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"The Maintenance and Repair of Cast Iron" an Historic Preservation Brief November 21, 2008


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The Maintenance and Repair of Cast Iron

John G. Waite, AIA
Historical Overview by Margot Gayle
The Maintenance and Repair of Cast Iron

What's in this article



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Introduction

What is Cast Iron?

Maintenance and Repair

Types of Deterioration

Condition Assessment

Cleaning and Paint Removal

Painting and Coating Systems

Caulking, Patching, and Mechanical Repairs

Duplication and Replacement

Dismantling and Assembly of Architectural Components

Substitute Materials

Maintenance

Summary

Selected Reading

Acknowledgements


Return to the Knowledge Base

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In 1849 Bogardus created something uniquely American when he erected the first structure with self-supporting, multi-storied exterior walls of iron. Known as the Edgar Laing Stores, this corner row of small four-story warehouses that looked like one building was constructed in lower Manhattan in only two months. Its rear, side, and interior bearing walls were of brick; the floor framing consisted of timber joists and girders. One of the cast-iron walls was load-bearing, supporting the wood floor joists. The innovation was its two street facades of self-supporting cast iron, consisting of multiples of only a few pieces--Doric-style engaged columns, panels, sills, and plates, along with some applied ornaments. Each component of the facades had been cast individually in a sand mold in a foundry, machined smooth, tested for fit, and finally trundled on horse-drawn drays to the building site. There they were hoisted into position, then bolted together and fastened to the conventional structure of timber and brick with iron spikes and straps.

cast-iron mausoleum and fence
The Slatter Family Tomb in Mobile, Alabama, consisting of a cast-iron mausoleum and fence, exhibits the wide range of uses of the material in the 19th century. Photo: Jack E. Boucher, HABS Collection.

The second iron-front building erected was a quantum leap beyond the Laing Stores in size and complexity. Begun in April 1850 by Bogardus, with architect Robert Hatfield, the five-story Sun newspaper building in Baltimore was both cast-iron-fronted and cast-iron-framed. In Philadelphia, several iron-fronts were begun in 1850: The Inquirer Building, the Brock Stores, and the Penn Mutuai Building (all three have been demolished). The St. Charles Hotel of 1851 at 60 N. Third Street is the oldest iron-front in America. Framing with cast-iron columns and wrought-iron beams and trusses was visible on a vast scale in the New York Crystal Palace of 1853.

In the second half of the 19th century, the United States was in an era of tremendous economic and territorial growth. The use of iron in commercial and public buildings spread rapidly, and hundreds of iron-fronted buildings were erected in cities across the country from 1849 to beyond the turn of the century. Outstanding examples of iron-fronts exist in Baltimore, Galveston, Louisville, Milwaukee, New Orleans, Philadelphia, Richmond, Rochester (N.Y.), and especially New York City where the SoHo Cast Iron Historic District alone has 139 iron-fronted buildings. Regrettably, a large proportion of iron-fronts nationwide have been demolished in downtown redevelopment projects, especially since World War II.


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