The Processes of Stone-Masonry.
When the stone is sawed to the proper size, the surfaces which are exposed to view, have to be made smooth and even. The tools used by the mason for this purpose consist of iron chisels of different widths, and principally of a sharp-pointed one called a pointer; these chisels are struck with a mallet made of a conical-formed lump of hard wood, fixed to a short handle.
Stone-Sawyer.
The pointer is used for chipping off the principal roughnesses on the face and edges, and for working the whole face over to bring it level, the workman trying his work by applying a straight-edge occasionally to it. When the front and edges are made true, the face is sometimes tooled over, so as to leave regular furrows in it, according to certain forms, by which the different kinds of work are distinguished. But this practice is going out of use, now that soft free-stone is so much employed in building. In old edifices, such as St. Paul’s, Whitehall, &c., &c., the stone will be found to be wrought on its face in the manner alluded to.
Stones in buildings are not only fixed with mortar, as bricks are, but are further secured in their places by being clamped together with iron clamps. These are short iron bars, from seven to twelve inches long, one and a half wide, and half an inch thick, according to the size of the stone; the ends of the clamps being turned down a little, to afford a better hold. A channel is cut in the two contiguous stones deep enough for the clamp to lie in, and the ends of the channel are sunk deeper, to receive the turned-down ends of the clamp; when this is put into the channel, molten lead is poured in to fill up the interstices, to keep the clamp in its place, and to prevent it from rusting.
From the expense of carrying and working stone, the walls of buildings at a distance from a quarry, such for example as those in London, are seldom now built of solid stone, but a facing of this material is applied only on the external surface of the wall, which is built of brick. This kind of work is called ashler work, and both the brick and stone-work must be executed with considerable care, to enable a wall composed of two materials to preserve its perpendicularity; it being obvious, that if the brick part yielded to the weight, it must, from its construction, do so more than the stone facing, and, therefore, the wall would bend inwards and become crippled.
The width of the courses of ashlers must, therefore, be made equal exactly to a certain number of courses of bricks with the intervening mortar, and the brick-work must be executed with such care, that this number of courses may be everywhere of the same width in the whole height of the wall. In every course of ashler there must be solid stones laid quite, or nearly quite, across the width of the wall to form a bond to the stone facing, and all the stones of the ashler must be fixed with iron cramps to one another and to these bond-stones. But, however carefully a faced wall may be executed, it is never so firm or durable as one built entirely of either material; indeed, if well executed, of good materials, and of competent thickness in proportion to its height, a brick wall is the most durable, light, and efficient structure that can be erected.
When stone is to be cut into cornices, mouldings, &c., the blocks having been sawed, the ends, top and bottom, are worked very true and parallel, or perpendicular to each other, and one edge or arris cut to a perfectly straight line; a thin wooden mould of the section of the cornice is then applied to each end, and the profile of the mouldings marked out on the stone. The workman being guided by this figure, cuts away the stone down to the general surface of the mouldings, and then proceeds to get the flat fillets of the mouldings perfectly straight and true by the rule; these again guide him in working the curved mouldings, such as ovolos, cavettos, cyma rectas, and ogees; when these are cut nearly to their profile, and perfectly straight on the bed line, they are finished off by being rubbed down smooth by thin long straight-edges of stone.
Foliage and carved work is executed by a better kind of workman, possessing some of the taste of an artist, and he works on the same general principles as a sculptor when executing a statue; it would be foreign to our present object, therefore, to dwell on this branch of the mason’s art.
It often, or even most commonly occurs, that the distance between two columns of a portico, is of greater length than a stone can be obtained, and if the architrave, or that part of the entablature immediately over the capitals of the columns, be looked at attentively, a stone will be perceived between the columns apparently unsupported, for neither end rests on the column, and the joints of those ends are upright, not presenting any character of a voussoir-stone or arch. The contrivance by which such an architrave stone is supported deserves to be described.
The stone in question has a projecting part, wrought at each end, of the form shown in the annexed figure; this projection is received into a corresponding cavity, cut in the end of the stone supported by the column, and the joint is thus really an arched or wedge-shaped one, though the bevel line is concealed, and the two stones, when put together, present only a vertical joint.
The mason uses squares, levels, plumb-lines, and straight-edges to set out his work, and trowels and mortar to set the stones with; but the latter is rather used to make the joints water-tight than to keep the stones together, this being effected by their weight or by iron clamping. Formerly the mason required far more accurate and extensive knowledge of geometry than is possessed by persons of the trade at present; this was when he was called on to construct groined and vaulted roofs, enriched with carved work and pendent corbels, where the nicest workmanship was required, to ensure the stability of the light and graceful columns and vaulting of a Gothic cathedral. It was this possession of superior skill and knowledge that caused the establishment of the Society of Freemasons, which dates its rise from the tenth or eleventh century.
Marble, from its costliness, and the difficulty of working it, is seldom, if ever, used in solid pieces in buildings; thin facings of it are set upon stone backings, much as rare woods are used in veneering by the cabinet-maker. The marble is sawn into thin slabs, like other stone, and the face is polished by rubbing on it the surface of another piece, fine sand, mixed up with water, being used to cause abrasion.
Various contrivances are resorted to for cutting marble, and building-stones generally, into curved forms. In some cases a lever is made to work at one end on a pivot, while at the other end is attached a curved piece of sheet-iron, which passing backwards and forwards over the stone, cuts it in a circular form. In other cases a cylinder of sheet-iron is formed; and this being allowed to fall vertically on the surface of the stone, and rotated rapidly, cuts out a piece of stone of the diameter of the cylinder. Sometimes, when a large circular piece of stone is required, a kind of wheel is employed, furnished on its under surface with four curved cutting-irons, and these cutters, when the wheel revolves, cut the stone. By a modification of the arrangements, an oval instead of a circular curve may be given to the piece of stone.
Chapter II.
ON THE DURABILITY OF STONE BUILDINGS.
“Everything belonging to the earth, whether in its primitive state, or modified by human hands, is submitted to certain and innumerable laws of destruction, as permanent and universal as those which produce the planetary motions. The operations of nature, when slow, are no less sure; however man may for a time usurp dominion over her, she is certain of recovering her empire. He converts her rocks, her stones, her trees, into forms of palaces, houses, and ships; he employs the metals found in the bosom of the earth as instruments of power, and the sands and clays which constitute its surface as ornaments and resources of luxury; he imprisons air by water, and tortures water by fire to change, to modify, or destroy the natural forms of things. But in some lustrums his works begin to change, and in a few centuries they decay and are in ruins; and his mighty temples, framed, as it were, for divine purposes, and his bridges formed of granite, and ribbed with iron, and his walls for defence, and the splendid monuments by which he has endeavoured to give eternity even to its perishable remains, are gradually destroyed; and these structures which have resisted the waves of the ocean, the tempest of the sky, and the stroke of the lightning, shall yield to the operation of the dews of heaven, of frost, rain, vapour, and imperceptible atmospheric influences; and as the worm devours the lineaments of his mortal beauty, so the lichens and the moss, and the most insignificant plants, shall feed upon his columns and his pyramids, and the most humble and insignificant insect shall undermine and sap the foundations of his colossal works, and make their habitations amongst the ruins of his palaces, and the falling seats of his earthly glory.”[1]
Although it is true that all human works must decay, yet it is a point of great importance to ourselves and our successors whether that decay be slow or speedy. The causes enumerated in the above eloquent passage, though sure, are exceedingly slow in their action, and provided the building materials have been selected with reference as well to their durability as to their beauty, the resulting structure may defy the corroding tooth of time for many ages, and we may thus transmit to a long posterity, lasting memorials of our wisdom and science, as well as of our piety. Modern science has, to a very great extent, enabled the architect and builder to determine beforehand what is the durability of any given stone; and it is with great pleasure that we now notice the extensive inquiry made at the suggestion of Mr. Barry, the architect of the new Houses of Parliament, under the Commission issued by Her Majesty’s Government, to investigate the qualities of stone in various parts of the kingdom, in order to select that which should best ensure perpetuity to this grand national monument. This commission, consisting of Mr. Barry, Sir H. T. De la Beche, Dr. W. Smith, and Mr. C. H. Smith, visited one hundred and five quarries, and examined one hundred and seventy-five edifices; and their collected specimens were then submitted to tests, both mechanical and chemical, by Professors Daniell and Wheatstone, of King’s College, London. In order to leave a permanent record of their labours, the Commissioners published a Report, and deposited in the Museum of Economic Geology, a variety of specimens of the stones which they had collected. From this Report, we select such details as are calculated to serve the purposes of popular instruction. The Commissioners did not consider it necessary to extend their inquiries to granites, porphyries, and other stones of similar character, on account of the enormous expense of converting them to building purposes in decorated edifices, and from a conviction that an equally durable, and in other respects more eligible material, could be obtained for the object in view from among the limestones or sandstones of the kingdom.
The Commissioners soon had striking proofs of the necessity and importance of this inquiry in the lamentable effects of decomposition observable in the greater part of the limestone employed at Oxford; in the magnesian limestones of the Minster, churches, and other public edifices at York; and in the sandstones of which the churches and other public buildings at Derby and Newcastle are constructed; and numerous other examples. The unequal state of preservation of many buildings, often produced by the varied quality of the stone employed in them, although it may have been taken from the same quarry, showed the propriety of a minute examination of the quarries themselves, in order to gain a proper knowledge of the particular beds from whence the different varieties have been obtained. An inspection of quarries was also desirable for the purpose of ascertaining their power of supply, and other important matters; for it frequently happens, that the best stone in quarries is often neglected, or only partially worked, in consequence of the cost of laying bare, and removing those beds with which it may be associated; whence it happens, that the inferior material is in such cases supplied.
Stone buildings decay more rapidly in towns than in the open country, where dense smoke, fogs, and vapours, which act injuriously on buildings, do not exist. There is also another curious cause which contributes to the durability of stone buildings situated in the country. In the course of time, the stone becomes covered with minute lichens, which, though in themselves decomposing agents, act with extreme slowness, and when once firmly established over the entire surface of the stone, seem to exercise a protective influence, by defending the surface from the more violent destructive agents; whereas, in populous smoky towns, these lichens are prevented from forming, and thus the stone is exposed to severer trials than stone of the same kind situated in the country.
As a remarkable illustration of the difference in the degree of durability in the same material, subjected to the effects of the air in town and country, the appearance is noticed of several frusta of columns, and other blocks of stone, that were quarried at the time of the erection of St. Paul’s Cathedral, London, and which are now lying in the Isle of Portland, near the quarries from whence they were obtained. These blocks are invariably found to be covered with lichens, and, although they have been exposed to all the vicissitudes of a marine atmosphere for more than one hundred and fifty years, they still exhibit beneath the lichens their original form, even to the marks of the chisel employed upon them; whilst the stone which was taken from the same quarries, (selected no doubt with equal, if not greater care, than the blocks alluded to,) and placed in the Cathedral itself, is, in those parts which are exposed to the south and south-west winds, found, in some instances, to be fast mouldering away.
Colour is more important in the selection of a building-stone to be situated in a populous and smoky town, than for one to be placed in the open country, where all edifices become covered with lichens; for, although in such towns, those fronts which are not exposed to the prevailing winds and rains, will soon become blackened, the remainder of the building will constantly exhibit a tint depending upon the natural colour of the stone.
The chemical action of the atmosphere produces a change in the entire matter of the limestones, and in the cementing substance of sandstones, according to the amount of surface exposed to it. The particles of the stone first loosened by the action of frost are removed by powerful winds and driving rains. The buildings in this climate were generally found to suffer the greatest amount of decomposition on their south, south-west, and west fronts, arising doubtless from the prevalence of winds and rains from those quarters.
Those buildings which are highly decorated, such as the churches of the Norman and pointed styles of architecture, generally afford a more severe test of the durability of a building-stone, than the more simple and less decorated castles of the fourteenth and fifteenth centuries; because, in the former class of buildings, the stone is worked into more disadvantageous forms than in the latter, as regards exposure to the effects of the weather. Buildings in a state of ruin, from being deprived of their ordinary protection of roofing, glazing of windows, &c., afford an equally severe test of the durability of the stone employed in them.
The durability of various building-stones in particular localities was estimated by examining the condition of the neighbouring buildings constructed of them. Among sandstone buildings was noticed the remains of Ecclestone Abbey, of the thirteenth century, near Barnard Castle, constructed of a stone closely resembling that of the Stenton quarry, in the vicinity, in which the mouldings and other decorations were in excellent condition. The circular keep of Barnard Castle, apparently also built of the same material, is in fine preservation. Tintern Abbey is noticed as a sandstone edifice, that has to a considerable extent resisted decomposition. Some portions of Whitby Abbey are fast yielding to the effects of the atmosphere. The older portions of Ripon Cathedral; Rievaulx Abbey; and the Norman keep of Richmond Castle, in Yorkshire, are all examples of sandstone buildings, in tolerably fair preservation.
Of sandstone edifices in an advanced state of decomposition, are enumerated Durham Cathedral, the churches at Newcastle-upon-Tyne, Carlisle Cathedral, Kirkstall Abbey, and Fountain’s Abbey. The sandstone churches of Derby are also extremely decomposed; and the church of St. Peter, at Shaftsbury, is in such a state of decay, that some portions of the building are only prevented from falling by means of iron ties.
The choir of Southwell Church, of the twelfth century, affords an instance of the durability of a magnesio-calciferous sandstone after long exposure to the influences of the atmosphere. The Norman portions of this church are also constructed of magnesian limestone, similar to that of Bolsover Moor, and which are throughout in a perfect state, the mouldings and carved enrichments being as sharp as when first executed. The following buildings, also of magnesian limestone, are either in perfect preservation, or exhibit only slight traces of decay: the keep of Koningsburgh Castle; the church at Hemingborough, of the fifteenth century; Tickhill Church, of the same date; Huddlestone Hall, of the sixteenth century; Roche Abbey, of the thirteenth century.
The magnesian limestone buildings which were found in a more advanced state of decay, were the churches at York, and a large portion of the Minster, Howden Church, Doncaster Old Church, and buildings in other parts of the county, many of which are so much decomposed, that the mouldings, carvings, &c., are often entirely effaced.
The report speaks in high terms of the preservation of buildings constructed of oolitic and other limestones; such are Byland Abbey, of the twelfth century; Sandysfoot Castle, near Weymouth, constructed of Portland oolite in the time of Henry the Eighth; Bow-and-Arrow Castle, and the neighbouring ruins of a church of the fourteenth century, in the island of Portland.
The oolite in the vicinity of Bath does not seem to wear well.
The excellent condition of the parts which remain of Glastonbury Abbey shows the value of a shelly limestone similar to that of Doulting; whilst the stone employed in Wells Cathedral, apparently of the same kind, and not selected with equal care, is in parts decomposed. In Salisbury Cathedral, built of stone from Chilmark, we have evidence of the general durability of a siliciferous limestone; for, although the west front has somewhat yielded to the effects of the atmosphere, the excellent condition of the building generally is most striking.
The materials employed in the public buildings of Oxford, afford a marked instance both of decomposition and durability; for whilst a shelly oolite, similar to that of Taynton, which is employed in the exposed parts of the more ancient parts of the Cathedral, in Morton College Chapel, &c., is generally in a good state of preservation, a calcareous stone from Heddington, employed in nearly all the colleges, churches, and other public buildings, is in such a deplorable state of decay as, in some instances, to have caused all traces of architectural decoration to disappear, and the ashler itself to be, in many places, deeply disintegrated.
In Spofforth Castle, two materials, a magnesian limestone and a sandstone, have been employed, the former in the decorated parts, and the latter for the ashler, and although both have been equally exposed, the magnesian limestone has remained as perfect in form as when first employed, while the sandstone has suffered considerably from the effects of decomposition. In Chepstow Castle a magnesian limestone is in fine preservation, and a red sandstone rapidly decaying. A similar result was observed in Bristol Cathedral, which afforded a curious instance of the effects of using different materials; for a yellow limestone and a red sandstone have been indiscriminately employed both for the plain and the decorated parts of the building; not only is the appearance unsightly, but the architectural effect of the edifice is also much impaired by the unequal decomposition of the two materials.
After enumerating these and other examples, the Report gives the preference to the limestones, on account of their more general uniformity of tint, their comparatively homogeneous structure, and the facility and economy of their conversion to building purposes; and, of this class, preference is given to those which are most crystalline. Professor Daniell is of opinion that the nearer the magnesian limestones approach to equivalent proportions of carbonate of lime and carbonate of magnesia, the more crystalline and better they are in every respect.
It was considered that this crystalline character, together with durability, as instanced in Southwell Church, &c.; uniformity in structure; facility and economy in conversion; and advantage in colour, were all comprised in the magnesian limestone, or dolomite of Bolsover[2] Moor and its neighbourhood, and was accordingly recommended as the most fit and proper material to be employed in the New Houses of Parliament.[3] This opinion was not arrived at, nor this recommendation made, until after a very extensive series of experiments had been completed by Professors Daniell and Wheatstone upon specimens of the stones of the various quarries visited by the Commissioners. The specimens, as delivered to these gentlemen, were in the form of two-inch cubes. These experiments were of a most comprehensive kind. The composition of the stones was determined by chemical analysis:—their specific gravities; their weights after having been perfectly dried by exposure in heated air for several days; then their weights after having been immersed in water for several days so as to become saturated; the object being to ascertain the absorbent powers of the stones, which was further tested by placing them in water under the exhausted receiver of an air-pump. The stones were also subjected to the process of disintegration, invented by M. Brard, the object of which is to determine, by easy experiments, whether a building-stone will or will not resist the action of frost. Lastly, the cohesive strength of each specimen, or its resistance to pressure, was tested by the weight required to crush it. This weight was furnished by a hydrostatic press, the pump of which was one inch in diameter: one pound at the end of the pump lever produced a pressure on the surface of the cube equal to 2·53 cwt., or to 71·06 lbs. on the square inch. These trials were made with caution; the weight on the lever was successively increased by a single pound; and, in order to ensure a gradual action, a minute was allowed to elapse previous to the application of each additional weight. It was noted for each specimen the pressure at which the stone began to crack, and also the pressure at which it was crushed.
The results of all these experiments (which are stated for each stone) gave a decided preference to the Bolsover magnesian limestone, which was noticed as being remarkable for its peculiarly beautiful crystalline structure, while it was the heaviest and strongest of all the specimens, and absorbed least water. Its composition was 50 per cent. of carbonate of lime, and 40 of carbonate of magnesia; the remaining ten parts consisting chiefly of silica and alumina.