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"The Maintenance and Repair of Cast Iron" an Historic Preservation Brief January 9, 2009


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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 addition to these exterior uses, many public buildings display magnificent exposed interior ironwork, at once ornamental and structural. Remarkable examples have survived across the country, including the Peabody Library in Baltimore; the Old Executive Office Building in Washington, D.C.; the Bradbury Building in Los Angeles; the former Louisiana State Capitol; the former City Hall in Richmond; Tweed Courthouse in New York; and the state capitols of California, Georgia, Michigan, Tennessee, and Texas. And it is iron, of course, that forms the great dome of the United States Capitol, completed during the Civil War. Ornamental cast iron was a popular material in the landscape as well, appearing as fences, fountains with statuary, lampposts, furniture, urns, gazebos, gates, and enclosures for cemetery plots. With such widespread demand, many American foundries that had been casting machine parts, bank safes, iron pipe, or cookstoves added architectural iron departments. These called for patternmakers with sophisticated design capabilities, as well as knowledge of metal shrinkage and other technical aspects of casting. Major companies included the Hayward Bartlett Co. in Baltimore; James L. Jackson, Cornell Brothers, J. L. Mott, and Daniel D. Badger's Architectural Iron Works in Manhattan; Hecla Ironworks in Brooklyn; Wood & Perot of Philadelphia; Leeds & Co., the Shakspeare (sic) Foundry, and Miltenberger in New Orleans; Winslow Brothers in Chicago; and James McKinney in Albany, N.Y.

Cast iron was the metal of choice throughout the second half of the 19th century. Not only was it a fire-resistant material in a period of major urban fires, but also large facades could be produced with cast iron at less cost than comparable stone fronts, and iron buildings could be erected with speed and efficiency. The largest standing example of framing with cast-iron columns and wrought-iron beams is Chicago's sixteen-story Manhattan Building, the world's tallest skyscraper when built in 1890 by William LeBaron Jenney. By this time, however, steel was becoming available nationally, and was structurally more versatile and cost-competitive. Its increased use is one reason why building with cast iron diminished around the turn of the century after having been so eagerly adopted only fifty years before. Nonetheless, cast iron continued to be used in substantial quantities for many other structural and ornamental purposes well into the 20th century: storefronts; marquees; bays and large window frames for steel-framed, masonry-clad buildings; and street and landscape furnishings, including subway kiosks.

The 19th century left us with a rich heritage of new building methods, especially construction on an altogether new scale that was made possible by the use of metals. Of these, cast iron was the pioneer, although its period of intensive use lasted but a half century. Now the surviving legacy of cast-iron architecture, much of which continues to be threatened, merits renewed appreciation and appropriate preservation and restoration treatments.


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