Digitized by the Internet Archive in 2017 with funding from Columbia University Libraries https://archive.org/details/onondagacutcastsOOonon Copyright 1925 ONONDAGA LITHOLITE COMPANY Syracuse, New York PRINTED IN U S. A ONONDAGA CUT CAST STONE Onondaga Litholite Company PLANT AND MAIN OFFICE: SYRACUSE, NEW YORK Two of these eagles, eight feet high, surmount each of the four pylons of the Wilmington Memorial Bridge, Wilmington, Delaware. Architect, Vance IV. Torbert, New York City. Onondaga Litholite Company, Syracuse, N. Y. HE Onondaga Litholite Company, pioneer c Purpose of in the manufacture of Cut Cast Stone, BookLt presents this book to those who have occasion to use Cut Cast Stone, that they may have a more thorough knowledge of the character- istics and possibilities of this building material. Many of the questions asked by the company’s customers are answered. Manufacturing processes, methods of finishing, and practical suggestions for its most efficient and practicable use are offered, with illustrations of the most popular finishes. ^^'^^The Onondaga Litholite Company was estab- Established lished in 1901 and its history is a record of constant and progressive development of the business of manu- facturing Cut Cast Stone. ^^^The company’s product never has been offered as a cheap building stone and quality and service have been the first considerations, always. Increased de- mand has demonstrated the appreciation of the users of the material and indicates that Onondaga Cut Cast Stone fills an important place in the materials listed for use in high grade modern structures. Fountain, Rodney Square IVilmington, Del. by Zantginger, Borie & Medary c . Philadelphia , Pa. mm Onondaga Cut Cast Stone The ‘Drafting c Rpom ■where all working plans are made l Modelling in Clay [ 6 ] Onondaga Litholite Company, Syracuse, N. Y '^s^^e^The company’s new plant has a capacity of Capacity 600,000 cubic feet of stone per year. The operating force that had its beginning more than twenty years ago has been developed into a complete staff of masters in the art of stone making. £g?>^^Each order for Onondaga Cut Cast Stone is handled in a thorough manner from its initial stage in the drafting room through every process in its manu- facture. Draftsmen with long experience in handling the various styles of architecture and classes of work keep in touch with the architect and contractor and give full co-operation during the progress of the work. The architect and contractor are kept informed of each step in the manufacture of the stone by means of blue- prints and shipping lists. The staff includes skilled modellers and carvers who follow this work through up to the time it is accepted as satisfactory in the building by the architect. Handling Orders Photographs of all clay models are submitted to the architect and changes are made until they meet with complete approval. If it is possible for the architect to personally examine and criticize the models ‘ 'Plaque , kVax Theatre ‘ Philadelphia , Pa. Frank E. Hahn, Architect ‘Philadelphia [ 7 ] Onondaga Cut Cast Stone Section of the ^Modelling c Room £ Making blaster dAlouId [ 8 ] Onondaga Litholite Company, Syracuse, N. Y. when completed, it is always advisable. If the archi- tect is unable to come to the factory, the models can be made under his supervision and by the artist in whom he has the most confidence. It has been found, however, that better results can be obtained if the carving of the material can be supervised by the modeller, thus insuring the proper feeling desired by the architect. c 'Architect’s Supervision A plaster waste mould is made from the ac- clay Models cepted clay model into which the material is poured, this plaster mould being cut away and the cast entirely recarved by skilled carvers under the supervision of the Master Modeller. ^^^•If duplicate casts are required, a glue model is made exactly following the lines of the accepted clay model. This allows the making of the number required for the work. Wood is used for the patterns which are made from isometric drawings, a templet taken from the architect’s detail being used. The pattern room is equipped with modern wood working machinery to assure accuracy. Coat of Arms York State Armory Cornell University '^\V » York State Architectural ‘Department 9 Onondaga Cut Cast Stone '-'-V; 1 « Pattern Shop Crusher mm . [10] Onondaga Litholite Company, Syracuse, N. Y. Sand moulds are used, sand being uniformly Sand Moulds tamped around the wood pattern. After the pattern is removed, the sand exactly reproduces the contour of the pattern. The selection of materials and their preparation according to strict formula has been the subject of thorough study since the establishment of the company. sss>g>v&^The Onondaga Litholite Company has ac- Aggregate quired marble quarries at Gouverneur, New York, from which a marble, probably the hardest American marble, is quarried and shipped in large pieces to the Syracuse plant. The marble having been crushed by large roller jaw crushers is further reduced in a disc crusher and by the use of manganese rolls, the size used varying from one- half inch to a fine sand size. The material is screened by power screens, each size being stored by itself. In assembling the material for mixing, the number of pounds of each size called for by formula is deposited in the mixer. Water and cement are added by [ 11 ] Column Cap designed by John T. Comes, Architect of Pittsburgh, Pa., for St. Ann’s Church Homestead, Pa. Onondaga Cut Cast Stone <5 Mixer and cAgitator Section of £ Moulding 'Room [ 12 ] Onondaga Litholite Company, Syracuse, N. Y. weight. This method insures the absolute uniformity and quality required in a high-grade Cast Stone. After being carefully mixed, the material is waxing transferred to a large portable mixer and carried by electric crane to all parts of the moulding room. Con- stant agitation keeps the material thoroughly mixed until it is deposited in the moulds uniformly and with- out any segregation of the aggregate. sss^v^ssTn casting, the portable mixer is lowered di- rectly over the mould, releasing a flow of the material through the long funnel directly into the mould. ^^r^>All reinforcing steel is placed where required c Remforcing before the mould is filled. necessary, anchor bolts are placed in the material before it is allowed to harden. Setting hooks are placed in all units for handling and setting the material. After the cast has hardened sufficiently, it is removed from the sand by cranes and carefully stored for curing. A uniform temperature is maintained which insures a thorough hardening of the material. Entrance Panel Qoode-Clement Building ‘■Buffalo, N. Y. Esenwein & Johnson, Architects ‘Buffalo, N. Y. [ 13 ] Onondaga Cut Cast Stone ‘‘Pouring Liquid cAggrcgate into mould, using ‘Portable Mixer ‘Reinforcement Placed in Mould before pouring ■ ■Bflfl H wmmmmmmmm mm t [ 14 ] Onondaga Litholite Company, Syracuse, N. Y. The sand adhering to the cast protects it from the air during the curing. After the stone is cured, it is finished by Finishing recutting all exposed surfaces either by machinery or hand. Carborundum machinery is used extensively: Carborundum saws for cutting and carborundum planers for removing the surface of the stone. This insures sharp arrises and true lines. Rubbing beds are used for ashlar work. The most modern machinery for cutting and handling stone, as well as special machinery for cutting Cast Stone, has been installed in order to insure high standards of workmanship. The Onondaga Litholite Company employs Hand Finishing perhaps the largest force of expert stone cutters for the production of hand finishes in the United States. cs?3H/^3sTn finishing Cut Cast Stone by hand, the cutters use the same hand tools that are used in cutting and finishing natural stone. Throughout the process of producing Cut Cast Stone a most rigid inspection is maintained. The material is checked for measurements in each depart- Canopy above Main Entrance St. Columba's Parochial School Schenectady, N. Y. M. L. & H. G. Emery and , , IV. Van Guy sling, Architects L D J cAlbany, N. Y. / i A j I- \ //ilV u 1 IaA i t~v \ g* r. 1 1 ■ • in |#‘ I /.IS I |L '^0 Onondaga Cut Cast Stone Shaping the Carborundum IVheels for c Planers oA ‘Planer at ■work [ 16] Onondaga Litholite Company, Syracuse, N. Y. ment, thus insuring close adherence to the architect’s details and drawings. After final inspection at the loading cranes, shipments the stone is placed in cars packed in shavings to pre- vent any breakage in transit. Shipments are made in the order that the stone will be required and as fast as the contractor requests, so as to insure the constant and uniform progress of the building. Full co-operation is given to the contractor throughout the progress of the work. Onondaga Cut Cast Stone is uniform through- out. It can be manufactured in any size with economy. Reinforcement placed in the stone effects a saving in structural steel which would be otherwise required. Reinforced Cut Cast Stone can be used in long spans and in positions where it would be impractical to use natural stone without structural steel or other support. c Distinguishing Qualities Cut Cast Stone is used where a very hard and durable stone is required for grade-courses, steps, and platforms. Because the stone is made according to proven formulas, which have been successfully used for many [ 17 ] cpediment Ornament Hocking Valley National Bank Lancaster , Ohio Simons , Brittain & English , Inc. oArchitectSy Pittsburgh , Pa. v Onondaga Cut Cast Stone Carborundum Sauo cutting Cast Stone Section of Hand Finishing c Department [ 18 ] ■■■■ Onondaga Litholite Company, Syracuse, N. Y. years, and a careful record of all work is kept, it is easy to duplicate this material in after years. Onondaga Cut Cast Stone is furnished in a Color and number of colors and textures, each kind of stone Ttxturi having a number. Cast Stone can be made in a variety of shades of the same color with excellent effect, thus avoiding a monotony of appearance often objectionable. Cut Cast Stone, made to blend in color and finish, can be used in connection with any local stone for trim. It is possible to match up natural stone which for some reason is not available or is too costly. s^^^Each cubic foot of Onondaga Cast Stone Weight weighs one hundred fifty pounds. Estimates are cheerfully given and are always Estimates based on true cost knowledge. It is obvious that stone requiring extensive hand carving and finishing would be more costly than machine finished stone. It is likewise true that special stones and finishes add to the cost in proportion to the extra labor involved. There is, of course, a great saving in casting the stone from approved clay models as compared [ 19 ] Entrance Shield Onondaga V alley School SMelnjin King, Architect Syracuse, N. Y. Onondaga Cut Cast Stone 'Duplication with the cost of shaping and carving from hewn stone. As the cost of the patterns enters so largely into the cost of the material, the amount of duplication is taken into consideration when making prices. Conng large work, it is possible to core the casts, reducing the weight greatly and lowering the cost of freight and handling at the building. This is particu- larly advantageous in making large columns where it is possible to give a wall of sufficient thickness reinforced with steel to give the same strength as a solid column. Columns thus constructed can be filled with concrete on the job. This is not often considered necessary. Comiccs Cornices can be designed to permit coring of the projection, reducing the weight of the overhanging portion and minimizing the amount of steel required to hold the cornice in place. Lifting hooks are cast in all stone for the use in setting and handling. Conduits for electric wiring can be cast in the stone if desired. Where stone is to be suspended from structural steel the necessary bolts and hangers can be cast in the stone. Steel rods can be cast in stone for bolting it down to the structure. Column Cap yefferson County Savings Bank IV aterto'wn, N. Y. Lansing & Green, Architects IVatertcwn, N. Y. [ 20 ] Onondaga Litholite Company, Syracuse, N. Y. If stone is used as veneer, "L” shaped stone TWr can be used at corners, giving a massive appearance to the stone work. The engineers of the Onondaga Litholite Company will gladly co-operate with the architect for any solution of these problems. Onondaga Cut Cast Stone can be repaired if accidentally damaged in setting or after the building has been finished. The repairs are permanent. The materials used in making repairs being identical with the material used in manufacturing the stone, these repairs can be finished so as not to be distinguished from the balance of the building. Stone broken can be replaced at the factory Wreckage without delay, stock material being kept on hand and necessary cutting machinery is available to replace the units. Stone arriving at destination in a damaged condition should not be removed from the car without first getting the freight agent to note the damage on the bill of lading. The claim will then be cared for at the factory, the damaged material being promptly replaced. Carved Panel First National Bank ‘Platts burg, N. Y. Harold J. Cook, Architect ‘ Buffalo , N. Y. 21 xT ^ ■ -u. ..iJ; v Onondaga Cut Cast Stone Handling Whenever possible, derricks should be used in lifting the stone off the cars and in handling stone from the cars to position in building. Bags half filled with soft wood shavings are good protection in transit from car to building. Care in handling and piling is reflected in the appearance of the finished building. The color of recut Cast Stone is determined by the color of the aggregate and not by the cement c , Portion of Ornamental Pane l yunior and Senior High School c Bald'winsville, N. Y. C. IV. Clark, Architect Cortland, N. Y. [ 22 ] Onondaga Litholite Company, Syracuse, N. Y. used. It is possible to use with the aggregate various mineral colors and the results are very interesting. These colors do not fade. Contrasts can be obtained by a mixture of Contrasts aggregates sharply contrasting in color — for instance by mixing a white marble with a black aggregate in various sizes and amounts. sss^v&^When it is considered that all the various ’Variety of finishes that have been used in the past on natural stone are available, the architect has open to him in this dependable material a wide variety of colors and textures never before easily available for use on the interior and exterior of his structures. cg^rg^The cost of a high-grade Cast Stone is so little more than the cost of inferior materials that it is practically negligible in the cost of the completed structure. [ 23 ] ‘Panel for Power House of c . Northern New York Utilities, Inc. IVatertown, N. Y. C. A. Rich, Architect Nlew York City cgg^&^Twenty years’ use has demonstrated that Onondaga Cast Stone will stand all necessary tests, and the longer the material remains in the building the more pleasing and better it becomes. I Capacity — 2.000 cubic feet per day. 600.000 cubic feet per year. >AGA LlTHOLITE COMPANY Insert shows original plant as it appeared twenty years ago. Onondaga Cut Cast Stone Specification The following requirements are essential in the manufacture of a good Cast Stone and should be mentioned in specifications: Aggregate — Granite or hard marble. Careful grading of the materials after crushing. The combination of the various sizes under carefully pre- pared formulas and by weight, so as to get a maximum density without the sacrifice of appearance. It is also essential that the cement and water be carefully weighed or measured. Too much water in the mix is detrimental. The careful cutting of all surfaces, gives the stone per- manent color, character in finish and texture. A good cast stone should be made uniform throughout. Necessary It should be kept in mind that it is impossible 1 P to use the proper formulas to get the best results un- less the equipment is available to properly handle and pour the casts. The best mixture cannot be bandied by band. To properly recut all surfaces of Cast Stone requires special machinery and skilled mechanics, not available in a small plant. A large plant and output allows of the neces- sary flexibility so that large contracts can be bandied Grotesque ‘Panel Teachers’ College Library Columbia University, Tlensi York City cAllen & Collens, Architects ‘ Boston , Mass. [26] Onondaga Litholite Company, Syracuse, N. Y and shipments made in the quantity and as required at the work. ssg>&v«&»It is needless to specify detailed methods of Experience manufacturing Cut Cast Stone, unless the architect or his representative can by personal supervision see that the specifications are carried out. It is more important to restrict competition to firms who have recognized facilities and experience to produce the grade of stone required. Acceptable firms should be named in the specifications. The contractor is put to a material loss if a cheaper material is rejected after the contract is secured, thus forcing him to furnish the better material at a higher price. ^w^=The color and finish should also be called for. c Approved It should be specified that a sample of the material SlV " pL ' required is in the architect’s office and it should be stated clearly that any material other than those men- tioned in specifications must have the approval of the architect before the bids are submitted. If after the specification is written, another material is accepted as satisfactory, all general bidders should be notified before opening of bids so the com- Grotesquc ‘Panel 'Teachers' College Library Columbia University, Tle'w York City cAllen & Collens, Architects c Boston , Mass. [ 27 ] Onondaga Cut Cast Stone c Architect's c Approval Competition petition may always be fair. Often the owner or the architect determines the material to be furnished and arranges for its purchase, giving to the contractors the price of the stone and other information necessary in making bids. It is often provided that bidders must not only get the approval of the architect before their material can be used, but that they must also show to the architect actual work which has been installed in a building at least five years. If a Cut Cast Stone is specified in competition with natural stone, care should be taken to specify the same finish for both materials. If a hand finished Cut Cast Stone is required in competition with machine finished natural stone, a figure for both machine and hand finish should be requested. Clay products are not fair competition for Cut Cast Stone. It is essential that the manufacturer have facili- ties for promptly replacing material broken or rejected at the building. The construction of the building cannot be held up for thirty days to await the manu- facture of new units. Carved Panel Hummel Office Building ‘ Philadelphia , Pa. Thomas, Martin & Kirkpatrick Philadelphia ■1/ Ononda ga Lit holite Company, Syracuse, n. Y. s^&v&&»The density and low absorption of Cast Stone eliminates the necessity of painting the back, as is customary for the softer natural stones. ^K^iThe same standard requirements called for in Standard good natural stone work should be applied to Cast Stone. It should be specified that stone must be properly reinforced to carry all loads and for handling. Setting plans submitted by the manufacturer should show all reinforcement as well as special anchoring, if necessary, in addition to the jointing, etc., and should receive the approval of the architect before the material is manufactured. cabinet containing samples of the most Samples popular finishes and colors will be furnished for per- manent use of the architect, or individual samples will be sent as required for any particular use, together with photographic reproductions of finishes. As soon as the stone is set in place, the mortar should be raked out to a depth of Loose dirt should be removed by the use of sponge and water. After the building is completed, stone work should be washed down, using soap chips and water [ 29 ] Column Cap designed by John T. Comes, Architect of Pittsburgh, Pa., for St. Ann’s Church Homestead, Pa. with stiff scrubbing brush. Do not use steel brushes. ‘ Poising is very important that acids should not be used in cleaning down stone. When cleaning down brick work with acid solution, be sure that stone in connection with brick work is thoroughly saturated with water, so that the acid will not penetrate stone. Then, as a safeguard, stone should be washed off again with hose and water. Joints should be well dampened and pointed as required. Mortar should be well tucked in. Monar 583^6^= Mortar should be composed of good, sharp sand and cement in the proportion of one part cement and one and one-half parts sand. White cement or lime should be used if light colored pointing is desired. mixing pointing mortar, the cement and sand should be mixed at least three hours before it is needed. Before using the material it should be re- mixed and water added until the material is of the proper consistency. If the above directions are care- fully followed there will be no shrinkage. ^^^^The Onondaga Litholite Company maintains branch offices and has representatives in several cities within its shipping radius. These offices and the entire organization at the factory are always available for co- operation with architects, contractors and builders. [ 30 ] Onondaga Litholite Company, Syracuse, N. Y SPECIFICATIONS following short specification is recommended for Cut Cast Stone: All stone work indicated on plans to be the product of the Onondaga Litholite Company, Syracuse, New York, or an approved equal. Contractors wishing to bid on other materials must have such material approved before opening of bids. No stone will be approved after the opening of bids. AGGREGATE: Aggregate to be of Granite or Hard Marble and uniform throughout. REINFORCING: Stone must be properly reinforced where necessary to carry loads and for handling. COLOR AND TEXTURE: Color and texture to be same as approved sample No. 100 (*) on file in Architect's Office. FINISH: All plain surfaces to be machine tooled, six cuts to the inch, (**) mouldings and smaller members to have smooth finish. (***) ANCHORS: All bolts, expansion bolts, anchors, ties, etc., required for the Cut Cast Stone shall be furnished by the steel contractor. All ashlar and similar shaped stones shall be anchored to the backing with heavily galvanized wrought iron anchors X" x IV 1 turned down into the stone lb" and extending into the backing 8" if the thickness of walls permits, the end to be turned up lb" into the backing. * Stone No. ioo, as called for above, is white in color. If Buff Granite is required, use No. 272. For plain Buff, use No. 202. For Gray Granite, use No. 170. Black Granite, No. 494. Pink Granite, No. 3115. ** Smooth finish may be used instead of six cuts to the inch. Plain surfaces can be changed to Fdammer Dressed or Fine Crandall Finish, which are hand finishes and more costly. *** Mouldings and ornamental work can have Hammer Dressed, smooth or Fine Crandall Finish. Six- cut machine finish cannot be used on mouldings and ornamental work. Hammer Dressed, Planer or Fine Crandall Finish can be used on all surfaces, alone, or in combination with any finish desired. Onondaga Cut Cast Stone Tlaner or Honed Finish ^Machine Tooled Finish four or six cuts to the inch [ 32 ] Hammer 'Dressed Finish generally used on Cut Cast Granite Onondaga Litholite Company, Syracuse, N. Y. Carborundum wheels are used in producing the smooth or honed finish and results in fine arrises and lines. Tooling machines are set up with a series of carborundum wheels that grind grooves into the surface of the stone. [ 33 ] Pneumatic hammers are used to pro- duce this six or eight cut finish. Onondaga Cut Cast Stone Fine Crandall Finish used extensively on some natural stones Coarse Crandall Finish used for heavier 'work c Point Finish is a ■very coarse finish used where a rough, sturdy appearance is desired on lower portions of large, massive buildings. [ 34 ] , • - . • __ cd ; * Onondaga Litholite Company, Syracuse, N. Y Many fine pointed teeth fas- tened together make up the hand operated tool which is used in producing the Fine Crandall Finish. Fdeavy pointed teeth lined up in a tool operated by hand gives the Coarse Crandall Finish as shown on the opposite page. Point Finish is put on with a single pointed chisel. Onondaga Cut Cast Stone ^CA/T /JONL /GELLnI ^LADlhJ(tf Q3DM.' Llf>f^OR_Y to k. Hamilton! cglldse. cuH|^H,nJ.Y. ccoLipcc. Y coeLsokI. AKHiyccy DyTOfi Ma>j Lxncujf.'p DY OJoi'iijAflfi LiyHoLijc Co P'feoeo^E.f'l.y. DCCUOPCD CL r tf or tcaccrY 'J ' ore PL Art Ce:' Jieot > .U. i'i Jec f/on j/iomf ti/afc 6/rc/rr one / 3 rack / V I •»>{ i>V/» - forte/ l/ofc P/MoffrdC/tef. DLjAILp JHOVING juppo & j /- joz Ha N la inIc CA/f JCQ.LZ.ti* [ 36 ] Onondaga Litholite Company, Syracuse, N. Y THE SOVEREIGN APARTMENTS Cleveland, Ohio Max Weis, Architect Cleveland Erected 1921 on East Boule- vard for the East Boulevard Apartment Company [ 37 ] Onondaga Cut Cast Stone Built entirely of Onondaga Cut Cast Granite Onondaga Litholite Company, Syracuse, N. Y. Onondaga Cut Cast Stone is especially suited to this class of work TYPICAL DETAILS TR.ACE.E.Y Windows FOE. 5T MANY'S CHUR.CH O O WE. GO NE.W YOR-R. TRACERY WINDOW St. Mary’s Church, Oswego, N. Y. Y OrJoilpAGA Li J^oLi jc-( ^yc^cu_5£., rl.y. i’tM P/pe 'Aire ' fa’ 2 ifS / f’ e ana ;//tw DotY£/./r/ 6 -