"carving" Archives | Browse Articles & Resources Written By Experts https://usenaturalstone.org/tag/carving/ Articles & Case Studies Promoting Natural Stone Fri, 10 Mar 2023 19:41:53 +0000 en-US hourly 1 https://usenaturalstone.org/wp-content/uploads/2019/07/cropped-use-natural-stone-favicon-2-1-32x32.png "carving" Archives | Browse Articles & Resources Written By Experts https://usenaturalstone.org/tag/carving/ 32 32 Range, Sustainability, and Beauty: Why Architect Craig Copeland Uses Natural Stone https://usenaturalstone.org/rangesustainabilityandbeautywhyarchitectcraigcopelandusesnaturalstone/ Tue, 29 Nov 2022 20:32:14 +0000 https://usenaturalstone.org/?p=10637 There is no mistaking natural stone for its range, beauty, and sustainability. These are among the many reasons Craig Copeland, an architect, sculptor, industrial designer, and partner at Pelli Clarke & Partners finds himself recommending natural stone to many of his clients.

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Range, Sustainability, and Beauty: Why Architect Craig Copeland Uses Natural Stone

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All photos appear courtesy of Craig Copeland.

There is no mistaking natural stone for its range, beauty, and sustainability. These are among the many reasons Craig Copeland, AIA, LEED AP BD+C, an architect, sculptor, industrial designer, and partner at Pelli Clarke & Partners finds himself recommending natural stone to many of his clients. He appreciates the qualities of natural stone, particularly marble and travertine, so much that he created another business, Situcraft, a natural stone carving and design studio in New York so he could design furniture made primarily using these types of stone.

 

Maximizing stone’s natural features

“I like natural stone because of the connections to nature and to the earth,” Copeland explains. Unlike other raw material also sourced from the earth, natural stone in its raw state is not only beautiful in its own right, he adds, but he can work with it directly as it is. “It also has incredible durability,” he adds. “There are other natural materials, like wood, that you can work with directly, but they don’t have the same kind of durability that stone has.”

In addition to the sustainability aspect of natural stone, Copeland is drawn to the look stone affords. He appreciates the variability of color and patterning or vein movement and the possibilities of enhancing those features with different textures.

 

Deciding how and when to use natural stone

As an architect, when Copeland and his team want to recommend the use of natural stone to a client, they engage the client and stakeholders in the process. It’s more of a question of where and how to use natural stone rather than if they should use it, he notes.

In many cases, he says, the best place to incorporate natural stone in the design is where you’re closest to the building, both visually and tactically. “Where you actually can see and touch the building or the architecture,” he explains. “I think that’s a big part of it – tapping into the power of stone and our connection to the earth through its use architecturally.”

From a sustainability standpoint, durability is an important reason he often recommends stone for projects. Unlike other materials that need to be updated or replaced regularly, natural stone is often the best choice but, also, with technological advances in extraction and application, a client can get even more expressive forms for a project.

“I think the other beauty of stone is that you can use the stone in a variety of sizes and really procure and enhance the resourcefulness,” he notes, especially as it relates to sustainability. This is important to him not only as an architect but as a designer as well. “There’s more consciousness and more possibilities today.” Where sustainability might have been an afterthought or not even considered in the past, today it’s in the forefront as people consider the role of building materials in mitigating climate change.

 

A natural stone vision for projects

When it makes sense, Copeland will suggest stone for projects even when the client hasn’t considered it. “We start by asking, ‘Where is the value?’” Copeland says. “How far can we extend the value of the stone on any given project? As we’re beginning to answer that question, we engage the clients and talk that through.”

In the case of commercial projects, he says the opportunities to incorporate natural stone might be the paving or the base of the facade. He admits he likes to turn things around sometimes to create interesting effects. For one project, Copeland took what traditionally would be a wood wall and had natural stone installed on the wall and floor in the lobby. “The effect was quite stunning,” he says.

 

Working in marble and travertine

His love for stone extends beyond his practice as an architect.

Copeland enjoys working with marble and travertine when designing furniture pieces for Situcraft. For larger pieces, he leans toward travertine. After spending time observing Henry Moore’s work, an English artist known for his semi-abstract monumental bronze sculptures, Copeland felt that travertine could also pull off those contours and curves.

“For the smaller pieces, I like working in marble,” he says. The type of marble he chooses will depend on what he’s designing and sculpting. “I really enjoy working with [Calacatta] Lasa in terms of its hardness,” he explains. “You can really get incredible detail, but it’s very difficult to work with, so it’s challenging.”

Another way he likes to challenge himself is through the use of wet or dry carving techniques. He enjoys working with stones that have larger deposits of quartz, although it might involve more of a wet carving approach. Most of the carving he’s done has been dry and according to Copeland, when travertine is dry, it actually carves incredibly well.

“The trick with the travertine is its strength is very different in different orientations,” he notes. “So it requires a different sensitivity than marble. Marble is a little bit more forgiving in that sense.”
There are many reasons Copeland gravitates toward natural stone for his architecture and furniture projects. One thing he always comes back to is that its beauty and durability as a natural product of the earth cannot be undermined.

On his Situcraft website, he shares: “Situcraft believes that stone helps ground art, design, and architecture to the natural and real world. Natural stone is the only material that is directly available from the earth, with unequalled durability and beautifully unique forms and colors – the tangible essence of over a hundred million years, available to our touch.”
For Copeland, it’s not a matter of if natural stone should be included in a design. It’s how.

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Master Stone Carver Focuses on Architectural Details https://usenaturalstone.org/master-stone-carver-focuses-on-architectural-details/ Sat, 16 Jul 2022 21:48:19 +0000 https://usenaturalstone.org/?p=10363 Fairplay is an artist and his medium is natural stone. He works with stones such as marble, limestone, and sandstone. While his studio is currently based just outside Cleveland, Ohio, his training began in Europe, where he specialized in hand-carved stone, marble sculpture, and ornaments.

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Master Stone Carver Focuses on Architectural Details

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All photos courtesy of Nicholas Fairplay.

 

It’s not every day a sculptor gets to carve one Romanesque statue as part of a project. Nicholas Fairplay had the opportunity to carve two using Indiana limestone that are now on permanent display as part of the College of Fine Arts building at Carnegie Mellon University in Pittsburgh.

Fairplay is an artist and his medium is natural stone. He works with stones such as marble, limestone, and sandstone. While his studio is currently based just outside Cleveland, Ohio, his training began in Europe, where he specialized in hand-carved stone, marble sculpture, and ornaments.

Fascinated by the large cathedrals throughout Europe, Fairplay visited one after high school and asked for a job. While they couldn’t hire him at first, he offered to work for free for six months. They brought him on staff and he showed up and soaked up everything he could. It was during that time he fell in love with sculpting and working with natural stone. “When I started carving natural stone, I just loved it,” he says. “I love that it’s three-dimensional.” At the end of his free training, the cathedral hired him.  

Today, Fairplay’s body of work can be seen on well-known buildings in London, including Westminster Abbey, St. Paul’s Cathedral, Houses of Parliament, and Hampton Court. He’s also worked on Windsor Castle.

When he arrived stateside, he wasted no time contributing to American buildings, including St. John the Divine in New York City, the Utah State Capitol in Salt Lake City and the five intricately designed niches at Carnegie Mellon University. Of the six niches created when the building was built in the early 1900s, only one was completed. The other five, according to Fairplay, were left unfinished and each niche was to be carved in a different architectural genre.

“It was a very difficult job because all the stone was on the wall,” Fairplay says. He and his team had to slowly cut part of the stone off the wall and work on it on a bench. While removing it, they needed to careful not to damage the work next to it. Other details were done while the stone was still on the wall. “It was like you find yourself carving upside down a little bit. It’s a little bit awkward.”

He researched the niches and statue designs since every detail had to be plotted and sketched out in advance. To create the Romanesque statues, he cut the blocks and kept those on the ground so he could carve them before placing them in the niche.

While carving Romanesque statues isn’t a project that comes across his studio often, Fairplay says this specialized training and artistry is sought out among homeowners, designers, and architects, especially when it comes to restoration projects or those who want truly one-of-a-kind pieces in their homes.

In cases when the client only has a general ideal of what they’re seeking, Fairplay goes one step further and creates pieces of art, carving leaves, snails, or lion heads.

When Fairplay was asked to add some carvings of sycamore leaves as part of the entrance of a gothic style home in Cleveland, Ohio, he knew the client was expecting cookie cutter cut outs and the same style throughout. He decided to carve each of them differently to give them character.

For example, he added a little curling on some of the sycamore leaves and on a few of them he included an “odd little animal,” he says. “In the spandrel, or the triangular piece on an arch, there are three leaves and a little frog,” he shares.

One piece features a cicada on one of the sycamore leaves. Another has a lizard running. According to Fairplay, you’re not meant to sit and stare at the carvings but rather to appreciate those little details when you come upon them. He wasn’t paid extra to include those details but as an artist with some artistic liberty on a project, he loves adding them because that’s what people notice, he says.

“It’s a little detail and you don’t want it to be too dominant,” he adds. “You want it to be just here and there. And that way, it’s more. It’s not in your face.”

Fairplay appreciates being brought into a project, whether it’s through an architect or residential homeowner, and having an opportunity to bring his artistic skills to the table. Recently he’s been commissioned to create large scale stone fireplaces for homes. Some feature details like a lion face (designed so the fire would be in the mouth area) while others are more subtle.  The artistry cannot be underestimated.

The fireplace featuring the lion face was smaller than other fireplaces he’s been designing as of late but even that was six feet tall by five feet wide. He’s currently working on five fireplaces in his studio, some in a gothic style, one provincial French and an elaborate Italian one in marble featuring a Cupid angel holding a shield.

Whether it’s a classic design or part of modern architecture, Fairplay believes that sometimes less is more. You don’t need carvings to appear throughout a building to appreciate the artistry. “I’m not for seeing carvings on every inch of the building,” Fairplay says. A little foliage or detail or ornament can go a long way.

“Some buildings need something like that to sort of enhance and be in balance with the building,” he notes. “To have a sort of small area with some ornament. If you think of art deco, the ornament is very limited and it can actually be very stylized too. But it can be fantastic.”

 

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Carving a Career in Natural Stone: A Conversation with Chris Miller https://usenaturalstone.org/carving-a-career-in-natural-stone-a-conversation-with-chris-miller/ Mon, 30 Nov 2020 17:40:26 +0000 https://usenaturalstone.org/?p=8237 Learn about the career of a successful stone sculptor, Chris Miller. He enjoys the entire process from design and planning to the physicality of working with natural stone.

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Carving a Career in Natural Stone: A Conversation with Chris Miller

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An earlier version of this article appeared in the September 2020 edition of The Slippery Rock Gazette. Reprinted with permission. Photos courtesy of Chris Miller and assigned copyright holders.

 

If you’ve ever explored the beauty and charm of small-town Vermont, chances are you’ve visited Vermont’s state capital, Montpelier. Located just a stone’s throw from Montpelier is the town of Calais, the home of the Kent Museum and the Robinson Saw Mill. It’s also the home of the renowned Chris Miller Studio.

Chris Miller is a seasoned veteran with hammer and chisel who has been creating art since childhood and sculpture since 1976. Mostly self-taught, Chris was influenced by many local artists, including the late Billy Brauer of Warren, Vermont, and the late Lothar Werslin of Sandgate, Vermont. It’s noteworthy to mention that Chris’ studio is conveniently close to the Rock of Ages Quarry in Barre, Vermont, an area known as the “Granite Center of the World” for well over a century. Chris loves the granite from this area. Ask him about Barre granite and he’ll readily tell you why he loves it.

 

Lessons Learned, Experience Earned

Chris opened his first studio at age eighteen, exclusively doing wood sculpture. However, he soon turned to natural stone. “I had always wanted to try stone, and a few years after opening the studio I went to visit the Vermont quarries. What’s the old saying: ‘When in Rome, do as the Romans’? So, after many years of doing exclusively wood, it was nice to try a different material and the techniques used to carve it, and it was a great mid-career challenge to add stone to the mix. There’s also a lot more work in the stone-sculpture world than in the wood-sculpture world.”

Chris has an extensive wood working and carving room in his barn, as well as an area for stone, but is only set up to work on projects up to about one ton. When doing larger scale work, he uses two different studios in Barre that he rents, he explained.

“For the big projects, there are forklifts, bridge cranes, saws, sandblasting, and all the great stuff needed. I tend to work big when I can, and having these tools is pretty wonderful. Because of my back, I try not to work on anything small anymore, because if it’s a hundred pounds or less, I tend to pick it up and move it! When I’m working in Barre, if it’s six, ten or twenty tons, I just wave the crane guy over and it gets moved.”

Chris works with both granite and marble. “I do much, much more granite than marble just because granite is much more durable, and there are more applications. If it’s an indoor figurative thing, marble is really good for that, but if it’s going to be outdoors for years and years, you’re going to want it to be granite. Both soft and hard stones have their qualities just like soft and hard wood. With hard wood you can do finer details better, and with soft wood you can move a lot faster. It’s the same with stone. Some people will suggest the idea for a sculpture, and I’ll know immediately if it should be in granite or marble, because each material also lends itself better to different subject matter. It’s also nice to go from granite to marble to wood and back again, just for a feeling of variety.”

It’s all about finding the right stone for the right project. “I use different stones for different projects, but I’m a big fan of Barre Gray granite, especially the dark gray. The grain is tight, it’s predictable, and it carves really well. Some of the softer granites are more difficult to carve, whereas some dark granites have larger grain and bigger pieces of quartz or feldspar. They are beautiful to look at when they are polished, and when used in carvings that have a broader form, these colors can work out very well. But when you’re carving something with a lot of detail, the colors and patterns can compete with the design. If you’re carving a face or something with fine detail, you don’t want the stone to compete with the design you are working on.”

 

Know Your Client’s Needs, Understand Your Market

Vermont has a program called Art in State Buildings that’s promoted by the Vermont Arts Council. Each year they grant several commissions for any number of buildings that the state is constructing. Six years ago, Chris was a team leader for one of these commissions and put together a group of four sculptors for a project in the Vermont Psychiatric Care Hospital. “We wanted to design something that would interact with a very vulnerable psychiatric population in the hospital, so we designed all these therapy animal sculptures, and put them throughout the hospital. We did seven, and from what I heard later on from the staff there, the patients had formed relationships with the animals, and it had a really big impact on them.”

Chris’s clients vary. “I’ll go from doing a public piece, to a collector, to a private commission, to a commercial job. Over the last six years, my work has been divided between museums, commercial work, the Vermont State House, small public sculptures, commissions for private collections and private sculpture parks. It runs the whole spectrum. It’s important to know who you are dealing with. The client can be an individual commissioning the sculpture for themselves, or for a gift, or for a commercial project or for an institution, where you are dealing with a committee. You have to know your audience, and you have to know the cost and know if they can afford it. So I listen intently, find out what the budget is, what their needs are, what’s important, and what the sculpture needs to do. All these things matter.

“After this initial process, I’ll have a basic concept, and I’ll then work with sketches and go back and forth with renditions. When approved, I then make a small sketch in clay (a little maquette), and when that’s approved, I make a scale model. Once they approve that, I make a mold cast in plaster, so I have a hard model to work from. Then, finally, when I’m ready to start carving, it’s a matter of measuring and enlarging from the model. So as far as imagining what the form is going to look like in the stone, all that work was done during the preliminary modeling.”

Chris enjoys the physicality of his work. “Being a sculptor is physically difficult, and why I enjoy my trade, says the guy with three back surgeries. Right now I’ve just completed a project in Georgia. It’s a truck made out of fieldstone, and there was a lot of lifting and hammering, but these trucks are a lot of fun to make. I get really solid reactions when people see them. It’s funny, I can do a beautiful statue, and people are really in awe, but I do a stone truck, and it really draws attention. So I tend to like that whimsical stuff. It goes over really well with a wide audience, and there’s no reason that it can’t be whimsical and crafted well at the same time. I do a fair amount of serious sculpture, too, but I do a lot more whimsical things, like the world’s largest granite zipper that’s displayed in Barre. I also love to do figurative work, and I’ve done six larger than life hands. I like using hands as a subject, because they can express quite a bit. You can express strength, gentleness and emotion with a hand, just as any kind of figurative work. I just really like hands.”

 

The Challenge of Working in Stone

“I’ve come to realize over the years, that when doing this kind of work you have to do a lot of designing and planning. Fortunately, this fits really well into my personality, because I enjoy problem solving. When somebody comes to me with an idea for a sculpture and there are parts of the idea that seem impossible, I sometimes think, how am I possibly going to do this? But I love the process of imagining a way to do this, and then having that idea rejected, and then having another idea and another idea and another idea, and by the end, I’ve taken the problem and challenges in the design and worked them out.”

Each project is like a new puzzle to solve. “The logistics of it, the practicality about how you are going to go about things and taking into consideration the parts that can break… there are so many different layers that have to work together, and that kind of challenge is incredibly fun, and fits the way my mind works. For example: at a recent remote job in Georgia, doing a project like this involved figuring out the tools I’d need, the materials, renting the equipment, coordinating the deliveries and putting a tent around it. It’s like being a contractor of a large-scale project, and I love this part of the job! When it’s a large sculpture project, with the design, the committees, the subcontractors and lots of moving parts, the design management of this is incredibly enjoyable, just because it makes me use my resources, and I find that really, really fun.”

When asked what a sculptor like Michelangelo might think of his work if he was alive today, Miller said, “He’d probably think I’m a hack! However, he might appreciate that I usually do all the work myself. In his era, the sculptor would design the model for it, and then there would be a team of specialist carvers: somebody who works on drapery, somebody who works on heads, somebody who works on hair and somebody who works on hands. There was a team, and that was the tradition.”

Chris enjoys the entire process. “I like the designing, making the model, roughing it out, the finish work and the installation. People think I’m crazy for wanting to do all of the process by myself. With his students and studio helpers, that’s how Michelangelo could produce hundreds of sculptures in his lifetime, and why I can’t, working by myself. Nevertheless, I’m going to keep doing this as long as I can. I figure I’ve got about another decade that I can swing a hammer. I’m sixty-two and never want to retire, but do want to go to a nine month per year work schedule, making larger public sculptures.”

When asked if he had any advice for up-and-coming stone artists, Miller said: “The thing to do when starting out is to make designs that you want to earn commissions for in the future, because when you’re starting out, you are going to make things on speculation, and if you want to be known as a figurative artist, you need to make figurative work.

“If you’re heading in the direction of public art, you need to do sculpture that would be suitable for public art. That way you can build up your portfolio while doing it with an eye on the future. Commissions are often awarded to sculptors who have a track record of public work. So, if you’ve done something suitable for a public piece, take a photograph of it, Photoshop it into a picture of a public square, and when you answer the call for artists, you can truthfully say, ‘this is a piece that I designed for a public setting.’ So do the kind of sculpture that you want to do to get orders for the future and build up your portfolio.”

To view Chris’s outstanding work, visit his website at www.chrismillerstudio.com.

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A New Take on a Classic Icon: The Winged Goddess of Victory https://usenaturalstone.org/a-new-take-on-a-classic-icon-the-winged-goddess-of-victory/ Thu, 18 Jun 2020 19:05:00 +0000 https://usenaturalstone.org/?p=7725 A Hellenistic sculpture of Nike of Samothrace is one of the world’s most celebrated sculptures. In 2017, it inspired a private Fortune 100 company in Portland, Oregon to reinvent the iconic artwork in the form of a stone wall carving.

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A New Take on a Classic Icon: The Winged Goddess of Victory

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An earlier version of this article appeared in Building Stone Magazine.

 

In Ancient Greece, the goddess Nike personified victory. She was a messenger whose wings enabled her to fly over the Earth rewarding victors of battle or athletic competition with fame and glory. The most famous depiction of Nike is the Winged Victory of Samothrace, also known as Nike of Samothrace. This marble Hellenistic sculpture dates to the second century BC and is one of the world’s most celebrated sculptures. In 2017, it caught the eye of a private Fortune 100 company in Portland, Oregon, who tasked a talented team of professionals to reinvent the iconic artwork on the wall of the executive boardroom at its corporate headquarters.

 

Reimagining a Classic

Peter Andrusko, master sculptor and owner of The Andrusko Group in Portland has been crafting stone sculptures for over thirty years. “The Winged Goddess of Victory,” a 15-foot-tall, 18-foot-wide bas-relief comprised of basalt and granite, is one of the most complicated and technically challenging projects he has ever worked on. “I’ve never done anything even remotely as complex,” he said.

“In May of 2017, I was approached by the project manager for special arts projects’ at Hoffman Construction Company and began a dialogue about the viability of creating a massive stone bas-relief sculpture. When I was approached by one of the West Coast’s leading general contractors, I was thrilled. They had found me, which in a sense partly validated decades of effort on my part in trying to become known as a source of quality and innovation in a very obscure artisan niche.”

Andrusko learned some “old school” stone techniques from his father, a successful brick and stone mason, but is mostly self-taught, specifically in robotic Computer Numerical Control (CNC) technology, which has been beneficial to his business. “Robotics is not only the future, more importantly, it’s an absolute gift of life to the carver,” he said. “About 15 years ago, the robotics industry changed and started becoming accessible to workshops. Let’s just say it’s a very natural fit and what I know of hand-craft and my natural abilities in technology found a very, very interesting nexus.”

To create The Winged Goddess of Victory sculpture and wall design, which relied on robotic CNC machinery, Andrusko utilized a basalt quarried in Moses Lake, WA, which was supplied by Stone NW in Vancouver, WA, and Indian Black granite from Savema in Pietrasanta, Italy. “This work is constructed from a very hard, dense and brittle local black basalt, which was then inlayed into a field of waterjet textured Italian black granite tile,” Andrusko said. “There is also some lettering carved into the granite, which is also the product of my studio and hand.”

The basalt used for the sculptural elements is a ubiquitous Pacific Northwestern material that is available in various colors, textures, and forms. “In this particular case, it’s an amazingly tight-grained satiny black that takes a polish,” said Andrusko, who worked with a local stone company that cut the rough blocks to-size and supplied the slabs, which were then cut to fit the super tight specs needed for the project. “The core block dimension is 3 x 6 x 24 inches. Of that overall depth, the carving is contained within just 2 1/2 inches of depth and is then inlayed into the Graffiti granite paneling covering the wall.

According to Andrusko, there are over 300 parts in the finished piece, many of which were first roughed into shape with CNC robotics technology, then hand-finished and fitted into the cut-to-fit granite. “It is a process essentially similar to the one used by many stone carving studios throughout time—in this case, using robotic machines instead of human workers, such as those famously employed by Rodin in his studio to perform the roughing from the original models, which in this case are digital files.”

 

Technology and Design

When designing the 7,500-pound sculpture, Andrusko worked with a professional digital art team, which created the digital renderings from which he worked. “The first and most important aspect of the project was the artwork,” the sculptor explained. “Initially, I was asked to provide the artwork, but the delivery date required for the completed work was rapidly approaching, so they hired a professional digital art team. We worked closely together during the first few months to refine the design. I produced an initial scale model of the carving in high-density urethane along with a full-size section that was approximately 4 x 5 feet.” After receiving feedback on the first scale model, a second was commissioned to confirm the changes would meet the demanding attention to detail.”  Based on feedback of the first scale model, a second was commissioned to confirm the changes would meet the demanding attention to detail.

According to Andrusko, the anticipated weight of the stone on its own was intimidating.  “The immediate need was to minimize the overall mass—getting as much detail as possible for something of this scale necessitated a balance between weight reduction (thickness of the module) and down-lighting. Also, keep in mind that all of this mass is hanging off the wall structure along a thin ribbon of floor inside of a modern-constructed building on an upper floor. Due diligence required some engineering attention.”

A compromise was found by creating a 3-inch thickness overall, with a 2 1/2-inch maximum range to work within. “This got us our range and the digital arts team was able to model the lighting and the relief topography to maximize the effect visually,” Andrusko said. “The reality is that there is a massive amount of ambient light in the space, which interferes to some degree with the LED down-light effect during the day, but some of the imagery was taken at night and one can see an amazing depth and clarity of surface that is truly a wonder; it appears far deeper and more defined than the 2 1/2 inches would suggest. A success by the design team and lighting specialists.”

The design team used displacement mapping to create the digital renderings, an alternative computer graphics technique that uses a texture map or heightmap to cause an effect where the actual geometric position of points over the textured surface are displaced, which gives surfaces a great sense of depth and detail, permitting self-occlusion, self-shadowing and silhouettes.

“The value of this is that the computer software I used to develop the cut files can accurately manage the range of black (lowest point) to white (highest point), which are, in essence, user-definable, which allows the Z-axis to be established properly so that everything fits in 3D,” Andrusko detailed. “The hand-carving is to blend and fit everything and to put the finishing touch into the carving.

“There was a great deal of struggling with the size of the file initially and trying to solve some problems like positioning into the fixed grid of the field materials that needed to be discussed and established before breaking the image into precise parts,” Andrusko explained. “Also, the client insisted on 1/16-inch tolerances between parts. Once all the grid issues were worked out, then the parts were segmented into the modules. I broke out the grid elements in granite from the basalt and cut stencils to mark and fit the granite part by part — hand-cut with a ring saw. I initially proposed that this be done with a waterjet, but in the midst of the time crunch, I elected to keep this in-house to cut by hand while the CNC machines were running. It turned out to be a very good decision for reasons I wasn’t expecting having to do with the final fitting. The G-code files were generated to run the machines and smaller parts were nested into the stones in groups. Everything was coded and numbered so that the parts could be fitted and mapped for the installation team.”

Constructing the 300 parts for the project required an intricate process. “The parts cutting involved an initial ‘roughing’ stage of milling,” Andrusko explained. “About 1/16 inch passes to get to the core shape of the part. The secondary stage of milling involved a smaller bit and a change of trajectory that netted the finished part fairly close to the final dimensions needed. That final step involved stacking the stones into a grid, hand-finishing and cleaning, and tightening the cuts and sharp edges in order to have a smooth transition between adjacent parts. The largest single area I was able to get flat at one time in the studio was approximately 4 x 4 feet.”

While the digital technology was needed to create a sculpture of this stature in such a short amount of time, Andrusko believes that hand-carving was still a key factor in the project’s success. “The robotics utilized in the studio amplifies the productive output of the carver manifold, but it still requires the breath of life of the master carver to perform the final steps by hand to finish and detail the sculpture,” he said. “However, what the technology allows is for a single individual to perform the work of dozens of people working practically non-stop for months on end.”

Even with the aid of technology, completing the project was still an arduous task. “I was able to keep running six CNC machines alone for most of four and a half months,” Andrusko said. “My day started at around 5 a.m. and ended at or near 10 p.m. Cutting hard stone requires a very attentive focus. Water supply is critical or there could be a fire, bit break, damage to the work piece, or at minimum a whole bunch of wasted time, so there was no practical way to run the machines all day every day as much as I wanted to or would have liked to. The machines needed to be monitored constantly and any instances of failure caught and corrected as soon as possible. I was often literally running and constantly on my feet moving between machines, changing parts out, swapping bits, clearing obstructed water lines and quickly became attuned to the sounds (healthy and otherwise) of each machine in the studio. I stopped keeping track of time, but it was a relentless grind of 14 to 18 hours a day, seven days a week, and other than a few hours for Thanksgiving and Christmas with family, it didn’t stop until I was done.”

 

The Installation

Andrusko gives the majority of the credit for the success of the installation to the project manager at Hoffman Construction Company and the installation team at Western Tile & Marble. “This was very much a team effort and the success of the whole was really a shared collaborative effort,” he said.

The installation, which was completed in about a month, required one stone mason and three tile setters. The team bonded the wall tiles to USG Corporation’s Durock Brand Cement Backer Board using Laticrete’s 257 Titanium thinset mortar, which is designed for the installation of large-format tiles and gauged porcelain tile panels and slabs. “Thicker carved stones were installed with Latapoxy 310 Stone Adhesive,” said Floyd Goodwin, project manager at Western Tile & Marble. “We used copper wire anchors into studs.”

Goodwin explained how the heavy, irregularly shaped tiles needed to be carefully installed to ensure flatness and desired joint thickness. “Maintaining joint dimensions and plumb was crucial because the carved stone had irregular edges and the substrate was wavy,” Goodwin said.

In addition to Laticrete’s 257 Titanium and Latapoxy 310 Stone Adhesive, the installation team also utilized Laticrete’s Permacolor Select cement grout and Latasil silicone sealant.

“They are truly professional craftsmen and I know they were also working under extreme stress and with a really tight schedule,” Andrusko said of the team. “They took my work and completed the site installation without a break or a scratch. I wasn’t needed onsite. There wasn’t a single punch list item related to the sculpture.”

Since the project’s completion, visitors have been amazed by the artwork and its resemblance to the original Winged Victory of Samothrace. “The client loves it,” said Goodwin.

The project received a 2018 Pinnacle Award from the Natural Stone Institute in the Architectural Carving/Lettering/Sculpture category. “One would assume the hope of any artist is to somehow imbue the breath of life into the inanimate; to effect in some profound way the beholder of the work,” Andrusko said. “That this now exists in the physical world where others can experience it makes me very happy.”

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How Artists Use Natural Stone to Create Timeless Sculptures https://usenaturalstone.org/how-artists-use-natural-stone-to-create-timeless-sculptures/ Thu, 13 Jun 2019 19:45:24 +0000 https://usenaturalstone.org/?p=6386 The beauty and versatility of natural stone are among the many reasons homeowners and builders gravitate to the material for their projects. Artists often are drawn to stone for similar reasons.

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How Artists Use Natural Stone to Create Timeless Sculptures

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The beauty and versatility of natural stone are among the many reasons homeowners and builders gravitate to the material for their projects. Artists often are drawn to stone for similar reasons.

My Comfort Clothes by Robin Antar. Limestone.

For artist and sculptor Sebastian Martorana, the challenge and beauty of the material was enough when he first began working with natural stone. “As I have grown, I now see natural stone as the best vehicle for the concepts that I want to explore,” Martorana admits. “Each stone, just like each sculpture, is unique. That cannot be said of anything that is cast or mass produced.”

Sculpture Robin Antar agrees.

In her abstract work, her challenge is to make heavy stone look like it is twisting, bending, and light. “I like the fact that it’s heavy and I can transform it into a sculpture which has movement and form so people don’t realize the weight of it,” Antar shares. “I also work to bring out the beauty of the stone in each piece, carving it in a way that showcases its natural properties.”

Her Realism in Stone series also transcends the weight perception. “I sculpted a pair of jeans in limestone,” she shares. “Nobody realizes it weighs 80 pounds—it just looks like a pair of jeans.”

Natural Stone Tells a Story

Permanent Separation Anxiety by Sebastian Martorana. Salvaged Beaver Dam marble. Photo by Geoff T. Graham.

Many of Martorana’s sculptures are made from salvaged material. In addition to the material’s geological origins and cultural association with memorial and permanence, each stone has its own specific history, which he appreciates and finds important.

“Where did it come from? What was it? When was it installed there? Why was it thrown away?” he asks. “Those answers inform each stone sculpture that I make.”

Even if the piece he uses wasn’t salvaged, where in the world it came from will be of significance to the completed work of art. It is rare for him to pick a stone at random for a sculpture as he always takes into account its individual story.

 

The Power of Natural Stone as a Form of Healing and Expression

As a sculptor, Antar is drawn to the subtraction process of carving and working with grinding tools. She also appreciates the challenge of taking an unworked, unpolished piece of stone that many might perceive as “dead” and make it come alive.

The Thinker by Robin Antar. Honeycomb Calcite. Photo by Morris Gindi.

Robin Antar, American sculptor, at work. Photograph by Morris Gindi.

The type of stone Antar uses depends on the mood of the piece since she says different stones give off different moods. She offers honeycomb calcite to illustrate her point. “It looks like candy in a way,” she explains. “And when I carve out figure shapes, it has a very different mood than white marble, for example. A sculpture in honeycomb calcite – a light, airy, glass-like stone – would have a completely different feeling than an opaque white stone like marble.”

Robin Antar with David’s Knot in Flames.

Sometimes she’s drawn to a type of stone because of the emotion she’s trying to express in the piece. Different emotions, different stones, she likes to say. When she created a piece to honor her late son, which she titled “David’s Knot in Flames,” she chose a 1,500-pound block of Turkish white marble with purple veins in it, her son’s favorite color and the “secret code” he whispered when life got hard and he needed her help. “If I had done that same sculpture in a honeycomb calcite, it would have had a completely different feeling,” she says, adding that working on that piece literally saved her life.

“Different textures can also create various emotions,” she adds. “The surface can be chiseled, polished, rough-cut.”

Jorge Vascano understands how Antar and Martorana when it comes to the visceral feelings associated with using natural stone to create works of art. He’s currently an artist-in-residence at the North American Sculpture Center (NASC), an annex of Precision Stone Inc. which has been serving the architectural and design community over the last 35 years. The NASC offers artists, trained and untrained, classes in traditional stone carving techniques, clay modeling, digital modeling, and digital fabrication.

Escombros by Jorge Vascano.

The stone Vascano chose to work with during a merit award sculpture residency in Carrara, Italy in 2017 was Bardiglio Nuvolato, a beautiful white and grayish stone full of veins.

“While I was sculpting, and revealing the forms of the sculpture, the natural attributes of the stone, such as the hardness, the way it would break, the inner colors, the smell, the sound when striking, the time it took and the physical demand [all] contributed to gradually see the sculpture differently,” he admits. “The nature of the stone was stimulating past experiences in my life, taking me to places in my mind I had not visited or considered in a long time.”

He began to see these visions in the stone slowly, as if the stone and the process were inviting him to go in a certain direction. He recalls the experience as beautiful because in those long hours of observation and understanding the stone, the material was allowing him to have a conversation with himself. “I felt the stone and its uniqueness were the vessel, the vehicle,” he adds. “At the end, the piece ended up having a way more intense feel that I initially anticipated.”

 

What It Means to Sculpt Using Natural Stone

Sebastian Martorana, sculptor and illustrator lives and works in Baltimore, Maryland.

Unseen by Sebastian Martorana. Montclair Danby marble. Photo by Geoff T. Graham.

Martorana likes to remind people that natural stone is a natural material, so the irregularity that comes with that should be expected and enjoyed. “If you want something that is going to be aesthetically consistent, you can find that in a cast material,” he says. “Natural stone can provide patterns within patterns that have been millions of years in the making. If you don’t appreciate that quality, then natural stone is not for you.”

Vascano feels artists are drawn to natural stone because it has a natural poetry. Unlike other types of material that can be used to create sculptures or art, he says using natural stone is completely different. For one, it’s hard and requires patience.

“You have to learn the feel of each stone to work with because each of them is different,” Vascano adds, noting that is also requires an understanding of how the material needs to be handled, while its composition and its physics also need to come into play in order to take advantage of the possibilities each stone has to offer as well as their limitations.

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Preserving a Sandstone Heritage https://usenaturalstone.org/sandstone-heritage/ Fri, 02 Nov 2018 17:40:56 +0000 https://usenaturalstone.org/?p=4594 Sandstone heritage lives on through the work of master stone carver Keith Phillips who uses traditional hand tools to carve stone at a modest workshop known as The Shed, he is passing on his skills to a new generation of Tenino stone carvers.

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Preserving a Sandstone Heritage

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Keith Phillips with Celtic cross.

The city of Tenino is a speck on the map of southern Washington. On a drive from Seattle to Portland, you’d probably miss it. But from the late 19th century well into the 20th, Tenino (pronounced Tah-NINE-oh) was known as the Sandstone Capital of the West. Builders from California to Montana kept its three quarries humming as they replaced scores of wood structures destroyed by fires with a stronger, more durable material. Tenino sandstone built the east wing of Washington’s first capitol building and Seattle’s first public library, as well as the Northern Pacific Railroad station in Missoula and churches and schools as far south as Stockton, California. The city’s own business district was lined with gracious sandstone buildings.

In the 1920s, the boom began to fade as builders switched to less expensive materials like brick, concrete, and steel. In what some considered the death blow, Tenino’s own school board chose brick over its native stone to build a new high school. The industry fell into decline and never recovered.

 

Bringing Sandstone Back

Bag of Groceries sculpture at Tenino Market Fresh Supermarket. Carved by Keith Phillips.

Though the industry is gone, Tenino’s sandstone heritage lives on through the work of master stone carver Keith Phillips, 71, who uses traditional hand tools to carve stone quarried from the last of Tenino’s three quarries. At a modest workshop known as The Shed, he is passing on his skills to a new generation of Tenino stone carvers.

Phillips’ handiwork can be spotted throughout the city—in a large mortar and pestle sculpture in front of the pharmacy, an elaborately-carved cross in front of First Presbyterian Church, and a whimsical sandstone bag of groceries next to the local supermarket. He started carving as a hobby in college after relatives gave him some Tenino sandstone. Later, he made stone fireplaces and did other small jobs. When a position as the quarry’s night watchman arose, he seized it, hanging around old-time quarrymen by day to gain pointers about cutting the stone. He learned carving by trial and error and through books.

Around the same time Phillips began receiving commissions for sculptures, the city started taking an interest in its history, commissioning restoration work on its old buildings. “I fell into a situation made in heaven,” Phillips said.

Ed Salerno carves Hard Candy sculpture.

His reputation spread and he soon had more work than he could handle. He has helped restore the state capitol in Olympia, buildings at the University of Washington, a historic museum in Oregon, a lighthouse, and many other buildings, as well as doing sculptures.

These days, Phillips gets help from Ed Salerno, who visited his studio a few years ago after seeing photos of his work at the city’s museum. A graphic designer, Salerno was intrigued by stone carving but had no experience.

Phillips taught him to carve leaves, then letters, and eventually, entire sculptures. “He built my confidence level, always pushing me toward the next thing,” Salerno said.

Dan Miller at The Shed.

“I shared with Ed as much as I could and he’s pretty much on his own now,” Phillips said. The two do projects together and separately, and recently collaborated on traditional “green man” and “green woman” carvings—faces surrounded by leaves—for a Tenino park.

Several years ago, Phillips and Salerno were joined by Dan Miller, who trained as a stone mason in his native England but had trouble finding work in Seattle, where he moved with his American wife. Impressed with a YouTube video showing Phillips making a sundial, he hunted the artisan down, and now works at The Shed two days a week.

“Working with Keith has changed my life,” Miller said. “It’s real stone carving and he’s a master mason. We’re passionate about what we do, and I can learn a lot from him.”

 

Keeping Traditions Alive

Though the carvers use electric saws and drills to break down the huge blocks of sandstone they get from the quarry, for restoration and carving jobs they use traditional hand tools, including a mallet, a chisel, a stone cutter’s framing square, and a compass. “It makes you appreciate how skilled the medieval masons were,” Miller said.

Ed Salerno, Dan Miller, Colby Russell, and Keith Phillips.

Softer and easier to carve than granite or marble, sandstone is well-suited to the old instruments. Though there are slight color variations, ranging from bluish-gray to tan, its texture is smooth and uniform. “It has the evenness of white bread, with no bumps,” Phillips said. “You can carve an angel’s face and it will come out with no blemishes.”

In addition to their carving and restoration work, Phillips and Salerno teach stone carving classes at The Shed. Salerno also has a new apprentice, 17-year-old Colby Russell, who is the great-great-great grandson of the founder of one of the local quarries. Like many of the city’s residents, Colby wants its sandstone tradition to live on. “Even if I don’t make carving a career goal, it’s something to hold onto for future generations,” he said.

“It’s important for young people to be exposed to traditional, age-old architecture,” Phillips said. “So many beautiful old buildings that should have been preserved have been torn down. That kind of thinking can change if there are more people like Dan, Ed, and me.”

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Recapturing the Lost Beauty of Stone at the Peninsula Paris https://usenaturalstone.org/peninsula-paris/ Wed, 27 Jun 2018 01:07:09 +0000 http://usenaturalstone.org/?p=4032 After an exhaustive 4-year renovation of The Peninsula Paris, the century-old building took a giant leap back to reclaim its rightful place among the city’s most impressive architectural structures.

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Recapturing the Lost Beauty of Stone at the Peninsula Paris

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After a four-year renovation, a historic hotel in Paris reclaims its place among the city’s most impressive buildings.

The Peninsula Paris is just steps from the Arc de Triomphe, but after an exhaustive years-long renovation, the century-old building took a giant leap back to reclaim its rightful place among the city’s most impressive architectural structures. And this being Paris, that’s saying a lot.

The six-story, 200-room luxury property re-opened its doors in 2014. A testament to the excruciatingly detailed nature of the restoration is that the original hotel took two years to build. Renovating it took twice as long.

The project was led by Paris-based restoration specialists Affine Design whose portfolio includes not only luxury hotels, but palaces. The firm’s mission is easy to grasp yet demands extraordinary mastery to execute: preserve the soul of a historic space by teasing out its stories and legends. In restoring the character of The Peninsula Paris, Affine Design aimed to give it a new architectural framework and context for fitting into its historical, geographical, and social roots.

A restoration project of this scope, expense, and scale is rare today. The structure was in rough shape. Multidisciplinary teams of restorers, artisans, craftspeople, gilders, and glazers—some 3,000 over the course of the renovation—were tasked with correcting poorly executed renovations and reversing years of neglect.

Original stone elements were badly damaged or caked in dirt. The façade had fallen into disrepair. Once-gracious moldings and design details were covered up behind false walls, partitions and ceilings. Affine Design officials characterized the modifications and alterations of the original building over its history as “brutal.”

The new façade used limestone from the very same French quarries in St Leu-la-Foret, Chauvigny and Comblanchien as the original structure, which opened as the Hotel Majestic in 1908. Twenty stonemasons from the monument specialist Degaine restored the area with intricate carvings of stone flowers, bows and ribbons. Each flower cascade took a single stonemason three weeks to complete. Wherever possible, missing pieces were carved by hand. In other cases, beyond-repair bas-reliefs were replaced with new stone sections, installed and hand-carved from scratch. Details were re-created from original documents and photos that were scrutinized and used as reference.

Fish scale-shaped roof tiles for the hotel’s towers were sourced from slate quarries in the Pays de la Loire region and fashioned by hand. Marble for columns was sourced near Campan in the French Pyrenees.

Affine Design, under the direction of its chief architect and founder Richard Martinet, worked with France’s heritage organizations including Les Architectes des Batiments de France, Les Monuments Historiques and La Commission du Vieux Paris to follow preservation protocols. Altering the building’s exterior, for instance, was forbidden. Many specialized teams came with a provenance having worked on heritage projects like the Louvre and the Palace of Versailles or international commissions involving the Statue of Liberty, the J. Paul Getty Museum in Los Angeles, and the Corcoran Gallery of Art in Washington DC. Some were family firms dating back generations.

When the hotel, built in the Second Empire style popular at the time, opened its doors for the first time last century, it immediately became the see-and-be-seen spot of high society. George Gershwin composed his classic “An American in Paris” here. It was also where the likes of Pablo Picasso, James Joyce, and Igor Stravinsky wined and dined. Between the first incarnation as Hotel Majestic and its current as The Peninsula Paris, the building was repurposed for a succession of uses. In 1936, it was sold to the French government and eventually converted to UNESCO headquarters. Later it transformed into an international conference center for the French Ministry of Foreign Affairs. No shortage of monumental events occurred under the ministry’s auspices, the most high profile of which was the signing of the Paris Peace Accords in 1973, which ended the Vietnam War. The space in now Bar Kléber.

From the start, the goal of the renovation was to blend new and old, to marry the limestone facades of the Haussmann style that makes the Parisian streetscape architecture so distinct with 21st century engineering feats and materials. The structure had to be reconstructed on a metal frame. The amount of steel used weighed the equivalent of five French high speed trains and the concrete used was equal to three times the weight of the Eiffel Tower.

Of the process, Affine Design’s Martinent once noted: “There was great joy in tearing down the ugliness and finding beauty underneath.”

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Elks National Memorial: A Spectacular Showcase of Marble from Around the World https://usenaturalstone.org/elks-national-memorial/ Thu, 03 May 2018 21:19:12 +0000 http://usenaturalstone.org/?p=3860 The stone monument incorporates 27 varieties of marble and has been considered “one of the finest marble installations in the United States” in a story published in Through the Ages trade magazine in 1926.

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Elks National Memorial: A Spectacular Showcase of Marble from Around the World

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When Chicagoans walk or drive past the stately Indiana limestone building located just a half mile west of Lake Michigan in the Lincoln Park neighborhood, they might wonder why the building is guarded by a pair of identical life-sized bronze elk. Little do they know that inside this circular building is one of the finest natural stone installations in the United States, featuring over twenty-seven varieties of marble.

Historic photo of the Elks National Memorial Headquarters Building.

The Elks National Memorial Headquarters Building was commissioned by the Benevolent and Protective Order of the Elks, one of the oldest and largest fraternal organizations in the United States, and dedicated to the memory of Elks who served in World War I. The monumental building, built in the classical Beaux-Arts style and based on the aesthetic and architectural design principles taught at the École des Beaux-Arts in Paris, was completed in 1926 and designed by Egerton Swartwout, best known for his work on monumental buildings and memorials, including the Missouri State Capitol.

We often focus on new buildings or remodeling projects and how to incorporate natural stone into the designs, but rarely do we pause to consider the beauty of structures that have withstood the test of time. Revisiting nearly century-old structures is a great reminder of natural stone’s sustainability and longevity.

When asked to discuss the style of the Memorial, architect Egerton Swartwout explained in a 1922 article of The Elks Magazine, “I might say it was classic, and more Roman than Greek; I would prefer to say it was modern, and that it was American.”

From the outside, the building looks dramatic and impressive. Walk through a 20-foot-high single arched bronze doorway and be ready for a visual feast. While many parts of the interior are of note, the crown jewel is Memorial Hall, which serves both the building’s main interior space and architectural focal point.

Memorial Hall: 27 Varieties of Marble from Around the World

The ground floor of Memorial Hall. Photo courtesy of Megy Karydes.

Memorial Hall soars to the total height of the building at 100 feet and the gilded dome above is remarkable, as is the marble found throughout the room, literally from top to bottom.

The space incorporates 27 varieties of marble and the National Association of Marble Dealers considered it “one of the finest marble installations in the United States” in a story about the building in its August 1926 trade magazine, Through the Ages.  From the marble floor to the second tier columns above as well as the 48 columns encircling the room and supporting the balcony, it’s like a showroom dedicated to marble from around the world.

“The basis marble,” wrote Swartwout in an issue of American Architect in the mid-1920s,

27 varieties of marble, as seen in the Memorial Hall.

“will be warmly tinted, slightly veined white marble, while the shafts of the columns are of the richly veined colored marble lighter in tone for the small order, as these columns are seen against the white marble background, Pavonazzo, Skyros, Cippolino, and five or six other varieties; and the upper columns are heavier and deeper in tone, Levanto, Tinos, Rouge Jasper, Verona, Alps Green. In the floor, which is a series of round and square panels, the same variety is followed. The coffered ceiling will be deep in tone and rich with color and gold and bronze figure in the niches should combine to make a very powerful but subdued effect.”

Sourcing Marble for Such a Grand Project

Sourcing the marble for such a massive space was no small feat.

A year and a half was spent securing, selecting and preparing all of the colored marbles used in Elks Memorial and the marble alone cost $578,000, according to the National Association of Marble Dealers 1926 article.

“Both color and soundness had to be carefully considered, as well as the size of the blocks and veining,” the article notes. “This marble installation affords a striking illustration of a fact that is frequently overlooked by the architect: that where any large work is in prospect, the marble should be ordered at least a year ahead, in order to allow time for the special quarrying necessary.”

Inside the Memorial Hall.

The marble was sourced from quarries throughout Austria, Belgium, France, Greece, Italy and the United States, including Vermont and Alabama. Beyond the gorgeous and striking marble columns, the walls around the rotunda and in the circular corridors, domes and some ceilings feature Eastman’s Cream marble from the quarries at West Rutland, Vermont. “This cream marble has a very soft texture that makes it suitable for intricate decorations and fine statuary and carving,” according to the article in Through the Ages. “Twenty-two thousand cubic feet of this particular material were required and in order to secure exact uniformity of tone, and the true cream color desired, it was necessary to take out two entire floors of the quarry — a total of about 150,000,000 cubic feet of marble.”

Yet, despite the size of the marble contract for this project, one mill handled the whole job.

At the time of its construction, few circular buildings had been built, save for the Pantheon in Rome and some smaller temples. “Because of the circular design, construction of the Memorial Hall was particularly difficult and called for extreme care, since all masonry, all brick and stone work had to be laid on a radius. Almost every piece of stone has a curved surface. The size of each piece was worked out, in advance, on the drawings, and each piece was numbered to correspond with its numbers on the plans. The manufacturing plant, at Carthage, Mo., where the stone was cut and finished, made every piece to fit into the mosaic as a whole, a job requiring the strictest accuracy,” according to The Elks Magazine article from July 1926.

The Elks National Memorial Headquarters Building may originally been dedicated to those who served in World War I but it’s since been re-dedicated to honor all American veterans serving in all later wars and conflicts. An enduring war memorial, it continues to exemplify fine craftsmanship with its use of luxurious building materials including limestone, marble, and bronze.

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Bringing Stone to Life: Why I Use Natural Stone https://usenaturalstone.org/bringing-stone-life-use-natural-stone/ Thu, 21 Dec 2017 18:41:53 +0000 http://usenaturalstone.org/?p=3490 Soapstone comes in a wide range of color combinations—browns, greens, greys, yellows, black speckles. Each type of soapstone has specific qualities, and each individual piece of stone has its own character.

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Bringing Stone to Life: Why I Use Natural Stone

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Soapstone. You can carve it using hand tools, and that is partly what drew me to it twelve years ago. Its beauty was another attraction: red, green, brown, grey, yellow, black, speckled patterns, and abstract veining, depending on what other minerals occur with it. It’s nice to work with, too: Soapstone is mostly composed of talc.

Choosing the Stone

These blocks of Brazilian and Canadian Soapstone show the difference between wet and dry color. Spraying water on the smooth surface helps you to see what the final colors will be, once the finish is applied.

Choosing the right stone is half the fun. I buy Brazilian soapstone at Stonebridge Imports, a stone distributor in Kitchener, Ontario. On a recent trip there I got to go out to choose stone from the big metal shipping container in their yard. Grey and brown blocks of soapstone were stacked on shelves along the container’s sides, and large soapstone boulders were piled in metal baskets across the floor. This time of year, the stone gets cold (and so do we!), so they bring it inside to special storage areas. What’s not to like about cavernous bays filled with shelves and bins of soapstone? The simplest way to see the colors is to spray the soapstone lightly with water (I call this “the beach pebble effect”). Brazilian soapstone comes in a wide range of color combinations—browns, greens, greys, yellows, black speckles. Each type of soapstone has specific qualities, and each individual piece of stone has its own character. It’s hard to decide what to choose, and it usually takes longer than I expect, but it’s always an afternoon well spent.  The large boulders are tempting, but I pass them by (with regret!) for smaller rough chunks and blocks, which are easier to transport and carve.

Searching for interesting Brazilian Soapstone at Stonebridge Imports in Kitchener, Ontario—a favorite road trip. Most importers or mines carry both blocks and rough chunks in various sizes.

I get Canadian Soapstone directly from Les Pierres Steatites, a soapstone mine south of Quebec City. Steatite is a traditional name for soapstone. The mine uses specialized tools for cutting blocks of soapstone directly from the rock face, so the quality of the blocks is high. Driving to the mine to buy the stone (20 hour round trip), would be hard to justify (although fun—maybe someday!), so I order online, and then it’s delivered to my door. There’s nothing like a stout box of soapstone to bewilder a delivery guy. Soapstone from this location is dense, and has subtle and elegant colors of medium to dark greens, sometimes dark grey. The new blocks are given a basic sanding, and then I run a damp cloth over the surface to get an idea of the colors and veining. This will help me decide what to carve, and how. The final carving will be enhanced by the beauty of the stone itself.

Carving the Stone

This is a typical setup for my workbench: sandbags, tools, dust mask. Unfinished carvings are nearby to switch to when I lose momentum with the current carving.

My home workshop in Port Rowan is dedicated to soapstone carving. Nature is my inspiration: turtles, ducks, owls, and other creatures at different stages of completion sit patiently on my workbench. Next to my sandbags and works-in-progress are hand tools with exotic names like half-round rasps, fishtail gouges, and rifflers. Along my workshop walls are blocks and pieces of raw soapstone on shelves and in milk crates, waiting to be transformed. Carving soapstone is very centering, and my mind calms and sorts itself while I quietly carve. A small carving gains warmth from your hands as you work with it, gradually developing its form: you could almost believe it has a life of its own.

After many hours of work and polishing, this Wood Duck, hand-carved from Canadian Soapstone, is ready to find a new home.

But a carving isn’t done until it’s sanded and polished, a process that can take hours of additional work, and days of drying. Sanding involves using several grades of sandpaper, then oiling the carving with many thin coats of oil. That first coat of oil is exciting—the true colors of the stone can be seen for the first time. Tung oil is my finish of choice: It is non-toxic, brings out the colors and veining, and gives the stone a lovely hand-rubbed patina.

Carving soapstone is a great way to spend the workday. Every day is inspiring, and I feel very fortunate to have the opportunity to work with this beautiful natural stone, and to create lasting works of art with it.

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An Education Carved in Stone https://usenaturalstone.org/education-carved-stone/ Mon, 09 Oct 2017 20:29:09 +0000 http://usenaturalstone.org/?p=3291 In a world of bytes and bites, the next generation of artisans is still studying with mallets and chisels and doing its part to carry over an ancient trade to another century.

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An Education Carved in Stone

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For most schools, establishing a campus in a former trolley barn would be enough to distinguish it from other colleges. But that’s not the real differentiator for the American College of the Building Arts (ACBA). The Charleston, South Carolina-based institution is the first in the country to offer four-year degrees in traditional craft specializations, including architectural stone carving.

An ACBA student carves a stone mantle. Photo courtesy of the American College of the Building Arts.

In a world of bytes and bites, the next generation of artisans is still studying with mallets and chisels and doing its part to carry over an ancient trade to another century. In training students, ACBA is helping to preserve America’s architectural heritage while elevating the stature of what some say is an underrated profession.

An early iteration of the school was as a nonprofit, offering a series of classes and workshops in response to the devastation left by Hurricane Hugo in 1989, a category four hurricane. By one account, more than 2,000 historic structures in Charleston alone were damaged or destroyed, and it immediately became clear the armies of trained artisans needed to handle the rebuilding and restoration in its aftermath were in short supply.

The program later evolved and expanded into a degree-granting college. Seven students made up the inaugural graduating class of 2009. For the better part of its young history, most classes took place at the Old Jail in downtown Charleston. Built in 1802 and decommissioned in 1939, the jail served as a training lab in which students studied restoration and preservation methods and put them into use on parts of the building itself. The school eventually outgrew the jail and last year moved into another historic structure, a renovated trolley barn.

Enrollment is small—roughly 20 full-time students. About half skew slightly older. “They’ve been and done something,” says Simeon Warren, an architectural stone carver, dean emeritus, and teacher. “They’ve figured out what they want to do with their lives and are now coming back.” Students hail from all parts of the country but they share a belief in the worth of the work and a passion for mastering the kind of skills that leave a lasting legacy, Warren says.

The American College of the Building Arts. Photo courtesy of Jason W. Kaumeyer.

ACBA offers six craft specializations including carpentry, timber framing, and architectural iron. Stone carving falls within the traditional masonry program, which provides freshmen and sophomores a foundation in the three subject areas of architectural stone, masonry, and plaster. Juniors and seniors then go on to specialize in one of the three preservation trades.

Students working in stone use largely the same methods and hand tools as those used in the original construction of Charleston’s 18th and 19th century buildings. They also master new techniques and technologies that have made the trade faster, more precise, and more efficient. Classroom and studio learning is supplemented with real-world experience by way of summer internships, both in the U.S. and abroad.

Students learn soft skills, too.  Stone carving is as much about patience, concentration, and critical thinking as it is about the ability to manipulate materials.

“You can’t rush through it,” says 2017 graduate Daniella Helline. “You have to take the time, get to know the material and learn how to use your tools the right way.”

Helline, originally from Rock Hill, South Carolina, was a senior in high school when she first toured the ACBA campus. “I fell in love with it. I wasn’t sure what I wanted to do. I’d always been creative, but I didn’t have any experience in any of the trades. I loved the fact that you could go to school where you did something with your hands every day,” she says.

Double infinity window inspired by Lincoln cathedral’s Bishop Eye. Designed by Simeon Warren and Cody James. Carved by Simeon Warren, Cody James, Daniella Helline, and Sam Friedman.

One class project Helline worked on is coming to fruition, the stone carving of a double infinity window, which will be installed in the ACBA library. The design was inspired by a large stained glass rose window called the Bishop’s Eye at the Lincoln Cathedral in England, where her British-born instructor Simeon Warren once apprenticed and Helline interned.

Ask Helline what goes through her mind while she’s stone carving and she doesn’t hesitate: “Don’t mess up. Carving is a reductive trade. You’re taking away material.

You can’t mess up because you’ll see the mistakes.”

As for the future, Helline has her sights set on the past. “I love restoration. I love old buildings and the idea of being able to keep buildings alive.” She’ll be doing that in Charleston, contributing to the preservation of the city’s historic building stock.

Helline is also part of a “cultural shift that recognizes the importance of the manual labor trades,” says Warren. “Until very recently, society assigned manual work less value. But we’re coming full circle.” Handcrafted is in. Maker industries are in. And the job outlook looks bright. Warren says, “We’re losing the last generation of artisans skilled at handling restoration of the country’s aging housing stock. If we train people to build quality new work and also conserve our historic fabric at same time, not only are we building structures that will become valuable, but we’re maintaining of the legacy of what we believe in as human beings.”

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