AN IMPROVED SYSTEM OF CASTING : OR MOULDING, APPLICABLE TO CEILINGS, INTERNAL AND EXTERNAL WALLS;
Year: 1872

page_text: LETTERS PATENT to Robert Stone, of Liverpool; in the County of
Lancaster, for the Invention of “AN IMPROVED SYSTEM OF CASTING :
OR MOULDING, APPLICABLE TO CEILINGS, INTERNAL AND EXTERNAL WALLS;
69
'
Sealed the 23rd August 1872, and dated the 15th April 1872.
PROVISIONAL SPECIFICATION left by the said Robert Stone at the
Office of the Commissioners of Patents, with his Petition, on the
15th April 1872.
I, ROBERT STONE, of Liverpool, in the County of Lancaster, do hereby
declare the nature of the said Invention for "AN IMPROVED SYSTEM OF
CASTING OR, MOULDING, APPLICABLE TO CEILINGS, INTERNAL AND EXTERNAL WALLS,
hOADS, NAVIGABLE VESSELS, AND OTHER LARGE SURFACE STRUCTURES," to be as
follows:-
This Invention relates to casting or moulding surface structures in
position by means of dies or moulds, and consists of an improved system.
of arranging and filling the moulds, and keying or attaching the moulded
sections together. The moulded work is formed in the position it is

page_text: intended to remain in, such as ceilings, roofs, the covering of walls,
forming of chimney pieces, skirtings, mouldings, and so forth, in contra-
distinction of first moulding or casting them, and then fixing them in
the position they are intended to permanently remain in.
In applying this Invention to, say, a ceiling the moulded work is
formed in sections by means of dies or moulds, having the required orna-
mentation sunk or raised thereon according to the design. The sections
are formed with key or dovetail edges, male and female, so that they key
or lock firmly together. The dies or moulds are formed with overlapping
jointed edges coinciding with each other so as to obviate or hide the joints
of the several sections being seen in the work. The moulds or dies are
placed in position below the ceiling; the plaster, cement, or fluid metal
is then run in from above. This arrangement of casting ceilings, floors,
and other surface structures is particularly applicable to the system of
flooring or roofing, for which Letters Patent were granted to the appli-
cant bearing date the 17th day of September, 1869, and numbered 2709,
but is applicable to ordinary roofs, ceilings, and other surface structures
constructed of wood, in which case the rafters, joists, or walls have added
to them a projecting ridge or a projecting course of bricks to form a key
for the liquid material forming the surface to key or attach.to.. The
moulds when placed in position may form the whole surface, or thọ sur-
face may be moulded in separate sections.
In using iron or other metal beams, joists, or rafters in connexion
with this system of moulding or casting surfaces, such beams, joists, or
rafters are perforated so that the plaster, cement, or fluid metal attaches
from either side of the beam through the perforations, forming literally
one amalgamated whole. In moulding or casting a surface, one portion
of the intended surface may be covered with moulds or dies when the
liquid is run into that portion; after which, when the liquid material is
sufficiently set, the moulds or dies may be removed, except those on the
outer edges, the moulds or dies being then placed in position and con-
junction with those remaining, thus making the counterpart of the surface,
and so on until the surface is completed. In the case of using ordinary
plaster or cement, laths, or fibrous material, or wire netting may be
introduced, when by this system a more perfect adhesion of the whole is
obtained by means of the plaster or cement amalgamating round the
laths, fibrous material, or wire netting, and thus increasing the strength
of the surface. Fibrous material may be introduced into the plastic

page_text: substance without bringing the same to the surface of the work, thus
giving additional strength. The moulds may be first faced with a layer:
of fine material, and then filled up with coarser and stronger substances,::
such as fire resisting cement, or a coarser description of plaster. Sand
may be placed on the top of ceilings, thus acting as a non-conductor in
the case of fire. In the event of fire, should the ceiling fall, it will
descend in a sheet, which would have the effect of damping or totally
extinguishing the fire below..
In applying this Invention to the surface of walls, the moulds or dies'
are placed just sufficiently from the face of the wall or partition to allow.
the plastic material to be run in from above.
In applying plaster or ornamental work to buildings the wall is
fitted with projecting dovetail bricks or their mechanical equivalent,
so as to key or attach the plastic work and to bind the same to the
3 surface and to sustain the weight. Ceilings and other surface structures
may be covered, or laid over with boards or other suitable surfacing.
When this Invention is applied to walls not originally constructed
to receive ornamentation, the moulded work can be secured in position.
by cutting cavities in the wall or inserting T iron projections. Cavities
may be left between the wall by placing core pieces against the walls
and withdrawing the same as the work proceeds.
In applying this Invention to horizontal surfaces such as foot or
roadways, promenades, and other similar surfaces, the moulds are turned
face downwards and held up a sufficient distance above the foundation
to admit of the requisite quantity of surfacing material to be run under-
neath. The mould in this case is formed with an orifice with a hopper
mouth for running in the plastic material.
:
i
In lieu of using the moulds for horizontal surfaces, plastic material may
be run on in sections by means of using dovetailed rails or guide pieces
and a roller, which roller is formed with a scraper or leveller running in
front, and a hopper shaped feeder. The roller runs on the rails or guides
feeding the fluid, then scraping or levelling it, and then rolling or setting
it. These rollers may be formed with collars or projections, leaving
grooves or gutters in the work. When one section is rolled or set the
rails are removed, replaced, and again laid parallel to the work, and the
action repeated, the plastic material entering into the dovetail groove left
by the rail, and thus keying or attaching to the completed work.
:
:
i

page_text: In the case of roadways, the grooves formed by the roller may be
filled in with wood or other clastic material to prevent draught animals
slipping.
In the case of footways and when desired they may be perforated so
as to carry off rain or surface water into the street channels, the foot- 5
ways being formed with cross channels moulded in them; the curb may
be of iron or stone with suitable openings tallying with the channels in
the footway; the said channels may be used for laying pipes or other
purposes, or the footways may be made with fluted or grooved channels
or gutters on the surface by means of the moulds or dies, or with a roller 1
as before-mentioned. When these channels or gutters are formed with
moulds or dies it is preferred to use heavy weights, by leverage or other-
wise, so as to stamp the channels or gutters clean.
Navigable vessels, boats, bridges, boilers, waggons, carts, and other
similar structures can be manufactured according to the before going 1
principle by means of moulds or dies and malleablized when cast.
In the case of casting a navigable vessel, a suitable dock or pit being
taken, the same is faced with sand or loam; iron or steel frames are
then introduced, by preference having undercut grooves at each side,
and lateral perforations or openings through the side. The frames being ?
set, there is then formed an internal core or mould, and around the dock
are erected a number of cupolas to supply the metal for filling the
moulds. Having secured the core the metal is run into the mould from
the several cupolas simultaneously, so as to fill in the spaces between
and around the frames, the metal amalgamating through the perforations
in the frames. When the metal is cool the core is removed and as
much of the external mould as deemed necessary. The sheel is then
packed internally and externally with peat charcoal, or other suitable
material, which is ignited and allowed to burn gradually for the purpose
of annealing or malleablizing the sheel.
In some cases it may be desirable to cast a vessel in large sections, in
which case the edges of the sections are formed with dovetail grooves,
so that moulten metal may be afterwards run in to lock the sections
together.

page_text: .
distinction of first moulding or casting them, and then fixing them in
the position they are intended to permanently remain in.
In applying this Invention to, say, a ceiling, the moulded work is
formed in sections by means of dies or moulds, having the required
ornamentation sunk or raised thercon according to the design. The
sections are formed with key or dovetail edges, male and female, so that
they key or lock firmly together. The dies or moulds are formed with
overlapping jointed edges coinciding with each other, so as to obviate
or hide the joints of the several sections being seen in the work. The
moulds or dies are placed in position below the ceiling; the plaster,
cement, or fluid metal is then run in from above. This arrangement of
casting ceilings, floors, and other surface structures is particularly
applicable to the system of flooring or roofing, for which Letters Patent
were granted to me bearing date the 17th day of September, 1869, and
numbered 2709, but is applicable to ordinary roofs, ceilings, and other
surface structures constructed of wood, in which case the rafters, joists,
or walls have added to them a projecting ridge of projecting course of
bricks to form a key for the liquid material forming the surface to
key or attach to. The moulds when placed in position may form the
whole surface, or the surface may be moulded in separate sections.
In using iron or other metal beams, joists, or rafters in connexion
with this system of moulding or casting surfaces, such beams, joists,
or rafters are perforated, so that the plaster, cement, or fluid metal
attaches from either side of the beam through the perforations, forming
literally one amalgamated whole. In casting or moulding a surface,
one portion of the intended surface may be covered with moulds or dies,
when the liquid is run into that portion, after which when the liquid
material is sufficiently set the moulds or dies may be removed, except
those on the outer edges, the moulds or dies being then placed in
position and conjuction with those remaining, thus making the counter-
part of the surface, and so on until the surface is completed. In the
case of using ordinary plaster or cement, laths, or fibrous material, or
wire netting may be introduced, when by this system a more perfect
adhesion of the whole is obtained by means of the plaster or cement
amalgamating round the laths, fibrous material, or wire netting, and
thus increasing the strength of the surface. Fibrous material may be
introduced into the plastic substance without bringing the same to the
surface of the work, thus giving additional strength. The moulds may

page_text: be first faced with a layer of fine material, and then filled up with
coarser and stronger substances, such as fire resisting cement, or a
coarser description of plaster. Sand may be placed on the top of
ceilings, thus acting as a non-conductor in the case of fire. In the
event of fire, should the ceiling fall, it will descend in a sheet; which
would have the effect of totally extinguishing the fire below.
•
In applying this Invention to the surface of walls, the moulds or dies
are placed just sufficiently from the face of the wall or partition to allow
the plastic material to be run in from above.
וי
In applying plaster or ornamental work to buildings, the wall is fitted
with projecting dovetail bricks, or their mechanical equivalent, so as to
key or attach the plastic work and to bind the same to the surface and
to sustain the weight. Ceilings and other surface structures may bo
covered or laid over with boards or other suitable surfacing.
When this Invention is applied to walls not originally constructed to
receive ornamentation, the moulded work can be secured in position by
cutting cavities in the wall or inserting T iron projections. Cavities
may be left between the wall by placing core pieces against the walls
and withdrawing the same as the work proceeds.
.
In applying this Invention to horizontal surfaces, such as foot or
roadways, promenades, and other similar surfaces, the moulds are turned
face downwards, and held up a sufficient distance above the foundation
to admit of the requisite quantity of surfacing material. to be run
underneath. The mould in this case is formed with an orifice with a
hopper mouth for running in the plastic material.
In lieu of using the moulds for horizontal surfaces, plastic material
may be run on in sections by means of using dovetail rails or guide
pieces and a roller, which roller is formed with a scraper or leveller
running in front and a hopper-shaped feeder. The roller runs on the
rails or guides feeding the fluid, then scraping or levelling it, and then
rolling and setting it., These rollers may be formed with collars or pro-
jections leaving grooves or gutters in the work. When one section is
rolled and set the rails are removed, replaced, and again laid parallel
to the work, and the action repeated, the plastic material entering into
the dovetail groove left by the rail, and thus keying or attaching to the
completed work.

page_text: In the case of roadways, the grooves formed by the roller may be filled
in with wood or other elastic material to prevent draught animals from
slipping.
In the case of footways and when desired they may be perforated so as
to carry off rain or surface water into the street channels, the footways |
being formed with cross channels moulded in them. The curb may be
of iron or stone with suitable openings tallying with the channels in
the footway. The said channels may be used for laying pipes or other
purposes, or the footways may be made with fluted or grooved channels
or gutters on the surface by means of the moulds or dies, or with a roller 1
as before mentioned. When the channels or gutters are formed with
moulds or dies, it is preferred to use heavy weights, by leverage or other-
wise, so as to stamp the channels or gutters clean.
Timber surfacing for footways, roadways, and other large surfaces,
may be easily applied according to my Invention. In this case I ]
roll. or otherwise form grooves in the cement, asphalte, or concrete,
which grooves are moulded with dovetail edges, worked out with a
scraper while the material is yet soft. Planks having dovetail edges
are fitted into the dovetail grooves formed in the cement, concrete, or
asphalte, the spaces are then filled in with other dovetail planks, thus 2
forming a timber surface without the use of nails, spikes, and other
similar fastenings. The timber should be dipped in boiling tar before
being applied.
Navigable vessels, boats, bridges, boilers, waggons, carts, and other
similar structures can be manufactured according to the before-going :
principle by means of moulds or dies and malleablized when cast.
In the case of casting a navigable vessel, a suitable dock or pit being
taken, the same is faced with sand or loam; iron or steel frames are
then introduced, by preference having undercut grooves at each side, and
lateral perforations or openings through the side. The frames being set, a
there is then formed an internal core or mould, and around the dock are
erected a number of cupolas to supply the metal for filling the moulds.
Having secured the core the metal is run into the, mould from the
several cupolas simultaneously, so as to fill in the spaces between and
around the frames, the metal amalgamating through the perforations in 8
the frames. When the metal is cool the core is removed and as much
of the external mould as deemed necessary. The sheel is then packed

page_text: course of bricks D¹. The dotted lines E represent where the moulds or
dies overlap, forming the mouldings F and hiding the joints. The beams C
are perfectly surrounded by concrete, and are thus hermetically sealed
and preserved. In Figure 2, G is a timber planking which is laid over the
concrete A, and held in position by the dovetail pieces C₁ of the beams C.
Figure 3 shows lapping of sections for ceilings and such like structures.
In Figures 4 and 5 the concrete A is run in above the moulds or dies B.
Upon the moulds or dies being removed the concrete is left in position
formed to the pattern represented by the mould or die. Figure 8 is a
sectional end elevation of a roller for laying surfaces; Figure 9 is a plan
of same; and Figure 10 a sectional side elevation. Plastic material is
filled into the hopper H, which feeds the material on to the surface to
be laid. H' is a scraper or leveller which follows the hopper, and
prepares the material for the roller K, which roller may be plain or
formed with collars, as shown. The roller has a groove or wheel M, 1
which takes on to the guide rail N. The roller is held in position on the
rail by the leading wheels O. The rails are laid over the portion of
surface to be operated upon, and after use are removed and relaid in a
parallel position, and the action repeated.
In some cases the rail N may have a dovetail edge, in which case the 2
plastic material enters into the groove left by the rail, and keys the
sections of the work together.
P are adjustable wheels or castors, which are attached to each end of
the rails N to enable the rails or frames to be moved into position, as may
be required. Figures 12 and 13 illustrate the method of working the 2
roller. At each end of each rail is fixed a bracket R, which supports a
shaft S, which carries friction or V pulleys, which pulleys are keyed on to
the shaft. An endless rope or chain is connected to the roller at each
side and passed over the pulleys, the pulleys being turned by a handle;
the roller is thus drawn backwards and forward along the rails and over 3
the work. When the hopper II is empty it is brought under the shoot
of the mixer and feeder, shown at Figure 13. This mixer and feeder
consists of a triple hopper T, which is charged with cement in the com-
partment T', and gravel in the compartments T. U is a shoot, and Va
mixing rack. V is a second rack, which mixes the cement with water 3
in proportion as required. The racks are turned by suitable handles.
X is a water tank, which is fitted with a "shower," regulated by a
valve Y. The tank X is also fitted with a cock Z and a hose Z'. The

page_text: hose is fitted with a suitable nozzle or rose. The hose may be of any
required length, so that the work may be moistened at any required part.
The roller hopper H is replenished with cement through the shoot U,
which is fitted with a hopper door.
In some instances it will be desirable to sprinkle the concrete over
with any soft material, such as lead ore, which is then rolled on to the
surface.
Sheet 2.-The roadway or footways may be groved, fluted, and per-
forated, as shown in Figures 14, 15, 16, 17, 18, and 19. In these cases
the footways may be formed with cross channels a moulded in them.
The curb 6 may be of iron, stone, or other suitable material. The
channels a may be used for laying pipes or for any other purposes.
Footways or roadways may be laid with grooves or gutters c by means
of moulds or dies, or with a roller, as before described, or dovetail
grooves d, Figure 21, may be formed in the work by means of timber
strips of that formation, or they may be moulded and then scraped, but
with a dovetail edge, the dovetail grooves then filled in with timber,
either to prevent draught horses or other animals from slipping, or to
form a permanent timber way, is will be well understood upon reference
to Figures 20, 21, 22, and 23.
In some cases it is desirable in laying the timber, as shown in the
Drawings, to fit the edges in with sheet lead.
Having now fully described and explained the nature and purposes of
my Invention, and how the same is to be carried into practical effect, I
wish it to be clearly understood that I do not confine myself to the
various descriptions of operations and apparatus as shown, as it will be
readily seen that the same may be considerably varied without departing
from my Invention; but what I claim as the Invention secured to me
by Letters Patent as aforesaid is,―
Firstly. The system herein-before described of casting or moulding
surface structures in position by means of dies or moulds, substantially
in the manner and for the purposes set forth.
Secondly. Perforating beams for use in supporting plastic material,
the plastic material annealing or amalgamating through the perforations.
Thirdly. The plain or collared roller and rail, and operation of using
same by running it on rails, shown and described at Figures 8, 9, 10,

page_text: and 11, for laying surfaces, of plastic material, substantially in the
manner and for the purposes set forth.
Fourthly. The improvements in working the rollers for laying surfaces
of plastic material, and the process of mixing and amalgamating such
plastic material, and a method of filling and replenishing the hopper in
connexion with the said roller, as shown and described at Figures 12
and 18, substantially in the manner and for the purposes set forth.
Fifthly. The improvements in footways and roadways, shown and
described at Figures 14 to 19, substantially in the manner and for the
purposes set forth...
Sixthly. The improvements in footways and roadways, and in filling
in the same or surfacing the same with timber, as shown at Figures 20
to 23, substantially in the manner and for the purposes set forth.
Lastly. The improvements applicable to shipbuilding, substantially as
described and set forth.
In witness whereof, I, the said Robert Stone, have hereunto set my
hand and seal, this Eleventh day of October, in the year of our
TA 1970
:
Witness,
FREDERICK JOHN CHEESBROUGH,
of 15, Water Street,
.
Liverpool.
ROBERT (L.s.) STONE.