Masonry Magazine May 2004 Page. 39
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May 2004
Masonry 37
"On the existing structure, some stones are rock-faced and some are of a more medium texture," says Caputo. "It was important also that we specify that the texture matched with that of the existing stonework."
Because the stones on the nave and educational structure are laid in a three-course, random-ashlar pattern, trim size was also an issue.
"In laying the rubble pattern, it was important that none of new stone was of a different height than that of the three heights of stone in the existing building," says Caputo.
He also adds that length conventions also had to be maintained, and cut-stone ends finished so they would chamfer back to the mortar joint in the manner of the original building.
Matching Mortar
ACHIEVING A GOOD MORTAR MATCH was also necessary in meeting the design vision for the new building. After substantial experimentation, a hand-mixed mortar, as opposed to a pre-mixed variety, was selected because of the control over pigmentation it afforded.
sestone and mortar were carefully selected achieve a match between that of new tion and existing structure.
"I believe we had to erect seven samples before we had a suitable color match," relates John Daniels, Project Foreman with Albert Wendt Construction, Glen Ellyn, III. "We had to steer away from pre-blended material and go with a Portland, lime and sand mix with a pig- ment die."
The solution, in Caputo's estimation, cured very nicely. "If the mortar would not have matched, the building's stone would have had a very different look. It was important that we achieved that natural color," he says.
While much of the stone arrived from the quarry already cut, lengths of stone were cut at the job site using a stone splitter. Also during construction, a team of seasoned masons used hand tools to trim stone and a special chisel to cut pitches.
"I was very fortunate to have the crew that I did for this par- ticular project," remarks Daniels. "All of the men on the crew were regular employees of Wendt Construction who have been with us for several years."
Due to the challenges presented in achieving appealing scale, fitting design detail and scrupulous stone application, Caputo's final thoughts were that the project was an excellent experience. "It really was a neat project to work on," he says, and the result, "is a wonderful enhancement to the context it's in."
Barbara Dutton is Communications Coordinator with Williams Architects and Williams Development, Carol Stream, III. She holds a B.A. in Journalism from Northern Illinois University, Dekalb, lil, and is currently working to attain an A.A.S. in Historic Preservation at the College of DuPage, Glen Ellyn, Ill She may be contacted at (630) 221-1212.
The Voice of the Mason Contractor