Improved Method of Producing Ornamented Hollow or Massive or Torsel Columns, with Mouldings All Round, of Rolled Bar Iron.
Year: 1896

page_text: Date of Application, 2nd Mar., 1896-Accepted, 16th May, 1896
COMPLETE SPECIFICATION.
Improved Method of Producing Ornamented Hollow or Massive
or Torsel Columns, with Mouldings All Round, of Rolled Bar
Iron.
LOUIS MANNSTAEDT, of Kalk near Cologne, Rhenish Prussia, Germany,
Rolling-mill Owner, do hereby declare the nature of this invention and in what
manner the same is to be performed, to be particularly described and ascertained
in and by the following statement:-
Making round posts or round columus with moulded ornaments all round upon
their outer surfaces and hollow or solid, of bar iron and other rolled or drawn, not.
cast metals, has not been effected to my knowledge, because a rolling mill on which
they could have been made with moulded ornaments on their outer surface all
round and spreading in all directions on it, is not existing; even if there had been
one composed of any number of co-operating rolls, it would not have been possible
to produce such columns but with a set of longitudinal separating edges between
the flat sides of the polygonal prismatic column thus produced. In some cases
there have been made polygonal bars or columns, approaching the circular section
with moulded ornaments of a simple character like ribs, rosettes, files of beads, and
similar simple mouldings in relievo, running lengthways, and interrupted by longi-
tudinal edges, but there have not been made posts with mouldings of a continued
all round design, varied in character and without prismatical or straightline
separating edges.
I have invented a method of producing hollow or massive columns or pillars from
rolled bars and showing on their outer circular surface on all sides moulded ornaments
of any richness of design or of simple character.
I proceed thus: First an intermediate product is made, in rolling or laminating
bars of such cross-section as will be suitable for the character and shape of the
ornamented column or pillar intended to be produced; therefore these rolled bars
are of various kinds.
That side of these bars, which has to appear on the outer surface of the pillars,
will be provided with the desired ornamental designs in rolling the bars, and the
profile or cross section and the distribution of the material in it will be chosen
for these bars in accordance with the intended column, because the success of the
method depends largely upon these points, 30 that the general shape of and the
repartition of the material in the cross-section of the intermediate product-without
regard to the ornaments-are determinants for the configuration of the final product,
the ornamented column.
Such intermediate product as described, is then used to form the circular,
ornamented, hollow pillar or column, of rolled bar iren, for instance, in winding it
so that it forms the closely coiled wrapping of a cylinder, cone or other real or
ideal core, and that the lower and the upper edge lines of the twisted bar remain
in close contact, forming a screw line, the pitch of which may be expressed by
the formula. d. tang a, when the width B of the bar-iron was B. d. sin a,
the angle a indicating the angle of inclination of the coil and d indicating the
diameter of the intended column; according to the width B of the bar-iron, which
is to be wound into a column, and to the diameter d of the latter, the augle a

page_text: will vary and be more or less acute and d and a being known, there is no difficulty
to determine beforehand, which angular direction will have to be given to the moulded
ornaments rolled on the bar iron, as for instance diamonds, folinge bandelets, in order
to have them appear on the finished column in a parallel line with its axis or in
a horizontal or inclined line.
These data for themselves are not sufficient to produce an ornamented column
of a given profile. The cross section of the intermediate product and the repartition
of material in it are of equally determinating influence on the final configuration of
the column.
In winding the rolled bars there are produced strains exerting their effect on the
side edges of said bars in a certain direction, as for instance in Fig. 1 of the annexed
drawing, a certain profile of cross section is shown, having an ornamented side a
which is exposed to strains in direction of the arrows X X, when undergoing
a twining or winding up operation for obtaining a hollow pillar with exterior
ornaments; these strains will tend to cross-bend the profile as indicated Fig. 2,
and the ornaments on the side a would be partly covered by the side flanges bending
inwardly. Therefore, instead of making an intermediate product of the cross-
section Fig. 1, it will have to be shaped conform to Fig. 3, so that the side a',
in winding a column of this bar, will be straightened so, that the ornaments moulded
on this side, will appear spread on a flat surfaced band-coil.
Plain flat surfaced profiles appear concave in a direction lengthways of the
pillar, and convex, or cylindrically rounded, when a section is taken vertically to
the longitudinal axis of the column; and in the direction at right angle to the line
of inclination of the coil, the sectional line will be a straight one.
For these particular reasons it is necessary to construct the profiles of the rolled
bars for the winding of columns of a concave part having to form the inside of the
column, and a convex or raised part, having to form the outer surface of the intended
column.
If columns are to be made with rounded or boultin coils winding round them,
the intermediate product is to be shaped according to the more flattened or
more rounded cross-section in which these boultins have to appear, like Figs. 4
and 4 or Figs. 5 and 5. In the first case the original half-round cross-section
changes but little in winding, because the boultin n and the ribs o will com-
pensate; in the second case however the ribs o' exerting a heavy pressure on the
arched portion p, will considerably compress it sideways so as to curve it more and
to bring it to a nearly closed circular shape. In my method therefore these two
profiles of rolled bars will produce columns as represented by Figs. 6 and 7
respectively.
Columns made by winding such simple profile bars, are hollow and consequently
will only resist to comparatively limited loads, but their resistance may be increased
by filling them inside with suitable material such as metal, cement and the like,
poured into them. The strength of columns made according to my new process
may also be increased by using for their production a bar of more complicate
profile and by combining such profiles as for instance & Fig. 8 with two cornice
profiles and, Fig. 8, filling partly up the empty spaces of the former, as shown.
The middle rib of the profile in tee form, going through uninterruptedly in the
centre of the column, replaces with advantage the filling up of the inner hollow
with cast metal.
The operation of winding up several profiled bars together, as those Fig. 8;
allows further important effects to be obtained. For instance, in winding a bundle,
formed of two iron bars, between which a copper or yellow metal bar is held, a
column is produced with an exterior red or yellow helical band running between
the iron coils, showing an exceedingly nice effect of beauty, such as has not yet
been obtained in columns of cast metal, and which has only been possible to
imitate in an inferior way by painting, a
substitute.
soon fading away and perishable
Obviously the effects of colour and ornaments may be obtained

page_text: in a most various and prominent way by combining differently coloured metals,
in alto-relievo or basso-relievo or in inarquetry style, in fact, in unlimited
richness.
The resistance of columns produced by my new method may still be increased
by giving the ribs or edges of the hars to be wound and which adjoin each other in
the helical line at the outer surface, such forms that they reach into one another or
with overlapping cramp edges or by interposing such bars between them, all of
which forms have a serrating or cramping effect on the contact parts of the edges,
when the bars are wound together.
A few of such forms are represented in Figs. 9, 10, 11, 12, 13, 14, 15 of the
drawing. In the same manner as several complicate profiles may be bundled to
form a strong substantial hollow column in winding, simple profiles may be
combined together to form hollow columns, provided their contact edges be
constructed of such shape that in winding they form close joints; thus columns
and hollow posts or tubular pillars may be produced as well by winding single
as by winding several suitably shaped bars of one and the same or of various
metals.
Tubular posts made in this way and having contact flanges in helical lines round
the column outside, may be strengthened by soldering, welding, rivetting or bolting
these flanges together, as shown for instance in Fig. 16. This operation also may
considerably strengthen the resistance of the column.
Finally my method is used for producing tubular, or hollow conical posts or
columns and likewise for columns or pillars of variable diameter in different heights,
as follows:
Flat or other rolled bars are used, having variable width, as for instance bars
with convergent sides and having suitable alto-relievo embossed mouldings on the
surface which diminish in width with the bar as well as in height as is represented
an instance in Fig. 17, I, I, III, or having parallel edges, but varying in thickness
of stuff, like Fig. 18 I, II. In twining such bars the weaker profile part will be
stretching more easily than the stronger profile part, consequently the former will
produce a part of the column of reduced diameter and the latter will give an increased
diameter of the coiled column; the cross-section Fig. 17 or 18' will produce the
great diameter of a tubular conical column, and the profile Fig. 17 or Fig. 18t
shows the cross-section producing the smaller diameter of the tubular conical column
intended to be made.
A straight rolled bar of profile Fig. 17 successively taking the shape of
profiles Fig. 17 and 17, increasing in width and diminishing in height,
when being wound to form a column, will give a conical product. The same
will be the case when a blank of section Fig. 18' gradually changes into that
Fig. 181.
If in
one and the same bar the cross-section is made varying from the
section Fig. 17 to section Fig. 17" and vice versa, the column produced will have
a wave like shape of alternately decreasing and increasing thickness as indicated
in Fig. 19.
When rolling such bars of variable width, the gradations of profile Fig. 17
to Fig. 17 or Fig. 18' to Fig. 18" must be insensibly increasing and decreasing
without sudden variation in width which presents no difficulty, provided the rolls of
the mill be conveniently calibered.
When using angle bars as intermediate product an acute angle will form the larger
diameter of the column, an obtuse angle will produce a part of the column with a
smaller diameter.
My method of winding rolled bars for making columns is not to be confounded
with the known process of simple twisting of rolled bars by which they are
brought in a helical form; it is obvious that in that way cylindrically round'
columns or pillars proper cannot be made and still less hollow or tubular
columns with moulded ornaments all round in alto-relievo or basso-relievo or

page_text: with half round or cornice shaped or round boultins as in Figs. 6 and 7, drawu
from nature.
The Figs. 20 to 23 (1, 11,) are respectively front views and cross sections of
rolled bars serving as blanks for inaking the columns shown by Figs. 20 to 23 (111.)
by any described method; Fige. 20 to 22 (1, 11) being made of channel or grooved
sections, and Fig. 23 (1, 11) showing an angle iron bar having on one outer
face ornaments moulded of diamond character, Fig. 24 shows a hollow column
of a richer design, made by twining together three rolled bars, adjusted
previously and composed of a tee section bar with moulded ornaments on the
outer cross-flange side, lauked by two rolled bars of cornice profile like those,
shown in Fig. 8.
As mentioned before, my method also comprises the production of massive or
solid columns of rolled iron or metal bars with ornaments all round their helical
surface of cylindrical form. For this purpose the winding of rolled bars of suitable
profiles is effected round an imaginary axis, which does not coincide with the axis
of gravity of the profile itself, so that here also, there is no simple twisting of a
bar round its axis.
An example of this class is represented by a simple pattern in Fig. 25, I, II, III.
A rolled bar of the cross section profile Fig. 25 11 is subjected to a winding
operation round an axis which is not the axis of the cylindrical main part of the
profile, but more or less distant from it sideways; so that the main body of the
bar section for itself appears as a helically wound rod in the finished column,
Fig. 25 with helically wound ornamenting baguettes surrounding it. The
distance a- may be great or small according to the distribution of material in
the intermediate product. The greater the distance of the twining axis 6 from the
gravity axis a of the sectional profile, the greater will be the diameter of the
finished massive column.
In place of an accumulation of material on one side of the profile, there may be
a channel or a fluted part on the side, in order to obtain a suitable distance of the
imaginary winding axis from the gravity axis of the main profile, as is shown for
instance in profiles Figs. 26 and 27.
Symmetrical profile sections would leave the core straight and only the appendix
protruding on the sides would appear as if wound helically round this straight
core.
Having now particularly described and ascertained the nature of my said inven-
tion and in what manner the same is to be performed, I declare, that what I
claim is:
1. A method of producing columns or cylindrical, conical, undulated or alternately
contracted and bulged coluinus or posts of rolled metal bars and with ornaments
spreading over the entire surface in alto-reliovo, moulded or flat designs or in
carved character (not in cast metal or embossel or pressed work) which consists in
winding helically one or more straight metal bars as an intermediate product or
blanks of suitable and appropriated profile section having ornaments rolled or
moulded thereon so that these bars form a serrated close envelop in helical lines
round a materially existing or an imaginary cylindrical core or round such a conical
core or other suitably shaped core, the upper and lower side edges of the so wound
rolled bars touching each other closely all round and thus producing a column
or post hollow or massive, and filling out or not in the first case the hollow space
formed in the interior of the column with a suitable metal or other substance cast
into it.
2. The process of making comical or alternately contracted and bulged columns
by using blanks rolled with ornaments of convergent form in width or in
thickness or alternatively convergent and divergent form in the sense of their
length.
3. The process of making massive or solid columns consisting in the winding of

page_text: rolled massive bars of unsymmetrical cross-sections around an imaginary axis
situated outside of the gravity axis of the respective profile sections.
Dated this 29th day of February 1896.
LOUIS MANNSTAEDT.
Karl J. Mayer,
Agent.