A NEW ECONOMICAL TERRA COTTA FACING FOR COMMERCIAL BUILDINGS
Ceramic Veneer is architectural terra cotta in the form of extruded square or rectangular ashlar slabs from lgin. to 2in. thick, weighing approximately 12h to 13 lbs. per sq. ft. glazed to selected colours and applied to the building facade by approved new fixing methods; it is an outstanding, permanent, first grade building product.
This new development in the manufacture of Terra Cotta Faience can be associated with the standard 4in. thick Hand Pressed Ware (weight approximately 26 lbs. per sq. ft.) which remains the recognised method of producing ornamental and special shapes other than Ceramic Veneer ashlar slabs and plain moulded sections.
Ceramic Veneer is manufactured from “de-aired” clay—a new process of production—which when burnt gives a very dense body. The clay is extruded through a die or pattern, during which process the blocks are dove-tail grooved at the back and later prepared at the top and bottom with slots for cramps.
Before glazing and burning, the blocks are machine surfaced to give a true face. The glazing to the desired colour and finish and burning follow the regular manufacturing process for architectural terra cotta.
A wide range of permanent, brilliant lustrous or matt glazed colours is available that will not fade nor discolour, and can be kept clean and bright by the simple process of washing down.
No colour can be too cheerful— no tone too bright for reproduction on Ceramic Veneer. The exceptions are Bright Red and Vermilions, the reproduction of which present difficulties to the Ceramist.
For ornamental pieces and special shapes that do not lend themselves to extruded manufacture, hand pressed ware is used. Decorative and ornamental effects on the plain surface of Ceramic Veneer are, however, made possible by the innovation of stencilled coloured decoration.
Manufactured at a heat which would destroy most materials, Ceramic Veneer is fire-resisting to the highest possible degree.
Ceramic Veneer provides a water-proof facing; the glazed face of the ware (actually glass) is impervious to moisture and will not absorb dust or grime. Any deposited surface film is not of a permanent nature and can be readily cleaned off, thus saving the cost of regular painting associated with many facing materials.
Ceramic Veneer can be used to provide architectural or colour interest in conjunction with stone, brick, stucco and other facing materials.
Plain string courses or moulded sections of any extent can be exextruded. (See illustration of typical shapes on page 7.)
Ashlar blocks 9in., lOJin., 13£in. and 16in. in height (including joint), either square or rectangular, to a maximum length of 21in. are standard sizes.
Any variation from these standard sizes such as rounded arrises, glazing other than on the face, returns to reveals, cills, mouldings, etc., are priced at special rates.
The setting or application of Ceramic Veneer to a building facade follows a sound constructional, quick and effective method as illustrated in the “Fixing Details” on the next page; this setting method has been provisionally approved by the Melbourne City Building Authorities. (For further particulars see Specification on page 6.)
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COP PEIL T - HÄNG
I S O HI FT III C SECTION of STANDARD SETTINGS FOR CONCRETE WALLS
SECTION OF SETTING FOII
SECTION OF RED CONCRETE WALL
F. S. SECTION SOFFIT JOINTS
The facing of the building, except as otherwise specified, will be of machine extruded terra cotta Ceramic Veneer to standard thickness of lgin. to 2in. and in approved selected glaze finishes.
All terra cotta to be well burnt, free from cracks, winding or other defects.
Any pieces of terra cotta, which, in the Architect’s opinion, are defective, shall be removed from the job, and the Contractor is to notify the Manufacturer that such pieces require replacement.
The terra cotta veneer shall be manufactured w i t h requisite grooves on back of blocks to ensure adhesion to cement compo bedding on wall. Blocks shall also be provided with grooves in edge to receive copper cramp-ons or wire ties.
All work shall be accurately set out and fitted by the Manufacturer before despatch to the job. Drawings
Drawings indicating exact location of terra cotta units by means of numbers identifying same, will be prepared by the Manufacturer and copies of such drawings are to be supplied to Architect and Con-traetor.
All blocks broken in transit are to be replaced free of charge. Any pieces damaged subsequent to delivery to job and requiring replacement, are to be immediately notified to the Manufacturer, who will supply additional pieces at the Contractor’s expense.
The terra cotta, after delivery to job and whilst awaiting setting, must be protected from damage by stacking on wooden laths or sacking and covering with bagging.
The Contractor shall arrange to construct boxing or formes for concrete structural walling or piers so that continuous horizontal chases or recesses 4in. wide and lin. deep shall be provided at centres to suit courses and at not more than 18in.
centres when formes are stripped. The rebate to be splayed on the top to facilitate forme stripping, but must be sharp and unbroken at the base.
Note: The concrete superstructure walls will present an improved surface for the keying of Krout hacking to Ceramic Veneer, if a slurry of cement and fine screenings is dashed on the concrete prior to the attachment of the Veneer.
Allow for building in concrete superstructure walls f^in. diam. galvanised wire, loop anchors at approximately 12in. and not greater than 16in. centres of terra cotta blocks horizontally and approximately 24in. centres vertically. Loop anchors are to be placed in concrete structural walls and free end is to project lain, from face of concrete.
Jin. mild steel vertical pencil rods at centres of terra cotta blocks up to 16in. in width and 2 rods to each block over this width shall be passed through projecting loop of galvanised anchors and be kept iin. out from the face of structural wall.
Each terra cotta block is to be secured to grout backing by means of 20-gauge copper cramp-ons turned up and down into slots in edge of the blocks (2 cramp-ons to each block where blocks are over 16in. in length); the opposite ends of such cramps are to be similarly turned up and down and anchored into grout backing behind terra cotta.
Such copper cramps will be supplied by terra cotta manufacturer at 17/6 per 100—averaging 10 to sq. yd.
Cramps are to be tied with No. 8 copper wire to vertical pencil rods.
The backing up of the terra cotta shall be composed of compo to the proportion of not moi'e than la parts sharp washed sand, 2a parts clean fine sand to 1 part cement, the mix being integrally watei'-proofed by the introduction of an approved water-proofing liquid in the exact proportions
specified by the manufacturer. This compo shall fill all voids and be tamped in with a rod or lath.
Where it is necessary bolt to concrete, where shown, galv. mild steel angles for the support of terra cotta spanning window or other openings.
All mild steel should be dipped in pure hot bitumen before fixing on job.
Angles spanning openings are to have slotted holes to receive lin. diam. hangers supporting soffit blocks.
Additional fixings for support of deep soffits to openings shall be provided in the form of Jin. diam. continuous rods tied to -jin. galvanised ties suspended from concrete beam. Similar ties are to be passed around iin. diam. pins at joints in terra cotta blocks.
The Contractor shall properly set all the terra cotta veneer in strict conformity to the setting details. All ware is to be thoroughly well wetted before setting.
Beds must be solid and all sides and cross joints filled solid with mortar composed of 3 parts sand to one of cement. Joints shall be iin. thick and shall be finally pointed up with a hard fill waterproofed mortar pointing paste, coloured to desired tone, to a depth of at least iin. Weatherings of large projecting surfaces to have joints pointed with an approved mastic caulking compound of selected colour.
Scaffolding and Centreing
General scaffolding, centreing, wedges, timber supports to soffits and arches and haulage shall be supplied and/or erected by the Contractor.
Uncompleted work shall be protected by boarding or bags and care must be taken that all arrises, cills and angles are protected against damage following setting.
At completion of work, remove all scaffolding, centreing and supports and clean down terra cotta with soap and water.
This colourful range of stock Ashlar Units and Moulded Sections shows the adaptability of Ceramic Veneer to meet every whim of the Designer.
• STRAIGHTFORWARD SETTING
•SECURITY OF ATTACHMENT.
• PERFECT ALIGNMENT.
The photo clearly illustrates grooves in structural walls ensuring definite keying of Veneer to building. The grooves also act as shelves which check settlement of the facing medium. Notice also vertical pencil rods fastened to concrete walls with wire loop anchors, and the copper Crampons attached to pencil rods.
Examelled Face Bhicks
Enamelled Face Bricks have found a ready place in modern Architectural Construction.
Primarily, they are made to bond with
common bricks as a backing on buildings
where weight is of secondary importance. \
As a structural unit they impart greater
strength to the walls of a building.
Enamelled Face Bricks are composed of a similar clay body and glaze as Architectural Terra Cotta. The standard brick is 9sin. x 4iin. x 3Ain:; it is glazed on the stretcher or the header face. Standard specials in the form of Quoins and Bullnose are also available and other special shapes can be made to order.
The many standard colours that are available—a few of which are illustrated—offer to the architect an unlimited scope for variety of treatment. Finished either smooth or matt textured in any of the plain, mottled or pulsichrome colour effects, the glazed surface of the brick cannot collect or absorb the dirt or grime of the atmosphere.
Enamelled Face Bricks are unexcelled in quality and durability; they cannot scale or discolour even under the severest climatic conditions. Tests of the lighter colours have established that when used on the exterior of buildings, they increase the light at street level by as much as 200 per cent, over darker materials, and that for flood lighting or night architecture they offer amazing possibilities. White glazed enamelled bricks were successfully used for the walls of the light area of the City Mutual Life Assurance Society’s Building, Sydney.
In addition to their use as a complete facing unit, these bricks afford unlimited scope as a trim or decoration to spandrels, piers and band-courses, etc. Other applications embrace linings to corridors, shopfronts, counters, light areas, bakeries and power stations; and indoor and outdoor swimming pools; for the latter purpose in conjunction with Architectural Terra Cotta life rails and scum trough.
Adelaide - Brisbane -
Hobart - Launceston
12th October, 1939.
"WUNDERLICH” CERAMIC FACING.
A copy of our Brochure featuring ’’CERAMIC FACING” — a new Architectural Terra Cotta development — has been mailed to you.
CERAMIC FACING is a colourful, permanent medium for facing the exterior and interior walls of modern buildings. It combines the attributes of colour and permanence with sound economy and a new ingenious constructional method of fixing.
Briefly, the outstanding features of CERAMIC FACING are
as follows :
It is manufactured in the form of square or rectangular ashlar units ranging in course heights from 10” to 17” and lengths of a maximum of 20”, and is finished with a glazed surface of any of the wide range of Terra Cotta permanent colours in plain or pulsichrome effects.
The actual method of manufacture is new. The units are extruded through dies in 4” thick hollow blocks. These blocks, after being glazed on both sides and "burnt”, are split in two; the resulting units are facing slabs 2” thick, glazed on one side with the reverse side ribbed for setting or fixing purposes.
The new setting or fixing method is illustrated on pages 4 and 5 of the Brochure, and whilst an ingenious method, has proved to be economical from the viewpoint of cost. The method embraces :
1. 4” r 1” sunk grooves in the concrete or brick structural walls at course heights.
2. Copper (preferably) or Galvanised wire anchors are built into the structural wall as the work proceeds, to take the vertical pencil rods.
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3. Half inch (£") diameter steel pencil rods are placed through the anchors, approximately from the face of the wall, and at the centre of each slab.
4. Copper crampons are inserted in the grooves at the top and bottom of each slab and wired back to the pencil rods.
5. The ribbed backs of the slabs are grouted and the slabs cemented to the wall.
These fixing methods result in the facing slabs forming an integral part of the main walling.
CERAMIC FACING, in addition to flat ashlar units, also embraces simple mouldings end flutings. Ornamental modelled shapes must
still be made by the "hand pressed" process.
As well as for entire facade treatment, CERAMIC FACING can be effectively used to emphasise dominant architectural features, for shop front trim, interior glazed ashlar walling, fireplace surrounds etc.
Our technical staff will gladly supplement the information contained in the brochure and submit estimates and details for CERAMIC FACING be the requirements large or small.
Noting that modern Architectural design relies mainly on the grouping of plain masses and the presentation of colour to gain desired effects, CERAMIC FACING is presented as a modern building material that offers a wonderful field to those interested in perpetuating ideas of form and colour harmony as applied to Architecture.
(Sgd.) J. GRAHAM
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