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NYC Townhouse Mock-up Ships from Boston Valley Terra Cotta

January 16, 2015 in Boston Valley ARCH Design Lab, NYC Townhouse by Tricia Herby

Just after the holidays, manufacture of the mock-up for the custom terra cotta rain screen system, designed by Michael K Chen Architecture for the NYC Townhouse, was laid out on the floor of Boston Valley’s warehouse. Prior to shipping, the mock-up was checked for glaze color conformance as well as profile tolerances. As displayed in the layout below, panels increase in height in either direction as they flow out from the center of the building (the right most column of panels in the photo is the “center”).

Michael Chen architecture, architectural terra cotta, boston valley terra cotta, NYC townhouses

Assembly of panels shows what the aggregation of the façade will look like

After months of planning and rendering, seeing the design come to life is exciting for the project team here at Boston Valley. For more information on the new building, check out the project’s page on MKCA’s website, and stay tuned for more updates as the project progresses by clicking here.

Michael Chen architecture, architectural terra cotta, boston valley terra cotta, NYC townhouses

Closeup of the panel shows the custom glaze color.

New Asian Center Turning Ringling Green

January 5, 2015 in #ConsiderTerraCotta, Ringling Museum by Nick Haas

Article originally appeared in the Sunday Herald-Tribune in Sarasota, FL on Sunday, January 4, 2015. Written by Susan L. Rife

STAFF PHOTOS / MIKE LANG
Workers hang green glazed terra cotta panels on the new Helga Wall-Apelt Center for Asian Art at the Ringling Museum of Art.

Three thousand handcrafted terra cotta tiles, glazed an iridescent green, are being painstakingly installed on the exterior of the future Helga Wall-Apelt Center for Asian Art on the campus of the Ringling Museum.

The tiles, made one at a time at Boston Valley Terra Cotta in Orchard Park, New York, weigh 60 to 70 pounds apiece, and are installed on a stainless-steel track and clip system.

…Bill Pottle, international sales manager for Boston Valley Terra Cotta, said the project is “all about how great buildings are built, a true collaboration with the architect, Boston Valley as the manufacturer, Steven High, even the board, working on the design and execution of the building in total.”

The building was designed by Machado and Silvetti Associates. Pottle said the green glaze color came from a magazine article Rodolfo Machado saw with a photograph of a man “standing in front of this magnificent 300-year-old fireplace and surround in green. ‘That’s the color I want,’ he said.”

Continue Reading the rest of the article here.

New Capitals for 250 Delaware Avenue Combine Old and New Fabrication Techniques

December 30, 2014 in #ConsiderTerraCotta, Delaware Court Building by Tricia Herby

Making components such as the pier capitals on the facade of the old Delaware Court Building shows the combination of old and new techniques involved in making highly detailed ornamental pieces. These, and many other intricate components involved in the replication of units for 250 Delaware Avenue have to be carefully and precisely detailed.

A point cloud scan of the facade (left) is used to extract a 3D model of the component (center) and then used to fabricate a final piece (right)

A point cloud scan of the facade (left) is used to extract a 3D model of the component (center) and then used to fabricate a final piece (right)

The process begins with taking a scan of the facade and then using that to make a CNC base file which will be used to create the plaster model and eventually, the mold.

File that was fabricated on the CNC router

File that was fabricated on the CNC router

It is apparent from the image the creation of the exact historic piece is twofold: the precise geometry is created by machine, and the handcrafted detail is added by skilled artisans. The plaster model is milled and additional clay is then sculpted onto this plaster base by the artists in the shop.

Finished capital on the production floor

Finished capital on the production floor

View of the detailed carving in the capital

View of the detailed carving in the capital

Follow this project along on our blog as it progresses, click here to see all of our posts on the Delaware Court Building.

Massive Terra Cotta Ornaments Revive Classical Style

December 17, 2014 in Boston Valley Terra Cotta by Tricia Herby

For the historic Tomochichi Federal Courthouse in Savannah, Georgia, restoration of the building has yielded large and intricately detailed pieces here at Boston Valley. The carefully sculpted ornamental brackets stand at around three and a half feet tall, and are fabricated with incredible detail, both in the ornamental sculpture and in the building attachment brackets.

Historic, architectural restoration, terra cotta, Tomochichi, Georgia

The scale and detail of these brackets make for a very imposing and impressive façade

Historic, architectural restoration, terra cotta, Tomochichi, Georgia

3D model of corner bracket

The Tomochichi Federal Courthouse was added to the National Register of Historic Buildings in 1974, and the entire façade is heavily ornamented. These pieces are going to be featured on the underside of the roof soffit. 129 single corbels and 12 corner corbels are currently in production

 Tomochichi Federal Courthouse, Savannah, Georgia, terracotta, architectural restoration, boston valley terra cotta

Many of these pieces are currently being made in the shop.

Roswell Park Clinical Sciences Center Features Terra Cotta Panels & Louvers

December 11, 2014 in TerraClad, Uncategorized by Tricia Herby

In the heart of the rapidly expanding medical campus of downtown Buffalo, NY, Roswell Park Cancer Institute is constructing an expansion of its own. The Roswell Park Clinical Sciences Center features custom terra cotta panels and louvers on its facade. The completed project will include 12,475 lineal feet of TerraClad™ louvers. Harmon, Inc. is panelizing and installing the facade units.

Roswell Park Clinical Sciences Center, Terra Cotta louvers, terraclad, Boston Valley Terra Cotta

Part of the completed portion of the facade
Roswell Park Clinical Sciences Center, Terra Cotta louvers, terraclad, Boston Valley Terra Cotta

Closer look at the ribbed terra cotta panels with corresponding airfoil louvers.

The 11-story building is currently under construction, right next to the existing Roswell Park Cancer Institute main building. More information on the expansion can be found at the Roswell Park website.

With the steel frame completed, 3 stories of the building are already clad

 

 

Custom Glaze on 59th Street & Columbus Circle Station, NYC

December 5, 2014 in Uncategorized by Tricia Herby

If you travel using the subway system in NYC, be sure to look around you while passing through the station at 59th Street and Columbus Circle. Three years ago the terra cotta adorning the walls of this station was cleaned, repaired and restored, revealing some of the most detailed and interesting terra cotta originally produced by the Grueby Faience Company. William H Grueby founded his company in 1894 in Boston, MA; it specialized in the production of ceramic vases, architectural terra cotta and faience tiles.

Grueby’s fame spread and his work became world-renowned upon his development of a matte green glaze which became his signature finish. Boston Valley Terra Cotta’s R&D Glaze department was tasked with replicating this matte green glaze for our restoration of approximately 60 blocks. Three years after completion of this project our work still looks great!

Columbus Circle, NYC, custom glaze, terra cotta, boston valley terra cotta

This tile depicting a ship at sea is one of the most recognizable features of the work in this station.

Columbus Circle, NYC, custom glaze, terra cotta, boston valley terra cotta

Bas-relief details in terra cotta units with the famous Grueby matte green glaze.