A NEW COMPOUND OR COM- POSITION FOR ARTIFICIAL STONE, AND FOR CERTAIN MACHINERY OR APPARATUS TO BE HARD IN MIXING AND A DRIVING MOD DA
Year: 1864

page_text: LETTERS PATENT to John Potter, of the City of Manchester, Civil and
Consulting Engineer, for the Invention of "A NEW COMPOUND OR COM-
POSITION FOR ARTIFICIAL STONE, AND FOR CERTAIN MACHINERY OR APPARATUS
TO BE HARD IN MIXING AND A DRIVING MOD
DAYD
Sealed the 28th October 1864, and dated the 4th May 1864.
PROVISIONAL SPECIFICATION left by the said John Potter at the
Office of the Commissioners of Patents, with his Petition, on the
4th May 1864.
I, JOHN POTTER, of the City of Manchester, Civil and Consulting Engineer,
do hereby declare the nature of the said Invention for "A NEW COMPOUND OR
COMPOSITION FOR ARTIFICIAL STONE AND FOR CERTAIN MACHINERY OR APPARATUS
TO BE USED IN MIXING AND APPLYING THE SAID COMPOSITION," to be as follows:-
The first part of my Invention consists in forming or producing a certain
description of artificial stone by the admixture of siliceous sand with a
certain proportion of metallic iron in a state of comminution.
The propor-
tion of the metallic iron to the sand may be in the ratio of from 3 to 10 parts
or more of iron powder to 100 parts of sand by measure; but the quantity
of iron powder required will depend upon its fineness and also upon the purity
of the sand; generally the finer the iron powder is the smaller the quantity
of it will be sufficient. The proportionate quantity of the two ingredients will
also depend on the purpose to which the artificial stone is to be applied. As
a general rule the harder the artificial stone is required to be, and the larger
[Price 8d.]

page_text: the quantity of the iron powder in proportion to the sand will be necessary.
Borings or turnings of iron, when sufficiently fine, will answer the purpose of
the iron powder here mentioned.
The second part of my Invention consists in the formation of sea walls (in
particular) of the artificial stone, or facing embankments formed of earth with
the same, and also artificial foundations for buildings or erections, also forming
the same into blocks for building and other purposes, or pieces of a variety of
forms, by casting the same in moulds, and thus giving the finished piece any
shape that may be required. After the composition is mixed it is necessary
that it should be moistened with water, which will in general be best done
after the composition is in the mould, or form, or place wherein it is to take
its shape. Water containing a quantity of common salt or sal ammoniac will
in general be found to be advantageous for this purpose.
The third part of. my Invention relates to apparatus for conveying the
materials from place to place and mixing the same. 'The conveying apparatus
consists in applying tubes or pipes combined with other apparatus. The con-
tinuous tube being placed at a certain inclination the materials are elevated
by other apparatus, and discharged into the upper end, they then flow down
the tube to their destination. The mixing apparatus consists of two funnels,
into one of which the siliceous sand is placed, whilst the iron powder is placed
in the other. As the materials descend from the funnels they are measured
by means of slides or stops, the slides or stops acting simultaneously in
descending pipes or tubes. The two pipes discharge the materials into one,
after which they pass or are placed in the compounding apparatus, in which
they are more perfectly mixed by being stirred or agitated together. The
compounding apparatus consists of a hollow cylinder open at each end, placed
in an inclined position and revolving on an axis. The composition enters the
hollow cylinder at the upper end, and is discharged at the lower end.
The fourth part of my Invention consists in the application and adaptation
of certain apparatus or means to the purpose of facilitating the application of
the artificial stone to useful purposes. I construct boxes or cassoons of wood
or metal of a suitable size or form. Into these the mixed materials are
poured, and being wetted as before mentioned, are left to harden into a solid
mass. I also apply the artificial stone as a substitute for piles of wood or iron,
this I effect by means of tubes, at one end of which is a loose tip or point. The
tube being driven into the earth (with the point foremost) a sufficient depth,
the tube is filled with the composition, the tube being then withdrawn, the
loose tip is left in the earth, and the hole as the tube is withdrawn becomes
filled with the composition, which being wetted hardens in the usual manner.
:

page_text: In certain cases, however, instead of extracting the tube I leave it in the
earth, and the same also with the cassoons formed of wood or metal.
The fifth part of my Invention consists in producing the iron powder directly
from certain ores or oxides of iron, which are naturally or may be reduced to
the state of powder; this powder being mixed with a proportionate part of
carbonaceous matter, and exposed to heat in a retort or other suitable vessel,
will give the iron powder required.
by the said John Potter in the Great Seal Patent Office on the 3rd
November 1864.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, JOHN
POTTER, of the City of Manchester, Civil and Consulting Engineer, send
greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Fourth day of May, in the year of our Lord
One thousand eight hundred and sixty-four, in the twenty-seventh year
of Her reign, did, for Herself, Her heirs and successors, give and grant unto.
me, the said John Potter, Her special licence that I, the said John
Potter, my executors, administrators, and assigns, or such others as I.
the said John Potter, my executors, administrators. and assigns, should
at any time agree with, and no others, from time to time and at all times
thereafter during the term therein expressed, should and lawfully might
make, use, exercise, and vend, within the United Kingdom of Great Britain
and Ireland, the Channel Islands, and Isle of Man, an Invention for.
"A NEW COMPOUND OR COMPOSITION FOR ARTIFICIAL STONE. AND FOR CERTAIN
MACHINERY OR APPARATUS TO BE USED IN MIXING AND APPLYING THE SAID COM-
POSITION," upon the condition. (amongst others) that I, the said John Potter,
my executors or administrators, by an instrument in writing under my,
or their, or one of their hands and seals, should particularly describe and
ascertain the nature of the said Invention, and in what manner the same
was to be performed, and cause the same to be filed in the Great Seal Patent
Office within six calendar months next and immediately after the date of the
said Letters Patent.
NOW KNOW YE, that I, the said John Potter, do hereby declare
the nature of my said Invention, and in what manner the same is to be

page_text: performed, to be particularly described and ascertained in and by the following
statement and accompanying Drawing (that is to say):
My Invention consists, first, in the application and adaptation of a new
compound or composition for forming or producing a certain description of
artificial rock or stone.
The second part of my Invention consists in the application of the artificial
stone to the purposes of constructing sea walls (in particular); also con-
structing, facing, or strengthening embankments; also forming artificial
foundations for buildings and other erections; also for forming the same into
blocks for building and other purposes.
The third part of my Invention consists, first, in the application and
adaptation of certain machinery to the purpose of conveying the materials
from place to place; second, in the application and adaptation of certain
machinery to the purpose of apportioning and measuring the respective
quantities of the several materials; third, in the application of certain
machinery to the purpose of mixing, combining, and compounding the different
materials.
The fourth part of my Invention consists in the use and application of boxes
or caissoons, for the purpose of giving to the artificial stone a particular shape
or form, or retaining it during the process of hardening. I also use these
boxes or caissoons in certain cases to retain permanently the artificial rock. I
also use the artificial rock as a substitute for piles which are usually made of
wood or iron.
The fifth part of my Invention consists in producing the iron powder directly
from certain ores or oxides of iron.
In order to make my Invention more clearly understood, I have hereunto
annexed a Sheet of Drawings, to which the following description relates, and
in which the same letters or figures of reference, or letters and figures con-
joined indicate the same parts.
The compound or composition of artificial stone or rock, constituting the
first part of my Invention, I produce as follows:-I procure siliceous sand
(of which river sand and sea sand are the best natural specimens), and
metallic iron in the state of powder. Borings, turnings, filings, or other
remnants of cast or wrought iron, when sufficiently fine, answer the purpose of
the iron powder; but I also produce the iron powder from certain ores or
oxides of iron. The proportions of the two ingredients may be varied, but in
general fourteen part of siliceous sand to one of iron powder, by measure,
or ten parts of siliceous sand to one of iron powder, by weight, will form an.
efficient composition for most purposes to which the artificial stone can be

page_text: applied; but these proportions may be varied, and in general the more the
quantity of the iron powder, the harder the resulting artificial rock will be.
A certain amount of other materials or impurities may be admitted into the
composition according to the purpose to which the artificial stone is applied.
The ingredients being well mixed together and moistened with water, become
converted in a short time into artificial rock.
The second part of my Invention relates to certain applications of the
artificial stone or rock. First in the formation of sea walls or embankments
to fence out the sea, c or the strengthening of such structures. For this
purpose I make use of the sand hills and other accumulations of sand on the
sea shore; this I mix with the iron powder as before described. If the
wall is to be constructed entirely of the artificial rock, I first construct a
caissoon or chamber of slabs or other inferior timber or material, and fix the
same on a spot where the wall or a portion of it is to be erected. The
caissoon is then to be filled with the composition of sand and iron powder
before described. The composition may be wetted with water before, being
placed in the caissoon, or it may be put in in a dry state, (which will in many
cases be most convenient), and afterwards wetted or left to be moistened by
rain or water from other natural sources.
"
Another mode of constructing sea walls (which in general I prefer) is as
follows: I build a slight wall of some harder material, which I support by
placing behind it a mass of the artificial rock. This will be understood from.
Figs. 5 and 6, in which Fig. 5 represents a section, and Fig. 6 a plan.
A, A, slight wall of some hard material; B, B. mass of artificial rock
supporting the wall. The composition is to be confined by a hoarding or
other means, until it is sufficiently set to support itself and the wall without
assistance. Second, embankments formed of earth I secure by coating them
with the artificial rock, the thickness of which must be regulated by circum-
stances, and which may be two, three, or more feet. The external surface of
the coating may afterwards be indurated as will be more particularly
explained hereafter.
Another mode of strengthening embankments formed of earth is shewn in
section in Fig. 7, which is also applicable to embankments already made.
In this case I form a trench through the embankment lengthwise, of a proper
form and dimensions, and fill it with the composition, which being wetted
hardens into rock; C, C, the earth forming the embankment; D, D, the
artificial rock. The trench may in many cases be made in the form of a
curve, so that the artificial rock will constitute an arch supported on abut-
ments at each termination of the embankment,

page_text: Third, in making artificial foundations, the process of which is simply
making an excavation of sufficient dimensions, and of a depth corresponding
to the weight of the erection to be placed upon it. The depth may con-
sequently vary from one foot to six feet or more, according to the weight or
pressure of the superstructure, and is to be filled with the 'composition in the
manner before described.
If a very heavy erection is to be placed on a
foundation, it will be advantageous to insert in the composition long and thin
strips of iron, which will greatly add to its tenacity and strength.
Fourth; for forming blocks of artificial stone, I provide boxes or moulds of
the dimensions and shape required. These are filled with the composition in
the manner already described, and left to harden a sufficient time: A ready
and cheap mode of effecting the same is as follows:-I prepare a model of
the proposed block, I then dig a hole in the earth in which I place the model,
and ram the earth firmly round it; the model is then withdrawn, and the
space filled with the composition, which is then slightly covered with earth
and left to harden. In this manner a single model will answer the purpose
of forming moulds for an immense number of blocks.
The third part of my Invention relates to machinery for conveying,
apportioning, and compounding the materials. Fig. 1 represents a side view
of the conveying apparatus; E. E, a tube of metal or other suitable material
placed in an inclined position, and supported by scaffolds F, F, &c. The
materials are elevated and discharged into the upper end of the tube E, E,
down which they pass, and are discharged at the lower end at the place
required. A convenient mode of elevating the materials is shewn in the
Figure, where El represents a moveable clevating tube turning on a centre
E2, fixed on the scaffolding. On the tube E1 being elevated into the position
shewn by dotted lines, it becomes connected to the tube E. E, forming one
continuous fube. The other end of the tube El is furnished with a funnel.
into which the materials are placed. When the distance to which the
materials are to be conveyed is considerable, it will be necessary that the
lower end of the tube E, E, should discharge the materials into a funnel at
the end of another elevating tube similar to the one shewn at El; this 'last
discharges the materials into another tube similar to E, E; and the process
of conveying the materials may thus be continued to any extent that may be
required. The inclination of the tubes will depend greatly on their smoothness
inside; the smoother the interior is the less inclination will be required.
Fig. 2 represents a side elevation of one mode of constructing the apportion-
ing apparatus. G, a funnel or hopper in which the sand is to be placed; from
this descends the tube or pipe G1, G1; in this tube work the two slides G2

page_text: and G3. H, another smaller funnel or hopper in which the iron powder is
placed; from this descends the tube or pipe H1, H1; in this tube works the
two slides H2 and H3. The two slides G2 and H2 are actuated by means of
connecting rods from the lever I, turning on the centre II, and the two slides
G3 and H3 are actuated by means of connecting rods from the lever J turning
on the centre J1. The lever I has a lower arm 12, and betwixt this lower arm
and the lever J plays the upper end of the lever K, turning on the centre Kl.
To the lever K, a reciprocating motion being given, it acts alternately (by this
arrangement) on the levers I and J. When it acts on the lower arm 12, of the
lever I, the slides G2 and H2 are withdrawn from the tubes G1 and HI, the
portion of the tube G1, above the slide G3, becomes filled with sand, and the
portion of the tube HI, above the slide H3, becomes filled with the iron powder.
On the reverse motion of the lever K, the slides G2 and H2 are allowed to
close, and the slides G3 and H3 are withdrawn from the respective tubes, and
the sand and iron powder descend into the funnel or hopper L, from which
they are conducted to the compounding apparatus, in which the ingredients
are more perfectly mixed together. The slides when not withdrawn by the
action of the lever K, are closed by means of a worm or other spring (not
shewn in the Drawing) connecting the arm 12 with the lever J. A vibratory
motion is communicated to the lever K by any adequate power.
The propor
tionate quantities of the two ingredients will depend on the relative capacities
of the tubes GI and HI.
and H1.
Another apparatus to be used for the same purpose is shewn in Fig. 3.
In this construction the slides are dispensed with, and wheels or drums having
vanes or buckets upon them are substituted instead; G, the funnel or hopper.
in which the sand is placed; GI, GI, the pipe or tube descending from the
same; H, the funnel or hopper in which the iron powder is placed; III, HI,
pipe or tube descending from the same; L, the funnel or hopper which
receives the combined ingredients from the pipes G1
These parts
are respectively the same as those shewn in Fig. 2.
furnished with vanes or buckets and turning on axis; it
case attached to the tube G1, G1, and forming part of it.
ing through the pipe G1, G1, enters the buckets of the
motion to it, and is discharged from it into the lower part of the tube G1.
H4, a similar drum working in a case or box attached to the tube H1, HI.
The iron powder descending the tube H1, H1, fills the buckets of the drum.
H4, and from thence is discharged into the lower part of the tube H1.
From
the lower orifices of the tubes G1 and HI the ingredients are discharged
into the hopper or funnel L, or other receptacle, from whence they are conveyed.
G4, a wheel or drum
works in a box or
The sand descend-
drum G4, giving

page_text: to the compounding apparatus. A pulley or drum is fixed on the axis of the
drum G4; this pulley gives motion to the drum H4 by means of a strap or
band which passes over another drum or pulley on the axis of the drum H4.
The relative velocities of the two drums G4 and H4 (and consequently the
relative quantities of the two ingredients delivered) will be regulated by the
relative sizes of the two band pulleys or drums, and by varying the respective
sizes of these pulleys or drums the proportionate quantities of the two ingre-
dients may be regulated to any degree of nicety which may be required. The
same results will obviously be produced by using toothed wheels instead of
these pulleys or drums. The working velocity of the apparatus may be regu-
lated by means of a brake or fan, or by being connected to some moving power.
If it should be required to add a third ingredient, another funnel with its
descending tube and appurtenances may be added to the apparatus, and so on.
Fig. 4 represents a side view (shewn partly in section) of the mixing and
compounding apparatus. M, M, two end frames which support the moving
parts; N, N, axis, supported in an inclined position, and turning in bearings
attached to the end frames M, M, N1, N1, a hollow cylinder attached to
the axis N, N, by means of rings furnished with internal arms. The interior
of the cylinder may be furnished with a number of small vanes which will
facilitate its action on the materials. .N2, driving pulley or wheel,- by which
motion is communicated to the axis N, N. N3, N3, two discs, fixed on the
axis N, N, and revolving with it; the use of which is to prevent the materials
getting into the bearings and abrading and destroying the rubbing surfaces.
O, a hopper furnished with a descending tube, into this the materials are placed
and are conducted by the descending tube into the interior of the upper end
of the cylinder N1, N1, by the rotation of which they are effectually mixed
and compounded together, which being effected they fall out of the cylinder
at its lower end on to the floor or into a receptacle prepared to receive them.
The inclination of the axis N, N, is to be regulated so that the ingredients
may be properly mixed without being too long detained in the interior of the
cylinder. To render the above machines fully effectual it will be proper that
the materials should be in a dry state.
The fourth part of my Invention relates, first, to the application and adap-
tation of boxes or caissoons, made of various shapes or forms as may be required,,
they may be constructed of wood or metal, and being filled with the compo-
sition (kept in a moist state a sufficient length of time), a block of artificial
stone is produced, which being removed from the caissoon, and indurated when.
necessary, is ready for use. I also use the caissoons filled with the artificial
rock in certain cases where it is required to have blocks or masses of the

page_text: artificial rock applied so as to act by their weight as well as by their size or
strength. In this case the caissoon is not removed, but remains as an external
covering to the artificial rock.. Second, I apply the artificial stone as a sub-
stitute for piles of wood or metal in the following manner:-
Figs. 8 and 9 represent the apparatus shewn principally. in section. P, P,
a tube of metal, at the lower end of which is the loose tip Q. The tube P, P,
is constructed in lengths, which can be coupled together when required; R, a
bracket fixed across the interior of the lowermost length of the tube. The
tube is to be driven a sufficient depth into the earth, when this is effected a
hook of a proper construction attached to a rope or chaint is lowered down the
interior of the tube, so as to take hold of the bracket R; by this means
the metal tube is to be withdrawn out of the earth, previous to which a quan-
tity of the artificial stone composition is to be poured into the interior. of the
tube, and as the tube is being withdrawn fresh quantities of the composition
are to be supplied. When the tube is therefore wholly withdrawn the space
previously occupied by it will be filled with the composition, which in time
will be converted into artificial stone. The loose tip Q is by this operation
In some
left in the earth and serves as a foundation on which the pile rests.
cases it will be desirable to leave the tube itself in the earth. 1
Fig. 10 represents a section of an artificial foundation resting on piles as
above described; S, S, S, S, piles of the artificial stone; T, T, mass of the
artificial rock resting on the piles. On this mass the building or erection is
to be constructed.
The fifth part of my Invention relates to the production of the metallic iron
powder directly from certain ores of iron, (such as the hematites, martial
pyrites, or the same after a portion of the sulphur has been extracted or such
others as may be sufficiently rich in iron) or oxides of iron (such as the black
and red oxides) produced in various processes in the arts. If the ore or oxide
is not naturally in a state of powder it will have to undergo the process of
grinding. The powdered ore or oxide is next to be mixed with as much
carbonaceous matter as will reduce it to the metallic state. This will vary
according to the nature of the ore or oxide under process, but in general, one-
tenth to a fifth part of absolute carbon in the carbonaceous matter will be
sufficient. Generally, mixtures of the ores and oxides will be advantageous,
as by a judicious apportioning and selection of them a less quantity of carbonȧ-
ceous matter will be required, and the process of reduction accomplished with
greater economy. The addition of a quantity of flux (such as carbonate of
lime) will in most cases be advantageous. The mixture is next to be exposed
to heat for three or four hours in a retort or other suitable vessel. The heat

page_text: should be gradually raised, but should not be raised so high as to melt the iron.
Different ores and oxides of iron will however require variations in the treat-
ment in order to bring them to a metallic state, but these variations .being well
known to metallurgists need not be further mentioned here. The mass being
allowed to cool will be the metallic iron powder required, mixed with some
amount of impurity, which, however, if the process has been well conducted will
not be injurious. Instead of using water for the purpose of moistening the com-
position, a solution of common salt or sal-ammoniac will be advantageous to
hasten the process of conversion. A solution of copperas (sulphate of iron) is
however the best which I have so far been able to discover for this purpose.
When the artificial stone is once formed, and is requisite that it should be
indurated to resist the effects of the atmosphere and attrition, quickline in the
state of solution, or milk of lime may be applied to it with good effect, as also.
other stone preserving applications. A certain amount of impurities may also
be admitted into the composition, but generally with injurious effect. However
carbonate of lime in the state of powdered limestone, powdered chalk, or
whiting may be used for some purposes with good effect to the extent of one-
tenth part or more of the whole or thereabouts; but the application of these
substances is to be regarded simply as adventitious and as forming no part of
iny present Invention.
F
Having thus described the nature of my Invention, and the manner in which
the same is to be performed, I would have it understood that I do not confine
myself to the precise details of construction and arrangement of the mecha-
nism and apparatus herein described, as these may be varied, but that what I
claim as new and of my Invention is as follows:-
Under the head of the first part of my Invention I claim, the application
and adaptation of a combination of siliceous sand and metallic iron in the
state of powder (into which combination other materials may be admitted
to a certain extent) for the purpose of producing artificial stone or rock as
herein described.
Under the head of the second part of my Invention I claim, first, the
application and adaptation of the artificial rock or stone to the purpose of
constructing sea walls and enibankments to fence out the sea (in particular);
also constructing, facing, or strengthening embankments in general; second
the application and adaptation of the artificial rock or stone to the purpose
of forming artificial foundations for buildings and other erections; third, the
application and adaptation of the artificial stone or rock to the purpose of
forming blocks for building and other purposes, as herein set forth and
described.

page_text: Under the head of the third part of my Invention I claim, first, the appli-
cation and adaptation of the conveying apparatus shewn in Fig. 1; second,
the application and adaptation of the opportioning apparatus shewn in Figs. 2
and 3; and, third, the application and adaptation of the compounding
apparatus shewn in Fig. 4 as herein set forth and described.
Under the head of the fourth part of my Invention, I claim, first, the applica-
tion and adaptation of boxes or caissoons for the purpose of giving various
shapes or forms to the artificial stone or rock, or permanently retaining the
same; second, the application and adaptation of the artificial rock or stone as
a substitute for piles of wood or metal and the apparatus for applying the same
as shewn in Figs. 8 and 9, and herein set forth and described.
Lastly, under the head of the fifth part of my invention I claim, the
application and adaptation of certain ores or oxides of iron to the purpose
of producing the metallic iron powder, or the mode or process of effecting the
same, so as to make the iron powder so produced, applicable and effective
to the purpose of producing the artificial stone or rock as herein set forth
and described.
In witness whereof, I, the said John Potter, have hereunto set my hand
and seal, this Second day of November, in the year of our Lord One
thousand eight hundred and sixty-four.
Signed by the within named John
Potter, in the presence of,
ROBERT LANGTON,
Engraver on Wood,
17, Cross Street,
Manchester.
JOHN POTTER. (L.S.)