Portland Brownstone was used in 1848 to build this cathedral, and again in 1862 and 1888 to construct its twin towers. It’s lavish gothic ornament began to delaminate and repairs have been ongoing throughout its life. Replacement of the east façade porticos and stairs was executed using St Bees sandstone and red granite. Old World stone fabricated the ornate sandstone detail in 11 months. Over 845 cubic feet of sandstone was replaced.
Designed in 1921 by Ralph Adams Cram in his signature Collegiate Gothic style, it was built by the university between 1924 and 1928. The chapel seats almost 2000 people. As part of a major restoration project in 2000 through 2002, Old World Stone produced over 200 Gothic pinnacles and finials, based on original samples and drawings. Matching Indiana buff limestone was used. Our saws were used to profile the overall shape, while hand carving added the detailed floral motifs.
In June of 1997 lightning struck the 210’ west spire of this French Gothic styled cathedral basilica. It required immediate attention to dismantle and rebuild the precariously hanging stone. Old World Stone hand carved 120 crockets and ornate elements for the spire. Twenty years later we are back, carving replacement stone for both spires and other areas of the cathedral. This time we are using 3D scanning and robotic milling to get the job done. Click on photos to enlarge.
The church was designed in the English Gothic style by architects Hewitt and Brown. They modeled it after Ely Cathedral, in England, which is famous for its octagonal tower. Construction was completed in 1916. In 2016, the congregation embarked on a capital campaign to restore their building. Replacement of some damaged tracery window stones was included in their scope of work. Partial replacement of a window is extremely difficult because the new stone must align exactly with the old. The unusual construction technique includes a mild steel armature and a plaster interior profiled finish on the tracery. Old World Stone utilized their 3D scanner and robotic milling technology to replicate the damaged units and ensured a perfect fit in the end. The stone is Indiana buff limestone.
Thirty tracery windows were replaced as part of a multi-phase exterior restoration project at Lehigh University. Built in 1887, the mason used a local sandstone with shallow bed heights. To compensate, the stone cutters turned the stone on its face. Within a few short decades the stone delaminated. Numerous patching attempts failed over the years and further delamination occurred. To permanently correct the problem, Wallace sandstone from Nova Scotia was fabricated to match the original geometric configurations. It is a durable stone with high beds which closely matches the original colour. CNC profiling and hand finishing are ongoing. The west front window was the last major window to be completed. We used our 3D scanner to record the irregular geometry so that we could replicate the details to fit the masonry opening and the stained glass. The chapel is listed on the National Register of Historic Places.
Interested in the stained glass related to this project? See Beyer Studio, Architectural Stained Glass
The wind blows hard across the plain in Oklahoma. A weather event, known as a micro-burst impacted the building and caused the west window to bow inwards 16 inches. The resulting deflection caused every unit of the stone tracery to crack or fracture. It all had to be replaced. Interior scaffolding and protective wood hoarding were installed while the glass and stone tracery were removed. We scanned the geometry and profiles of the tracery window while it was still in place and used robotic milling and CNC routing to cut the replacement tracery window. The stone carvers in our banker masons' shop completed the final finishes and hand-cut details.
We are now beginning work on Phase Two of this project, which is the replacement of the south window, also damaged during the micro-burst. Scanning of the tracery window, still in place, has just been completed. Please check back to view our progress!
Interested in the stained glass related to this project? See Associated Crafts - Willet/Hauser Architectural Glass