IMPROVEMENTS IN THE MANUFACTURE, CONSTRUCTION. AND ORNAMENTATION OF ARTICLES MADE OF TERRA COTTA. STONEWARE, AND PLASTIC CLAYS ADAPTED FOR THE CONSTRUCTION OF FIRE-PROOF STAIRS, STEPS, LANDINGS, SLABS, TILES FOR ROOFING AND PAVING, CHIMNEY SHAFTS, COLUMNS FOR BUILDINGS, POSTS OR STANDARDS, PEDESTALS, AND STATUES, AND IN THE METHOD OF MOULDING THE SAME
Year: 1861

page_text: ETTERS PATENT to Mark Henry Blanchard, of No. 74, Blackfriars Road,
in the County of Surrey, Terra Cotta Manufacturer, for the Invention of
"IMPROVEMENTS IN THE MANUFACTURE, CONSTRUCTION. AND ORNAMENTATION
OF ARTICLES MADE OF TERRA COTTA. STONEWARE, AND PLASTIC CLAYS ADAPTED
FOR THE CONSTRUCTION OF FIRE-PROOF STAIRS, STEPS, LANDINGS, SLABS, TILES
FOR ROOFING AND PAVING, CHIMNEY SHAFTS, COLUMNS FOR BUILDINGS, POSTS
OR STANDARDS, PEDESTALS, AND STATUES, AND IN THE METHOD OF MOULDING
THE SAME"
Sealed the 28th June 1861, and dated the 3rd April 1861.
PROVISIONAL SPECIFICATION left by the said Mark Henry Blanchard
at the Office of the Commissioners of Patents, with his Petition, on
the 3rd April 1861.
I, MARK HENRY BLANCHARD, of No. 74, Blackfriars Road, in the County
of Surrey, Terra Cotta Manufacturer, do hereby declare the nature of the
said Invention for "IMPROVEMENTS IN THE MANUFACTURE, CONSTRUCTION. AND
ORNAMENTATION OF ARTICLES MADE OF TERRA COTTA, STONEWARE, AND PLASTIC
CLAYS ADAPTED FOR THE CONSTRUCTION OF FIRE-PROOF STAIRS, STEPS, LANDINGS,
SLABS, TILES FOR ROOFING AND PAVING, CHIMNEY SHAFTS, COLUMNS FOR BUILDINGS,
POSTS OR STANDARDS, PEDESTALS AND STATUES, AND IN THE METHOD OF MOULDING
THE SAME," to be as follows:-
According to the methods heretofore generally practised of manufacturing
columns, posts or standards, pedestals, landings, slabs, and tiles, considerable

page_text: practical difficulties have presented themselves to prevent alteration or dis-
tortion of the forms of the articles during the operation of drying, burning,
or baking in the kiln, especially columns and large slabs. I propose by
this Invention to overcome these difficulties and objections by the
following means.
First, as regards the improvements in the manufacture of columns, it
consists in shaping a hollow cylinder or shell of terra cotta in lengths, say, of
four feet each, in a mould formed in two parts, in the direction of its length;
the plastic material is first spread over the surface of one half of the mould; a
rod of metal is then placed thereon lengthwise of the mould, and the plastic
material worked round and about the same; another similar rod is then
placed by the side of the former rod, and at any desired distance therefrom,
and the plastic material worked around same as before, and this is repeated
around the half mould. The plastic material is then worked over the whole
until a half cylinder or shell has been formed, so that when the aforesaid rods
are withdrawn hollow chambers or channels are thus formed about midway in
the thickness of the aforesaid half cylinder or shell. The other half of the
mould is similarly treated, and the two half shells are united together, and to
a moulded base or cap piece if required, to form either the top or bottom of
the column, and in this state the moulded material is dried, then removed from
the moulds, and placed in the kiln to be burnt or baked. The aforesaid
hollow chambers allow the hot air and vapours to pass through them, and thus
preserve the moulded form from distortion or aiteration of shape. To construct
a column, say eighteen feet long, I place four of such lengths, one upon the
other end wise, connecting them together by cement. I then insert solid or
nearly solid cores or dowells ofterra cotta, stone, or iron, inside same, the dowells
being of such lengths as to break joint with each length of hollow cylinder, and
I connect or grout the whole together with cement, and finally, I affix the cap
of the column thereto, moulded in half moulds, as before stated. A column
thus made I have found extremely strong, and this mode of manufacture
applies to chimney shafts, posts, pedestals, standards, and similar articles.
Secondly, as regards the improvement in the manufacture of landings,slabs,
and tiles; it consists in forming holes longitudinally and transversely of the
material in the thickness thereof in moulds, as before stated, or otherwise.
Thirdly, as regards the improvement in the ornamentation of articles made
of terra cotta, stoneware, and plastic clays; it consists in impressing the
plastic material with the ornament, in a mould or moulds, either with or
without the before-mentioned hollow channels, and then removing some of the
plastic material by hand, or indenting by the mould, then burning them, and

page_text: afterwards filling in such removed or indented partswith colored clays, marble,
stones, wood, metals, scagliola, vitreous and other colours, and, if necessary,
afterwards enamelling the whole surface; or instead of indenting the surface,
I propose to print a device or pattern on the surface of the material, and then
burn same in, and enamel the entire surface. Terra cotta, stoneware, and
plastic clays thus treated are well adapted for fireproof stairs, steps, and
statues, and constitute a very ornamental and durable material.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said Mark Henry Blanchard in the Great Seal Patent Office
on the 2nd October 1861.
TO ALL TO WHOM THESE PRESENTS SHALL COME. I, MARK
HENRY BLANCHARD, of No. 74, Blackfriars Road, in the County of Surrey,
Terra Cotta Manufacturer, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Third day of April, in the year of our Lord
One thousand eight hundred and sixty-one, in the twenty-fourth year of Her
reign, did, for Herself, Her heirs and successors, give and grant unto me,
the said Mark Henry Blanchard, Her special licence that I, the said Mark
Henry Blanchard, my executors, administrators, and assigns, or such others
as I, the said Mark Henry Blanchard, 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 "IMPROVEMENTS IN THE MANUFACTURE, CONSTRUCTION, AND ORNA-
MENTATION OF ARTICLES MADE OF TERRA COTTA, STONEWARE, AND PLASTIC CLAYS
ADAPTED FOR THE CONSTRUCTION OF FIREPROOF STAIRS, STEPS, LANDINGS, SLABS,
TILES FOR ROOFING AND PAVING, CHIMNEY SHAFTS, COLUMNS FOR BUILDINGS, POSTS
OR STANLARDS, PEDESTALS AND STATUES, AND IN THE METHOD OF MOULDING THE
SAME," upon the condition (amongst others) that I, the said Mark Henry
Blanchard, my executors or administrators, byan 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.

page_text: NOW KNOW YE, that I, the said Mark Henry Blanchard, do hereby
declare the nature of my said Invention, and in what mauuer the same
is to be performed, to be particularly described and ascertained in and by
the following statement, that is to say :-
According to the methods heretofore generally practised of manufacturing
columns, posts, or standards, pedestals, landings, slabs, and tiles, considerable
practical difficulties have presented themselves to prevent alteration or dis-
tortion of the forms of the articles during the operation of drying, burning,
or baking in the kiln, especially columns and large slabs. I
propose by this
Invention to overcome these difficulties and objections by the following
means-
First, as regards the improvements in the manufacture of columns; it
consists in shaping a hollow cylinder or shell of terra cotta in lengths, say,
of four feet each,in a mould formed in two parts in the direction of its length;
the plastic material is first spread over the surface of one-half of the mould;
a rod of metal is then placed thereon lengthwise of the mould, and the plastic
material worked round and about the same. Another similar rod is then
placed by the side of the former rod, and at any desired distance therefrom
and the plastic material worked around same as before, and this is repeated
around the half-mould; the plastic material is then worked over the whole
until a half-cylinder or shell has been formed, so that when the aforesaid rods
are withdrawn hollowchambers or channels are thus formed about midway in
the thickness of the aforesaid half-cylinder or shell. The other half o
the mould is similarly treated, and the two half shells are united together,and
to a moulded base or cap piece, if required, to form either the top or bottom
of the column; and in this state the moulded material is dried, then removed
from the moulds and placed in the kiln to be burnt or baked. The aforesaid
hollow chambers allow the hot air and vapours to pass through them, and
thus preserve the moulded from distortion or alteration of shape. To con-
struct a column, say, eighteen feet long, I place four of such lengths one
upon the other endwise, connecting them together by cement. I then insert
solid, or nearly solid, cores or dowells of terra cotta, stone, or iron inside
same, the dowells being of such lengths as to break joint with each length
of hollow cylinder, and I connect or grout the whole together with cement,
and, finally, I affix the cap of the column there to moulded in half-moulds,as
before stated. A column thus made I have found extremely strong, and
this mode of manufacture applies to chimney shafts, posts, pedestals,
standards, and similar articles.
Secondly, as regards the improvement in the manufacture of landings,slabs,

page_text: and tiles; it consists in forming holes longitudinally and transversely of the
material in the thickness thereof in moulds, as before stated, or otherwise.
Thirdly, as regards the improvement in the ornamentation of articles made
of terra cotta, stoneware, and plastic clays, it consists in impressing the plastic
material with the ornament in a mould or moulds, either with or without the
before-mentioned hollow channels, and then removing some of the plastic
material by hand, or indenting by the mould; then burning them, and after-
wards filling in such removed or indented parts with colored clays, marble,
stones, wood, metals, scagliola, vitrious, and other colors; and, if necessary,
afterwards enamelling the whole surface; or, instead of indenting the sur-
face, I propose to print a device or pattern on the surface of the material,
and then burn same in, and enamel the entire surface. Terra cotta, stone-
ware, and plastic clays thus treated are well adapted for fireproof stairs,
steps, and statues, and constitute a very ornamental and durable material.
In order to explain my said Invention as completely as possible, I now
proceed to describe the best means I am acquainted with for carrying the
same into practical effect, reference being had to the illustrative Sheets of
Drawing accompanying these Presents, and to the numeral figures and
letters of reference marked thereon respectively, as follows:-
DESCRIPTION OF THE DRAWINGS.
At Sheet 1 Figure 1 represents an elevation of a complete column con-
structed according to my said Invention. Figure 2, disconnected portions of
said column, showing dowells F and G, passed through same. Figure 3
represents portions ofthe column; H and I mark the longitudinal perforations
in the column and dowell; J and K mark the thickness of the shaft and size
of the dowell. Figure 4 represents a half mould for forming a column, and as
it would appear when ready to receive the plastic material, alsó a rod passed
through the collars. Figure 5 represents one of such said rods detached from
the mould. Figure 6 represents a plau or section of the mould with holes
through the collar thereof. Figure 7, portions of the said mould in perspective
ready to receive the plastic material. Figure 8 represents one of my improved
slabs partly inlaid; the parts marked A are the parts indented and left for
inlaying B marks a series of holes formed in the edge of the slab, and
extending transversely thereof, and C marks a row of holes extending longi-
tudinally thereof. These slabs can be ornamented with any device or pattern
during the making or moulding of same, or they can be inlaid, as previously de-
scribed, after they are burnt. Figure 9 represents a slab with a plain surface
left for printing, painting, or stencilling any device thereon in color, and D and E

page_text: mark a series of holes extending longitudinally and transversely thereof.
Figure 10 represents a block passed through a moulding die, formed with au
ornamental device produced by a series of chambers extending throughout its
entire length, and A, B, C, denote the marking where the block is to be cut
through or sliced so as to form tiles. Figure 11 represents a tile cut off the
said block and readly to be filled in or inlaid with the several materials, as pre-
viously described or otherwise, or said tiles may be used to form open or
trelliswork, and by these means I can produce tiles and slabs of any design
and of an ornamental character in a speedy manner, and at a small cost.
At Sheet 2 Figure 12 represents a plan; Figure 13, a front elevation, and
Figure 14, a side elevation of my improved stairs or steps. Figure 15 is the
tread thereof, and Figure 16 the end of the stairs. Figure 17 represents
front of risers, and Figure 18, under side of soffit. Figure 19, the end of
step, shewing the chambers or perforations formed by the sods, as before stated.
Other forms of staircases and modes of decoration or ornamentation than
those exhibited by the Drawing may be employed, and stairs or steps thus
made are intended to be fixed in the manner commonly practised of fixing
stone stairs or steps.
At Sheet 3, Figure 20 represents an elevation of posts and rails arranged
for agricultural and other fencing purposes. These posts can be made of any
ornamental design to support wire or metal work, or for the enclosure of
ornamental parks or grounds; Figure 21 is a longitudinal view of said post,
shewing its construction; and Figure 22 is a plan or cross section thereof,
exhibiting the perforated chambers extending through said post; Figure 23
is a front view of the post, and Figure 24 a side view of same; Figure 25
represents a mile or distance post adapted for railways; Figure 26, a ground
plan of same.
parts
Figure 27 represents a telegraph standard, and Figure 28 a plan of same,
with holes extending longitudinally through it. A marks the dowells passed
through the entire length of the standard, and B, C, D, are divisional
of said standard. These standards can be made to any design or of any form,
and can be lengthened to suit any desired height by a series of lengths, or
metal or other suitable material can be attached thereto by means of bolts,
nuts, and metal bands.
i now proceed to describe the mode of manufacturing columns according to
my said Invention, as follows:-I shape a shaft or form of any given size
and design in wood, plaster, or clay, at a given length, and model, carve, or
engrave any pattern thereon as may be desired, and after so completing same,
the aforesaid model of the shaft or object I then lay upon its side on a bench

page_text: or table, and proceed to draw a line the entire length on each side of the shaft
or object, marking its diameter in halves or in suitable divisions for moulding;
I then bed clay or other suitable materials up to the aforesaid lines, in order
to form a thickness for one half mould to be taken in plaster of Paris or any
other suitable material. After the aforesaid has been prepared with a pre-
paration of grease, oil, or clay water, to prevent such plaster or material
adhering to the aforesaid model column or object, I then apply fluid plaster
of Paris or other suitable material in such divisions according to the usual
method of piece-moulding, and when the operation is complete I place a
collar or stop-piece, made of metal or wood of the half circle or division, and
place it at each end or side of the model, with a given number of holes
through, as may be required for the thickness of the column or object to be
made. I then place a shell or case mould, formed of iron, plaster, wood, or
any other suita le material, and place over the whole piece-mould encasing
the aforesaid collars. After this operation is complete I turn the other half
or division of the imbedded model over, and form the other half mould in a
similar manner, thus forming an entire mould round the said model, column,
or object; I then separate the mould, and remove the model, remove the
pieces from the case, and place them in their respective half or divisional
cases. The mould is then ready to receive the terra cotta or plastic material,
as described with reference to Figures 1, 2, 3, 4, 5, 6, 7 of Sheet 1; and
this mode of moulding is applicable to the manufacture and construction of
fire-proof stairs, ste s, landings, slabs, roofing, paving, or ceiling, tiles, slabs
for facing of buildings, chimney shafts, columns, pilasters, friezes, and blocks
for buildings, and all other similar articles in forms or diminishing faces, or
surfaces of an ornamental or florid description or character.
The manner in which I proceed to manufacture the above-named articles
in terra cotta, stoneware, or plastic clays, shown at Figures 16, 17, 18 of
Sheet 1, is as follows:-I place a thin layer of the plastic material in a
mould of the construction lastly described, and then pass a metal or wood rod
or bar through one of the holes made in the collar or stop-piece, as before
described, through the whole length or breadth of the mould, and pass said
rod or bar into the opposite hole in another collar placed at the other end
of the mould to receive the same; by these means the rod is kept in its
position. I then work the plastic material round and about the said rod or
bar, and continue this operation with other similar rods or bars until all the
holes have been filled. The thickness of the article being thus formed, I
procced to set this half of the mould aside until the other half or divisional
mould has been similarly treated; I then place the two half moulds together.

page_text: the joint and thickness I then form by working together with some of the
plastic material; I then remove the rods, thus leaving channels or chambers
through the longitudinal or transverse parts of the moulded article, to
facilitate the drying and burning thereof, and set the full mould aside for
the plastic material to stiffen or dry, and when sufficiently dry I remove
the mould from the article made. The joints or seams of the mould I
carefully clean off the article in the usual way, and put the article aside
to dry, and when sufficiently dry I place the same in the kiln for burning.
As regards the mode of manufacturing cores for columns, posts, standards
of a plain description suitable for telegraph, railway, and other purposes,
also for blocks and tiles for buildings, in order to expedite and lessen
the cost of these articles, I express or force the plastic clay, terra cotta,
or stoneware material by the aid of steam or labor power through
moulding dies or orifices similar to the dies now in use of any given
for or shape, and by fixing a central core to the die plate, with a number
of small cores attached to main core, 1 produce longitudinal openings or
chambers in the thickness of the material, thereby affording greater facility
for drying or burning the same; articles, thus made, I join together in their
plastic state, or after burning, by means of the aforesaid dowells and cement
as before stated. To construct a column, post, standard, or upright of
any given form or length, I place the several divisional parts thereof on or
within each other, and then I insert solid or nearly solid cores or dowells
of terra cotta, stone, or iron inside same. The dowelis being of such lengths
as to break joint with each length of hollow cylinder, and I connect or grout
the whole together with a suitable cement or material, and, finally I affix a
cap or capping piece moulded in half or divisional roulds as before stated;
columns and articles thus made I find extremely strong, and this mode of
operating applies to the manufacture of steps, stairs, chimney shafts, posts,
pedestals, standards, uprights, and similar articles. As regards my improve-
ments in the manufacture of landings, slabs, and tiles for roofing, paving,
flooring, and ceilings and facings of buildings it consists in forming holes
longitudinallyand transverselyof the material in thethickness thereof in moulds
as before stated, or otherwise. As regards my improvements in the ornamen-
tation of articles made of terra cotta, stoneware, and plastic clays it consists
in pressing the plastic material with the ornament in a mould or moulds
or moulding dies with the before-mentioned hollow channels or chambers, and
then removing some of the plastic material either by hand or by indenting
same by the mould, then burning them or afterwards filling in such removed
or indented parts with colored vitreous clays, marbles, stones, wood, metals,

page_text: scagliola suitable cement or material,vitreous andother colors. And I prepare
slabs in terra cotta, stoneware, or plastic clays for the faces or surfaces o
buildings, walls, or ceilings, panels or friezes in such sizes or divisions as may
be required. I then prepare the surfaces of such slabs for fresco painting or
stencilling thereon bymeans of roughing thefacesor surfaces with a plasterer's
float covered with felt, cork, or other suitable material, for the purpose of
forming a rough or keyed face or surface for holding on such colors, and
while the slabs are in a green or moist state, I then paint in fresco or impart
in color any design or subject, I then dissect such slabs in such divisions as
may be required or desired; and when sufficiently dry I remove them to the
kiln for burning, and burn the same in at one baking or burning; or I glaze
or enamel the entire surface, if required, and when such parts or divisions
are burnt or baked I place them again together to form one entire surface.
Terra cotta, stoneware, or plastic materials treated in this way constitute a
very ornamental and durable material.
Having now fully described and set forth the nature and object of my said
Invention of "Improvements in the Manufacture, Construction, and Ornamen-
tation of Articles made of Terra Cotta, Stoneware, and Plastic Clays adapted
for the Construction of Fireproof Stairs, Steps, Landings, Slabs, Tiles for Roof-
ing and Paving, Chimney Shafts, Columns for Buildings, Posts or Standards,
Pedestals and Statues, and in the Method of Moulding the same," together
with the best means I ain acquainted with for carrying the same into practical
effect, I would remark, in conclusion, that I am aware that cylinders or tubes
have heretofore been formed of plastic materials in the shape of steps and
columns of a single thicknessand parallelwidthbypassing same through dies, I
desire it therefore to be distinctly understood that what I claim asmy Invention
intended to be secured to me by the above in part recited Letters Patent is,―
First, the mode herein described and illustrated by reference to Figures
1 to 7 of Sheet 1, of manufacturing articles from terra cotta, stoneware, and
plastic clays by forming or shaping the same in moulds so constructed and
operated with as to leave chambers or passages therein for the purpose of
preventing alteration or distortion of the shape of the moulded article during
the operation of drying and burning or baking in the kiln as above stated.
Secondly, I claim the mode herein-described and illustrated by reference
to Figures 8 to 19 of Sheets 1 and 2 of manufacturing and ornamenting
and inlaying stairs, steps, slabs,and tiles made from terra cotta, stoneware, and
plastic clays.
Thirdly,I claim the mode herein described and illustrated by reference to the

page_text: several Figures of Sheet 3 of manufacturing posts, standards, and uprights
from terra cotta, stoneware, and plastic clays.
In witness whereof, I, the said Mark Henry Blanchard, have here-
unto set my hand and seal, this Thirtieth day of September, in
the
year of our Lord One thousand eight hundred and sixty-one.
MARK HENRY BLANCHARD. (L.s.)