue this fact is abundantly illustrated by the citation of the experiences of the initial plant installed by the inventor, A. A. Pauly, at Youngstown, Ohio. The demand of the public is for absolutely safe homes at reasonable prices. This public needs only to be educated to the merits of con¬ crete structural tile in order to know how to satisfy this want. Those contractors, architects and concrete engineers who have already used this product are meeting with great success and without exception, unreservedly endorse its good qualities. The Public’s Endorsement is Evidenced by the Success of the Initial Plant Sanitary, Fireproof, and Economical Homes are Herein Proved Practical For Every American Family Vaughn Residence on Glen Aven Street 1 The Concrete Stone and Sand Company Youngstown, Ohio Pauly Concrete Tile Must Logically Replace Wooden Construction In the Near Future Concrete Structural Tile The Embodiment of Every Essential Qualification for Modern Construction Structural tile of concrete is conceded to be the most advanced attainment of the industry, and it is absolutely independent of all the other branches of concrete building materials or construction sys¬ tems. It is the route by which the initial cubic yard of concrete (Portland cement, a suitable aggregate and water) attains its highest value. It is now reduced to a business proposition contain¬ ing a substantial profit for manufacturer and user alike. The system for manufacturing this material is easy to understand, practical and the most scien¬ tific method of handling concrete. Structural tiles of every useful shape and size can be produced of concrete, and such tile have many important advan¬ tages over all other materials that have heretofore been produced for purposes parallel to those for which concrete structural tile is useful and appli¬ cable. All the structural tile made by our system are cast or molded by specially designed machines in steam-heated molds, the materials having first been properly proportioned, mixed, and prepared for pour¬ ing. Excess water being driven off by steam, the tile is ejected from the mold mechanically, and then annealed or cured in an oven provided with steam connections giving a definite progression of heats and moisture so as to secure quickly the complete and perfect crystallization of the concrete material. The finished tile has the minimum porosity for the absorption of water obtainable in concrete, while at the same time the highest fire resisting quality is attained, both being due to the extreme density of the concrete produced by the process. The corners, edges, angles and plane surfaces of the tile are all mathematically correct, and in this respect these concrete tile outclass every other building material of whatever composition or for whatsoever purpose. The economic uses for such materials ars apparent to every practical constructor of buildings. Exhaustive tests have been conducted to establish the structural value of this new building material, to prove its strength in compression, the amount of absorption when immersed in water, and its resist¬ ance to fire—these being the three elements of im¬ portance to be considered in every building mater¬ ial. All such tests have been conducted publicly upon a practical and thorough basis, and every one of them has demonstrated this type of concrete tile to possess the highest qualifications in each of these requisites. The tests are taken up in detail upon another page. The practical construction work that has been done during the past two years, under the eye of the inventor of the system and machinery for mak¬ ing the tile, Mr. A. A. Pauly, of Youngstown, O., has been highly successful in every case, as exhibit¬ ed by scores of houses finished and now in use. The inventor has organized and established an exten¬ sive plant, which at the present time is crowded with business to its capacity, and is being operated at a substantial profit. The basis of operations can be expressed in a few words: By means of this system the typical or initial cubic yard of concrete, costing approximately $3, is transformed—by a factory cost of approximately $1—into a commodity readily salable at from $7 to $10, according to the size and configuration, which commodity will find a ready sale in unlimited quantities. The success of the pioneer plant is convincing proof that in the Pauly system for concrete struct¬ ural tile manufacture lies a wonderful opportunity in a new phase of the manufactured building mater¬ ial business. One that contains, indeed, a substan¬ tial profit, with a growing future, which logically will develop an enormous demand. The Concrete Stone and Sand Company is plac¬ ing the Pauly tile machines with well qualified manufacturers, having suitable concrete aggregates and capital to insure the installation of plants capa¬ ble of carrying on this business successfully. This action is based upon the tremendous local growth of the business and upon the constantly in¬ creasing demands for concrete structural tile from all parts of this country and foreign lands. The machines are leased only; this plan being adopted in order to insure the lessee of the exclusive control of the machines in the territory in which he operates, dur¬ ing the life of his lease. We wish to urge a careful examination of these and following statements, as only such parties as will engage to make and maintain a high grade product, can become lessees of these machines. We are always glad to discuss this proposition with those contemplating an entrance into this branch of the concrete industry, and extend herewith a cordial invitation to all those wishing to visit our plant and meet the inventor in person. The Concrete Stone and Sand Company Youngstown, Ohio 2 The Minimum of Material Scientifically Prepared so as to Attain Maximum Strength 3 Tlie Concrete Stone and Sand Company Youngstown, Ohio All Tests were Conducted in the Presence of Authoritative and Impartial Witnesses The Concrete Stone and Sand Company Youngstown, Ohio 4 Record Photographs of Fire Test Proving the High Fire Resistance of Concrete Tile Every Test has Proven Pauly Concrete Structural Tile to be Both Practical and Economical Practical Fire and All the tile made a very favorable showing in repeated fire tests, seeming in every way to be su¬ perior to any other parallel material that could be found. At the suggestion of Mr. Chas. Connell, a concrete engineer-contractor of very considerable attainments, and the building authorities of the city of Youngstown—C. C. Knox, building inspector; Capt. W. H. Loller, chief of the fire department; Arthur Young, city engineer, and others—it was decided to give the concrete tile a practical fire test, by means of an elevated floor span constructed so as to provide for placing a very hot fire beneath it. Such a floor span was constructed under the supervision of Mr. Connell. It was 12'xl6' in size, and consisted of four piers, 2 feet square, rising 4 feet from the level surface of the ground. Two reinforced concrete beams 8"xl6" and 16' long, par¬ allel, and resting upon the piers at each end of their 8-inch surface, carried the span. Shearing brackets, monolithic with these beams and also the piers, were provided at both ends, and these were rein¬ forced with two %-inch lug bars. Each of the beams was reinforced with two 16-foot girder frames, provided with connected shearing mem¬ bers. Twelve joists or ribs of reinforced concrete, connected the two beams in the following manner: At each end of the span a joist measuring 8"x8" and reinforced with four %-inch lug bars connected the two beams. Next to this were laid a row of eight of the concrete tile. Next to these approach¬ ing the center, was laid another rib 4"x8", rein¬ forced with two %-inch lug bars, and this process was continued until ten ribs, each constructed in exactly the same manner, and alternating regularly with rows of eight tiles, completed the span, with 11 rows of tile. The tiles were laid flush with the ribs at the bottom, and being only 6" through, left the 8-inch ribs projecting 2" above the top of the tiles. This 2-inch space above the tiles was filled with gravel concrete, and the upper surface trowel¬ ed off to a finish like first-class sidewalk work. The beams and ribs as well as the monolithic piers were all made of good gravel concrete. Forty of the tiles used were made of cinder concrete; forty of slag concrete; and eight of gravel con¬ crete. All the centerings were removed from the span when three weeks old, and was carefully in¬ spected to see that the work was in perfect condi¬ tion. When the span was thirty days old it was load¬ ed to 200 pounds for every square foot of its sur¬ face, and ten days later it was subjected to a fire test of the severest possible character. Some four and a half cords of combustible material were placed beneath the floor span, consisting of wood fagots—and these were thoroughly saturated with kerosene. A torch was applied at 7 a. m. and fire sustained with increasing intensity until 9:30 a. m., when water from a 20-pound pressure nozzle was Compression Tests applied to the fire and heated under-surface of the span, directly against the tiles. It required forty- five minutes to reduce the temperature so as to make it possible to approach the test structure. Ex¬ amination developed the fact that practically no damage had been done to the tile by this severe test. The evidences of the intensity of the heat were easily observed. The interior surfaces of the concrete piers showed many glassy spots, indicating that the sand had fused. Pyrometric cones placed as close to the fire zone as practical, indicated more than 1,800° F. This public test was conducted in the presence of the following persons: Capt. W. H. Loller, chief Youngstown fire department; D. Heinselman, chairman board of public service; Chas. C. Knox, inspector of buildings; A. G. Young, build¬ ing contractor; Angus S. Wade, supervising archi¬ tect; C. T. Agnew, county commissioner; C. H. Connell, engineer-contractor; Fred K. Irvine, editor Rock Products, and the inventor, A. A. Pauly. In addition to these, many other individiials who took an interest in the demonstration were present. This publicly conducted test was recognized as so practical and valuable as a criterion that a statement covering the facts as above set forth, and alleging them to be authentic, was drawn up and signed by all the above witnesses of the test. A compression test was made at the Gulick, Henderson & Co. laboratories at Pittsburg, the re¬ sult of which was as follows: Report of Compression Test of Concrete Hollow Tile Made for Albert A. Pauly, Youngstown, Ohio. Pittsburg, Pa., Dec. 13, 1907. Laboratory Number Mark Dimensions Total Sec. Area Load Pounds Crushing Strength Weight sq. in. per. sq. in. 2(011 Rock 11.72" x 11.45" 134.19” 26,720 199 6.02" 26012 Slag 11.82" x 11.50" 135.93" 26,480 194 6.00" State of Pennsylvania, County of Allegheny, ss: Before me, a notary public in and for said county and state, personally appeared Henry Gulick, Jr., of*the firm of Gulick, Henderson & Co., who swears that the above statement is a true and correct report of the test made. Sworn to and subscribed before me this 13th day of December, 1907. GULICK, HENDERSON & CO. (Seal) By Henry Gulick, Jr. W. A. Feltyberger, Notary Public Commission expires January 16, 1909. Recently a fire test was conducted in the pres¬ ence of the following gentlemen connected with the local public service: J. B. Kennedy, county com¬ missioner; C. C. Knox, city building inspector; W. H. Lawlor, chief of the fire department; E. S., Wal¬ ton, retailer and distributor of building supplies; M. E. Dennison, cashier of the First National Bank; Charles H. Connell, concrete contractor-engineer; J. D. Gibson and J. B. Kennedy, Jr. The Concrete Stone and Sand Company Youngstown, Ohio The Best is none too Good and the Best Is Cheapest in the Bong Bun Correct Dimensions and Simple Forms The Tiles Illustrated Here Have Been Used Extensively in the Construction of All the Buildings Shown in This Catalogue No. 8. 8" x 8" x 16” No. 10. 8" x 10" x 16" No. 14. 8" x 8" x 16" No. 15. 8" x 10” x 16" Fifteen Four and Five-Room Houses in This Group The Concrete Stone and Sand Company Youngstown, Ohio 6 The Fan da mental Ilasla In the Manufacturing; of Pauly Tile is Scientifically Correct Concrete Applied to Dwelling House Construction By Ross F. Tucker, Member American Society Civil Engineers; President Concrete Association of America (Written during the first use of Pauly concrete tile.) The next step in the extension of the use of con¬ crete will be its adaptation to the construction of dwellings. With the army of block machines that are on the market and the great quantity of the “output” from these machines, the bulk of which goes into dwelling house work, it might be assumed that the step above mentioned had already been taken. In a sense it has, but it is a step that, in the writer’s opinion, has done concrete a question¬ able service. The technique of the method of man¬ ufacture to which all block makers are restricted is fundamentally wrong and can never be of great value, either constructively or decoratively. The ten to twelve per cent, of water used in mixing is not sufficient to lubricate the particles of aggregate, nor to develop the full set of the cement. Such material cannot possibly have the density nor the strength of a properly made concrete. All the ramming and tamping in the world, all the pressure that can be exerted by hydraulics or otherwise will not compress a dry-made concrete into a dense, water-tight block. The particles of aggregate arch on themselves and cannot be forced to fill corners and interstices without sufficient lubrication to al¬ low the faces and surfaces of the aggregate to slip on one another. On the other hand, the moment that sufficient water is added to secure the best re¬ sults for density and strength, the material is too soft to be removed from the moulds and the so- called block machines are of no value at all. It is curious that so many people have taken to block-making as if there were something new about it. The old-fashioned artificial stone of thirty years ago was made of the same material and in the same manner as with block machines today and the re¬ sultant material had all the defects of these later productions,—a soft, absorbent, spongy mass, of low compressing strength, requiring all sorts of treatments to make it waterproof. The whole prac¬ tice is wrong and the only difference between the old method and that of today lies in the numerous mechanical devices, which, with greater or less in¬ genuity, reduce the labor and mould cost to a mini¬ mum. By reason of the faults that Ae at the very beginning of all block-making, I do not consider that the steps taken in that direction have been of any great value to the industry as a whole, nor need we expect anything of importance to come out of it in the future. All walls built of such material must be so constructed as to avoid the dampness that such concrete must necessarily acquire, and the very softness of the stone precludes any surface treatment that can be called interesting or satisfy¬ ing in any degree. All concrete, to be strong and sound, must be wet concrete, far too wet to be delivered from its mould for considerable periods of time. The prin¬ ciple of selection of aggregates, combined with in¬ telligent combination and mixing, secures results that, in a finished product, are astonishing and ab¬ solutely impossible of attainment by any dry pro¬ cess block-machine that ever was devised. Again, solid wall construction is very limited in its application to dwelling house work. While we have about solved the problem of the mill and fac¬ tory building, both structurally and economically in reinforced concrete, the same cannot be said at all in respect to dwelling houses. In the mill and fac¬ tory structure we have a relatively large amount of concrete as compared with the lumber and labor in¬ volved in the making of the forms, whereas, in the dwelling house, with the cut-up surfaces and irregu¬ lar openings, the rates of cost of forms to concrete is out of all scale or proportion and puts concrete practically out of the running in comparison with other material. Moreover, the internal stresses, particularly the shrinking of concrete masses, are such that concrete walls of this kind are almost sure to crack. They must be furred or an air space formed, as otherwise they will be damp and ex¬ tremely unsatisfactory. In the fall and spring there is likelihood of condensation on the inside of an unprotected concrete wall, and, last of all, it is a difficult matter to give a solid wall any architect¬ ural treatment that can be called satisfactory, ex¬ cept at a very considerable expense. The wooden house is, of course, a menace to com¬ mence with and should be only built as a last resort. Such a house covered with metal lath and furred has some excellent architectural possibilities, but when well built, will not be found to be cheaper than a rough brick wall, for the frame must be sheathed, papered, metal furred and lathed and covered with scratch coat of mortar before it is in condition to receive the stucco. This will be found to approximate closely the cost of brick work. Much has been said about the faults of stucco work, but like many other failures in the use of concrete, they are traceable to the ignorance of the users rather than to the fault of the material. Stucco has been abused about as much as any other material that the writer knows of, but it will do good service every time if properly made and ap¬ plied. I have placed ornamental stucco on the ex¬ terior of a power house on the St. Lawrence River, on tile, brick and lath surfaces where it has been subjected to a yearly range of 120 degrees tempera¬ ture for ten years, and it is as good today as when applied, although the plastering on the inside, made exactly the same way, of the same material, came off in pieces a yard square on the same walls within two months after it was applied. There are great possibilities in the future of stucco when properly handled. But for this de¬ velopment must come a cheap wall. The writer had occasion to make a study of this problem of a cheap wall construction ^for stucco application for the late Standford White, who, had he lived, would have taken some steps to show what can be done in dec¬ orative stucco. But all existing methods have been too expensive and we must devise a cheap dry wall before we can make material progress in dwelling house work. The terra cotta wall is a relatively cheap wall, but its lack of fire-resisting qualities, its tremendous expansion under heat, make it a dan¬ gerous wall, unless insulated and protected. The nearest approach to the ideal wall for concrete dwelling houses seems to kave been worked out by A. A. Pauly, of Youngstown. He has a method of delivering wet concrete from moulds in a clever and very economical manner and seems to have solved the problem of handling wet concrete and produc¬ ing a dense, strong building unit at a very low cost. He has already done considerable building and his development will be watched with great in¬ terest. With such a wall, the extension and possi¬ bilities of concrete decoration are unlimited and the future will give us fire-proof homes of high struc¬ tural and architectural value at low cost. The method is so simple, the requirements of skilled labor are so greatly reduced, that houses of con¬ crete, fire-proof throughout, may be constructed at a price to compare favorably with wood, and upon the walls may be applied a great variety of color and texture effects, in stuccos made of many ma¬ terials, enlivened with masses of color in Faience and Mosaic, that give the architect great oppor¬ tunity for the exercise of his artistic abilities. It will create a school of design adapted to the ma¬ terial and be productive of a style of dwelling pos¬ sessing individuality and character, combined with durability and permanency such as we know little of thus far in our suburban architecture. The Concrete Stone and Sand Company Youngstown, Ohio 7 A Home Built of Concrete Tile 1* nn Asset which is Everlasting Type of an Economical and Strictly Fireproof Residence Fig. 4 PLAN OF FIRST FLOOR The Concrete Stone and Sand Company Youngstown, Ohio 8 Concrete Tile Can be Applied with Facility in Every Type of Construction HOI£.3 ■ TH/IO- WH/CH TO t r?our? coucrpe 7~£ f/lu •Jt’E/HEOHC ErfLH, U/iT^L.-FOfcLARGE- • W/MDOW-OPFWMGi • Fig. H 13E/CK 7-T/ES- rr - 3 ~7~i 3 m LLJfi L Q 1 l -! i IjgggEgj |f|; rip-- 1- 1

m * a/ r ' m l&f * Sullivan Apartments, at Falls and Mill Miller & Ford, Architects gates, the same aggregates being used in the manu¬ facture of the tile with the same kind of Portland cement. After these curtain walls are laid the en¬ tire surface will be gone over with pneumatic bush hammers and pick hammers so as to surface out the distinctive character of the aggregate, thereby introducing an extremely economical and tremendously effective exterior surface, which has as yet never been used upon a large scale, although mass concrete surfaces have been treated in this way with the most excellent results, -but at very considerable cost. Beyond the artistic value of this method the structural value obtained by the use of concrete structural tile is a matter of the first im¬ portance, for the reason that the beams and columns of the steel frames are thereby relieved of fully one-half of the dead wall load necessary to figure where twelve-inch curtain walls of brick are used that would not in any way add to the strength, dur¬ ability or usefulness of the building with the ad¬ ditional weight. Concrete fire-proofing tile has been specified for all of the partitions and furring in this hotel building, and were selected on account of the perfect dimensions and uniform shapes of the tile with the attendant economy in the plastering and finishings of the interior, which is not obtainable with other, materials. Whether the exterior treat¬ ment just described is employed in this particular instance or not, the conference in which the matter has been considered develops a principle of artistic exterior treatment which will be very widely used in the building season of 1910, with as many varia¬ tions and particular specifications as each case will suggest. Block of Workingmen’s Houses on Cypress and Gibson Streets The Concrete Stone and Sand Company Youugstovtn, Ohio 22 Concrete Walls of Pauly Tile Present Itlenl Surfaces for Artistic Decoration Hamilton Stores and Flats on Market Street Upon the topic of the decoration of exteriors and the treatment of tile walls in particular cases, our associated companies, as well as the develop¬ ments in our own operations, bring to light almost every day some new variety of treatment quite within the reach of ordinary economical building practice. Future developments in this particular line are indicated by the increasing interest con¬ stantly expressed by the most eminent architects, engineers and men of prominence in learned voca¬ tions, in all parts of the country, by communications showing a very comprehensive study of the subject along independent and new lines. For partitions and curtain walls in buildings having reinforced concrete frame, or steel cage con¬ struction, concrete hollow tile is the lightest ma¬ terial of sufficient strength for these purposes. The true, plane face of the tile when used in partition work, offers the best surface for holding plaster yet introduced. Mechanics spreading plaster on con¬ crete tile partitions cover from a third to a half more surface in a day, with ease and satisfaction, and at the same time saving 20 to 25 per cent, of the mortar. In partitions it is light on account of the hollow space, materially relieving the dead load upon the structural members that carry the build¬ -¬ in floor construction in connection with ribs of reinforced concrete, the concrete tile is superior to any other because the fresh concrete rapidly be¬ comes a solid, inseparable mass with the tile. The even edges and angles are a distinct advantage in cheapening the cost of centering floor and roof spans from beneath, as the true surfaces of the tiles bear squarely upon the boards. Practice has de¬ veloped surprising economies in this line of work by the use of concrete tiles rather than materials that have been in use for the same purpose heretofore. Tile Partitions Used in Connection with Solid Concrete Outer Walls 23 The Concrete Stone and Sand Company Youngstown, Ohio Great Strength and Extreme Lightness are Combined (Qualities in Panly Concrete Tile Century Building on Federal Street Owsley & Boucherle, Architects. C. H. Connell, Contractor Interior of the Macaroni Manufacturing Company’s Building on Federal Street Kling & Fink, Architects. C. H. Connell, Contractor The Concrete Stone and Sand Company Youngstown, Ohio Concrete Tile are Equally Useful for Buildings llevoted to Business and Pleasure Wells-Salow Building on Federal Street Angus S. Wade, Architect Garage on Broadway Pauly Garage 25 The Concrete Stone and Sand Company Youngstown, Ohio Pauly Concrete Structural Tile Embody All the Essential Qualities of an Ideal Building Material Safe and Artistic Residences at Lowest Cost The widest angle of usefulness, and at the same time the most important development of the con¬ crete industry, is that which provides the safest and most permanent, and at the same time the most sightly and convenient homes for the people. The first step of civilization, the inseparable duty of the head of every family, is to provide a shelter, and the first consideration is the safety of the occupants by day and by night, awake and asleep. Not until Mr. Pauly’s inventions were completed has it been possible to construct a concrete home at a price within the reach of a large majority of the human family, while with the use of the materials made by his system there is no longer excuse for any householder to face the danger of fire loss or the dread of the destruction of life. The carefully compiled statistics bearing upon this subject throughout the entire United States are, indeed, astounding to contemplate. Fire losses in residence properties are annually set down in figures that reach into the hundreds of millions, and the acknowledged incompleteness of these returns indicates conservatively that no less than one billion of dollars is turned into smoke and ashes regularly with each succeeding year. The misguided opinions of the past are most forcefully expressed in the fact that no less than 90% of the homes of American families are built exclusively of wood, in spite of the progress of the last two score years, in which a very increasing number of brick and concrete houses have been introduced. Figures do not make an adequate picture to the mind of the reader, but when one contemplates that the loss of life by the burning of homes in the United States every year amounts to more than the total slaughter in all the battles of the recent Russo-Japanese war during two exceptionally bloody campaigns, some idea can be formed. Nearly all of these lives, by consulting the records, will be found to have been wiped out either while the people them¬ selves were overtaken ip sleep or in frantic en¬ deavors to save the lives of others. It has not been confined to the rich or to the poor, to the influential or to the humble, to the old or to the young, but American citizens from every walk of life, from the lawmakers in the halls of Congress to helpless in¬ fants who were not responsible for their own acts. Within the year of 1909 a number of populous cities were almost entirely wiped out by fire, as evidenced at Dallas, Texas; Rochester, N. Y.; Kala¬ mazoo, Mich., and others needless to mention here. The force and effect of Mr. Pauly’s invention for the manufacture of non-burning structural and fire¬ proofing material is to place within the reach of every investor in a home the distinct possibility of entirely eliminating such danger and risk, and with such economy that it really amounts to a matter of choice without additional cost. At Youngstown, Ohio, where the initial plant of the inventor is located, this material is already Residence on Belmont Avenue The Concrete Stone and Sand Company Youngstown, Ohio 26 By-Products from Quarries and Blast Furnaces will Eventually Replace Lumber Youngstown Transfer Company Stables on Phelps Street recognized by the community at large, on account of the many satisfactory examples of homes which have been completed, that all builders without ex¬ ception are giving it serious consideration. The demonstration has been so complete and far reach¬ ing that every builder considers first that his home must be of concrete tile to make it safe. Beyond this he appreciates the artistic, sanitary and economical features which have been equally as sub¬ stantially established. The home market for concrete structural tile has been won beyond any question, and the merits of the material will be just as readily recognized by builders of every locality where these goods are ob¬ tainable. The parent company at Youngstown, in corn- junction with a number of associate companies lo¬ cated at the most important markets of the country, are providing the means for distributing this ma¬ terial as conveniently as it is possible for such an important business with such enormous quantities of detailed specifications. At the present time the materials are available in very extensive territories, and the invitation of this company to everyone who contemplates the building of a home is to communi¬ cate with the head office at Youngstown, Ohio. Workingmen’s Flats on Bond Court 27 Tlie Concrete Stone and Sand Company Youngstown, Ohio I bars every other bar to \ span across as shown for tie Your Home Can be Made Absolutely Fireproof by Using Pauly Concrete Construction Throughout