Rusticated concrete block

Last updated
Rusticated concrete block is used here to mimic the appearance of rusticated natural stone. The pattern on each block is identical. The Veillard House.jpg
Rusticated concrete block is used here to mimic the appearance of rusticated natural stone. The pattern on each block is identical.

Rusticated concrete block is the handmade product of in-field advances in cement making. [1] These concrete blocks first appeared in the late 19th century and are used mainly in residences and small building construction and are meant to resemble rusticated stone blocks. Rusticated concrete block involves a rough surface with a carved bevel detail around the edge of the face of the block. [2] The rough texture of the face is created by running the concrete across a cast-iron face plate or by using a plaster mold taken from a cut stone block. [3] This process of texturing concrete block was streamlined by an inventor named Harmon S. Palmer who created a machine that combined the processes of texturing and forming the concrete blocks. Palmer's integration of the rusticated concrete block forming processes allowed for the material to gain national notoriety and led to its eventual inclusion in the Sears kit homes. [1]

Contents

History

Due to its low cost, concrete was a popular replacement for stone as a structural building element. [2] As a building material, concrete was historically consigned to unseen structural positions such as behind a veneer or in the basement, but evolutions in texturing technology produced concrete blocks that could perform aesthetically as well as structurally. [4] Rusticated concrete blocks, often referred to as rock-faced concrete blocks, from then on were seen as a cost-effective substitute for natural faced stone and from a reasonable distance could pass for the real thing. [2] These rock-faced blocks were valued not only for their low cost but also for their natural fire resistance, sound absorption, and energy efficiency. [4] Additionally, installment time was reduced as the irregularity of the faces eliminated the high level of precision needed in placing plain faced blocks. [5]

Inclusion in Sears catalogs

The process of forming rusticated concrete blocks was simplified to the point that Sears was able to start selling concrete block machines in their catalogs to the general public. A catalog from 1939 offered two options for buyers interested in forming their own concrete blocks. The "Wizard" Concrete Block Machine was available for $32.95 and produced 8 × 8 × 16 inch blocks in a "Medium rock-face design". For $52.95, a prospective buyer could get the "Triumph" Concrete Block Machine which had the capacity of producing between 200 and 250 blocks per day. [6]

Difference between RCB and CMU

The differences between rusticated concrete blocks and concrete masonry units (CMU) are quite minimal. In fact, rusticated concrete blocks could be considered a type of concrete masonry unit. The main difference here is the treatment of the face of the concrete. As its name suggests, rusticated concrete block involves rustication, leaving the face that will be on the outside rough and often raised towards the middle. While architects may specify RCB as a cladding element, CMU is more often used in behind-the-scenes structural work. [7]

Present day use

More recently, concrete fabricators have achieved the rusticated look through a process of splitting double-sized blocks with a sharp angled blade. As the aesthetic value of textured concrete block has become recognized, sales have steadily risen and many manufacturers have come to refer to it as architectural concrete block. Architects have begun specifying these concrete blocks not only for back-up walls but for cladding as well. [4] The discontinuation of the practice of using plaster molds has eliminated repetitive patterns across concrete block faces, that hinted at their illegitimacy as natural stone, and allowed for irregularity that casts a variation of light and shadows. [5] Once seen as a building material only suitable for low-budget projects, concrete block, through these advances in texturing and ornamentation, has become a highly desired conduit for architectural design. [4]

See also

Related Research Articles

<span class="mw-page-title-main">Masonry</span> Building of structures from individual units of stone, brick, or block

Masonry is the building of structures from individual units, which are often laid in and bound together by mortar; the term masonry can also refer to the units themselves. The common materials of masonry construction are brick, building stone such as marble, granite, and limestone, cast stone, concrete block, glass block, and adobe. Masonry is generally a highly durable form of construction. However, the materials used, the quality of the mortar and workmanship, and the pattern in which the units are assembled can substantially affect the durability of the overall masonry construction. A person who constructs masonry is called a mason or bricklayer. These are both classified as construction trades.

<span class="mw-page-title-main">Wall</span> Vertical structure, usually solid, that defines and sometimes protects an area

A wall is a structure and a surface that defines an area; carries a load; provides security, shelter, or soundproofing; or, is decorative. There are many kinds of walls, including:

<span class="mw-page-title-main">Stonemasonry</span> Creation of buildings, structures, and sculpture using stone

Stonemasonry or stonecraft is the creation of buildings, structures, and sculpture using stone as the primary material. It is one of the oldest activities and professions in human history. Many of the long-lasting, ancient shelters, temples, monuments, artifacts, fortifications, roads, bridges, and entire cities were built of stone. Famous works of stonemasonry include the Egyptian pyramids, the Taj Mahal, Cusco's Incan Wall, Easter Island's statues, Angkor Wat, Borobudur, Tihuanaco, Tenochtitlan, Persepolis, the Parthenon, Stonehenge, the Great Wall of China, and Chartres Cathedral.

<span class="mw-page-title-main">Plaster</span> Broad range of building and sculpture materials

Plaster is a building material used for the protective or decorative coating of walls and ceilings and for moulding and casting decorative elements. In English, "plaster" usually means a material used for the interiors of buildings, while "render" commonly refers to external applications. Another imprecise term used for the material is stucco, which is also often used for plasterwork that is worked in some way to produce relief decoration, rather than flat surfaces.

<span class="mw-page-title-main">Building material</span> Material which is used for construction purposes

Building material is material used for construction. Many naturally occurring substances, such as clay, rocks, sand, wood, and even twigs and leaves, have been used to construct buildings. Apart from naturally occurring materials, many man-made products are in use, some more and some less synthetic. The manufacturing of building materials is an established industry in many countries and the use of these materials is typically segmented into specific specialty trades, such as carpentry, insulation, plumbing, and roofing work. They provide the make-up of habitats and structures including homes.

<span class="mw-page-title-main">Stucco</span> Construction material made of aggregates, a binder, and water

Stucco or render is a construction material made of aggregates, a binder, and water. Stucco is applied wet and hardens to a very dense solid. It is used as a decorative coating for walls and ceilings, exterior walls, and as a sculptural and artistic material in architecture. Stucco can be applied on construction materials such as metal, expanded metal lath, concrete, cinder block, or clay brick and adobe for decorative and structural purposes.

Siding (construction) Exterior cladding on building walls

Siding or wall cladding is the protective material attached to the exterior side of a wall of a house or other building. Along with the roof, it forms the first line of defense against the elements, most importantly sun, rain/snow, heat and cold, thus creating a stable, more comfortable environment on the interior side. The siding material and style also can enhance or detract from the building's beauty. There is a wide and expanding variety of materials to side with, both natural and artificial, each with its own benefits and drawbacks. Masonry walls as such do not require siding, but any wall can be sided. Walls that are internally framed, whether with wood, or steel I-beams, however, must always be sided.

<span class="mw-page-title-main">Concrete masonry unit</span> Standard-sized block used in construction

A concrete masonry unit (CMU) is a standard-size rectangular block used in building construction. CMUs are some of the most versatile building products available because of the wide variety of appearances that can be achieved using them.

This page is a list of construction topics.

<span class="mw-page-title-main">Natural building</span>

A natural building involves a range of building systems and materials that place major emphasis on sustainability. Ways of achieving sustainability through natural building focus on durability and the use of minimally processed, plentiful or renewable resources, as well as those that, while recycled or salvaged, produce healthy living environments and maintain indoor air quality. Natural building tends to rely on human labor, more than technology. As Michael G. Smith observes, it depends on "local ecology, geology and climate; on the character of the particular building site, and on the needs and personalities of the builders and users."

<span class="mw-page-title-main">Rustication (architecture)</span> Masonry technique of texturing

Rustication is a range of masonry techniques used in classical architecture giving visible surfaces a finish texture that contrasts with smooth, squared-block masonry called ashlar. The visible face of each individual block is cut back around the edges to make its size and placing very clear. In addition the central part of the face of each block may be given a deliberately rough or patterned surface.

<span class="mw-page-title-main">Autoclaved aerated concrete</span> Lightweight, precast building material

Autoclaved aerated concrete (AAC) is a lightweight, precast, foam concrete building material suitable for producing concrete masonry unit like blocks. Composed of quartz sand (SiO2 with impurities), calcined calcium sulfate (or plaster of paris), lime (CaO), cement, water and aluminum powder, AAC products are cured under heat and pressure in an autoclave. Invented in the mid-1920s, AAC simultaneously provides structure, insulation, and fire- and mold-resistance. Forms include blocks, wall panels, floor and roof panels, cladding (façade) panels and lintels.

Akoustolith is a porous ceramic material resembling stone. Akoustolith was a patented product of a collaboration between Rafael Guastavino Jr. and Harvard professor Wallace Sabine over a period of years starting in 1911.It was used to limit acoustic reflection and noise in large vaulted ceilings. Akoustolith was bonded as an additional layer to the structural tile of the Tile Arch System ceilings built by the Rafael Guastavino Company of New Jersey. The most prevalent use was to aid speech intelligibility in cathedrals and churches prior to the widespread use of public address systems.

<span class="mw-page-title-main">Precast concrete</span> Construction product produced by casting concrete in a reusable mold

Precast concrete is a construction product produced by casting concrete in a reusable mold or "form" which is then cured in a controlled environment, transported to the construction site and maneuvered into place; examples include precast beams, and wall panels for tilt up construction. In contrast, cast-in-place concrete is poured into site-specific forms and cured on site.

<span class="mw-page-title-main">Architectural terracotta</span> Fired clay construction material

Architectural terracotta refers to a fired mixture of clay and water that can be used in a non-structural, semi-structural, or structural capacity on the exterior or interior of a building. Terracotta pottery, as earthenware is called when not used for vessels, is an ancient building material that translates from Latin as "baked earth". Some architectural terracotta is actually the stronger stoneware. It can be unglazed, painted, slip glazed, or glazed. A piece of terracotta is composed of a hollow clay web enclosing a void space or cell. The cell can be installed in compression with mortar or hung with metal anchors. All cells are partially backfilled with mortar.

<span class="mw-page-title-main">Cast stone</span> Material simulating natural stone

Cast stone or reconstructed stone is a highly refined building material, a form of precast concrete used as masonry intended to simulate natural-cut stone. It is used for architectural features: trim, or ornament; facing buildings or other structures; statuary; and for garden ornaments. Cast stone can be made from white and/or grey cements, manufactured or natural sands, crushed stone or natural gravels, and colored with mineral coloring pigments. Cast stone may replace such common natural building stones as limestone, brownstone, sandstone, bluestone, granite, slate, coral, and travertine.

<span class="mw-page-title-main">Architectural sculpture in the United States</span>

Architectural sculpture is a general categorization used to describe items used for the decoration of buildings and structures. In the United States, the term encompasses both sculpture that is attached to a building and free-standing pieces that are a part of an architects design.

Nanakshahi bricks were decorative bricks used for structural walls during the Mughal era.

Studcast concrete, also called "pre-framed concrete", combines relatively thin concrete layers with cold formed steel framing to create hybrid panels; the result is a panelized system usable for cladding, curtain walls, shaft walls, and load-bearing exterior and interior walls. Studcast panels install in the same manner as prefabricated steel stud panels. The technology is applicable for both factory prefabrication and site-cast (tilt-up) wall construction on almost all types of buildings, including multifamily housing, schools, industrial, commercial and institutional structures.

<span class="mw-page-title-main">Structural clay tile</span>

Structural clay tile describes a category of burned-clay building materials used to construct roofing, walls, and flooring for structural and non-structural purposes, especially in fireproofing applications. Also called building tile, structural terra cotta, hollow tile, and clay block, the material is an extruded clay shape with substantial depth that allows it to be laid in the same manner as other clay or concrete masonry. In North America it was chiefly used during the late 19th and early 20th centuries, reaching peak popularity at the turn of the century and declining around the 1950s. Structural clay tile grew in popularity in the end of the nineteenth-century because it could be constructed faster, was lighter, and required simpler flat falsework than earlier brick vaulting construction. Each unit is generally made of clay or terra-cotta with hollow cavities, or cells, inside it. The material is commonly used in floor arches, fireproofing, partition walls, and furring. It continues to be used in Europe to build fire-resistant walls and partitions. In North America the material has largely been replaced by concrete masonry units.

References

  1. 1 2 "Concrete Block". Old House Journal: 46. May 2017 via Gale.
  2. 1 2 3 "Upon This Rock: A Foundation in Stone Construction". The Historic Huntsville Quarterly of Local Architecture and Preservation. 27. Fall 2001.
  3. "Rock-Face Concrete Block". Concrete Engineering. 5: 270. 1910 via ProQuest.
  4. 1 2 3 4 Sullivan, Ann C. (April 1996). "Concrete Block's New Face". Architecture: 115 via Gale.
  5. 1 2 Hobbs, H. F. (November 1, 1910). "Defense of the Rock-Face Design of Concrete Block". Concrete. 10: 72 via Google Books.
  6. Sears Building Materials. MBJ collection. Sears, Roebuck & Co. 1939.{{cite book}}: CS1 maint: others (link)
  7. "Concrete vs Split-Face Blocks". www.aaa1masonry.com. Retrieved 2017-11-30.