September 17, 2014 in #ConsiderTerraCotta, Boston Valley ARCH Design Lab, Boston Valley Terra Cotta by Boston Valley
The Excelsior Hotel in New York, NY is a landmarked building on the Upper West Side overlooking the American Museum of Natural History and the Rose Center for Earth and Space. Boston Valley is working to restore its stately exterior using our digital modeling and 5-axis routing capabilities.
The basic form of the column capital in the photo below was routed in plaster and our craftsmen subsequently carved the detailed scrolls and leaves onto the form with clay and plasticine. This reduced the time required to produce this mold.
The original terra cotta blocks atop the Excelsior Hotel.
Our use of Rhino on this project has assisted in understanding how the complex units such as engaged columns fit into the facade, or the sculptural quality of the decorative shield panels at the window spandrels.
A 3D assembly drawing of the window surround
Engaged column condition with water table
August 28, 2014 in #ConsiderTerraCotta, Boston Valley ARCH Design Lab, Carmelite by Boston Valley
The Carmelite Monastery of St. Louis, Missouri will be receiving newly restored custom twisted columns. The 16 unique supports are currently being manufactured here in Orchard Park by Boston Vally Terra Cotta.
Column assembly, cornice and base.
This project was the first of its kind here at Boston Valley Terra Cotta. The project has been bid entirely for our new 3-D software and machining processes. To preserve the existing structure, the columns are split in half and will be assembled on site. The team did this in such a way that there are as few custom column sections as possible. This reduces machine and manufacture time, increasing factory throughput.
Twisted column, split into 4 components.
Take a look at this short clip of the 5-Axis CNC Router in full 5-Axis action on a twisted column section:
CNC model of column base assembly @ Boston Valley Terra Cotta.
August 22, 2014 in #ConsiderTerraCotta, Delaware Court Building by Boston Valley
Boston Valley has received glaze color approval for the 250 Delaware Avenue project from the project’s architectural firm Diamond Schmitt and owner Uniland Development. The white satin glaze will be used on all terra cotta blocks, returning this building to its original finish. Previously, the blocks had been repaired and painted numerous times throughout their years of service.
Mock up for color approval of 250 Delaware Project
The glazed blocks shown in the mockup (above) will be part of a column assembly. This assembly surrounds the windows and doors on the first two stories of the newly constructed building.
250 Delaware Project: 3D drawing of the mock up units.
Base detail of 250 Delaware Project.
Column and base detail of the 250 Delaware Project.
See more posts here (or select “Delaware Court Project” from the ‘Projects” menu to sort your view) to follow along with the progress of the 250 Delaware Avenue project.
August 18, 2014 in #ConsiderTerraCotta, Museum Project, Ringling Museum by Tricia Herby
Executive Director Steven High, Erin Christy (Director of Planned Giving), Cliff Walters and Susie Walters from the John and Mable Ringling Museum of Art accompanied Rodolfo Machado and Craig Mutter from Machado and Silvetti Associates to Orchard Park, NY to visit Boston Valley Terra Cotta. In addition to touring the plant, the group was updated on the progress of units being manufactured for the new addition to the Ringling Museum of Art called the Center for Asian Art.
The Ringling Museum project team poses for a photo with BVTC’s Bill Pottle, project lead Jim Smokowski & John Krouse (far right).
The visitors got to see first hand the combination of technology and craftsmanship being employed by Boston Valley to manufacture their facade units. The project was modeled in Rhino, models were carved on our CNC machine and are being hydraulically pressed on our RAM press or alternately will be slip-cast in the coming weeks. See more about the project here.
National Sales Manager Bill Pottle (right) shows off the mock-up wall for the new addition.
Rodolfo Machado (center) inspects the block precision and glaze.
August 12, 2014 in #ConsiderTerraCotta by Boston Valley
Fresh From The Kilns
The fully-glazed antefix units for the Department of Justice roof have just made it out of the kilns on their last firing cycle. These are for the Robert F. Kennedy Department of Justice Building in Washington, D.C.which is the headquarters of the United States Department of Justice.
The 114 units underwent four different glazing and firing cycles. The different glazes finishes were all hand applied throughout four firing cycles. Different firing temperatures were used to ensure the gloss finish glazes would not run into each other and so that the gold finish would properly adhere. Now these beautiful pieces are on their way to Washington to be installed as part of a re-roofing project.
August 7, 2014 in #ConsiderTerraCotta, Northeastern University by Boston Valley
Fabrication of the massive blocks that will adorn Northeastern University’s Hastings Building in Boston, Massachusetts is finishing and the first crates are packed for shipping. This project features some of the largest block we’ve ever made at Boston Valley.
The project began when Northeastern University bought the Hastings Building from the local YMCA with plans to turn it into student housing.
Inverted Water Table Mock-up.
These massive block measure just under 4 feet long.
Floral detail on blocks of Northeastern University’s Hastings Building.
Read more: Mammoth Units Recreated in Boston Valley’s Mold Shop.