Article originally published in the FABRICATOR magazine Nov/Dec 1999 Edition and was written by Robert A. Baird who was the president of Cast Iron Restoration Management and one of the original founders of Historical Arts & Casting, a firm specializing in the design and manufacturing of architectural cast metal ornamentation.

The Rebirth Of A Cast Iron Gem (Part 3 of 3)

A community rallies to the cause of restoring a beloved courthouse.

Roofers install slate tiles on the southwest quadrant of the courthouse roof.Replacing the Slate and CopperApproximately 25 percent of the courthouse slate roof was damaged and needed replacement. A determination was made to remove all of the slate, saving the good tiles. The roof was re-sheeted with ¾-inch plywood, dried in, and the new slate laid on one quadrant. All of the original slate was re-laid on the other three quadrants of the roof.

Replacing the Slate and Copper

New copper flashing and gutters were installed for the entire roof system.  Each one of the decks on the central dome was sheathed in copper.  This material was fabricated on site by Vulcan Supply, a sheet metal and roofing contractor from Vermont.

Restoring the Statues

One of the more visible elements of the restoration was the removal and restoration of the copper statues originally built by W.H. Mullens of Salem, Ohio.  These heroic size statues were all removed at the beginning of the project and shipped to Vermont for restoration.  Each statue was disassembled, new copper armatures installed, repairs made, and then refinished.

Prior to installation, the seven statues that adorn the courthouse were displayed to the public at the Miami County Fairgrounds

Little was known about the full level of detail incorporated into the statues until historical photographs were uncovered in Salem, Ohio, in a local historical museum.  These photos not only showed the level of detail in Mullen’s work, but also revealed numerous missing elements from the statues that were re-manufactured.

When the statues arrived back in Troy, Ohio, they were exhibited at the fairgrounds.  Thousands of county residents came to get a close look at the figures that had stood as sentinels and watched over their community for 100 years.  Special workshops were held for school students to learn, see, and experience the skills required to repair and create this wonderful repoussé metalwork.

On the central dome, four large cast iron and glass clock faces were removed during the restoration.  The original movement to these clocks had been modified over the years and was not original. The weight driven mechanism had been converted to electricity and the striker for a large bronze bell was disconnected.  Because of the reliability of new electric clocks, the old movement mechanism was replaced; however, the bell was restored and connected to the new clock.  The old movement was put in a permanent display on the main floor of the courthouse.

Exterior Lighting

With the restoration nearing completion, Heapy Engineering, a local electrical engineering firm, was given the challenge to design exterior lighting for the courthouse.  They also helped develop a lightning protection plan for the susceptible metal roof.

The two-year restoration plan was completed on schedule and just in time for a large celebration on the July 4^th, sponsored by the county commissioners.  The courthouse was rededicated with over 34,000 in attendance.  The gala event was complete with a laser light show, great food, and tours of the courthouse.

Miami County Courthouse, Troy, OH

I have come to realize that a project of this size and scope cannot be done without the efforts of a lot of people.  This particular project would never have been so successful without the support and efforts of the many professionals, community leaders, and volunteers who lent their support.  Truly, their training and expertise brought about the rebirth of this old gem, Miami’s Pride.

Part 1 of 3

Part 2 of 3

Article originally published in the FABRICATOR magazine Nov/Dec 1999 Edition and was written by Robert A. Baird who was the president of Cast Iron Restoration Management and one of the original founders of Historical Arts & Casting, a firm specializing in the design and manufacturing of architectural cast metal ornamentation.

The Rebirth Of A Cast Iron Gem (Part 2 of 3)

A community rallies to the cause of restoring a beloved courthouse.

By Robert A. Baird

Time to Restore

Prior to starting the actual restoration, 43,000 pounds of pigeon waste and other debris were removed from the attic.  Scaffolding was erected from the ground for the pavilions but was cantilevered off the masonry around the corner domes.  Scaffolding was also set around the central dome.  An elevator lift was set up from the ground to the rooftop allow for the movement of material to and from the building.

A view from the inside shows the riveted iron structure and cast iron panels on the central dome.

Dismantling

With the site ready to start work, the laborious task of removing every piece of cast iron from the top of the central dome was started.  Each piece of iron was documented, catalogued, and then later inspected and numbered during the removal process.  Severely corroded material was scrapped and all usable material was removed from the site to be sandblasted and repainted.  Over 15,000 cast iron parts ranging from a few pounds to several hundred pounds were removed.  The demolition and installation crews grew to as many as 25 men and the work went year round after the first winter.

Restoring the Structure & Iron

The beauty of cast iron structures from this period is their simplicity.  The Miami County Courthouse was no exception, with a simple riveted iron structure or framework laced together with tie rods supporting the cast iron skin.  The combination of the cast iron bolted to the riveted iron structure created a very sound roof support system.  For the most part, the structure was in good condition and needed only to be cleaned, painted, and some minor reinforcement.  All of this work was completed in the field.

Connecting the restored cast iton panels to the central dome.

The restoration program for the cast iron was quite a bit more involved than the structure.  Over 50 percent of the cast iron had to be replaced, which meant new patterns were needed and new components cast.  Over 700 patterns had to be manufactured to produce the thousands of cast iron parts required.  Because shrinkage was critical, old parts could not be used as patterns.  Historical Arts and Casting had the responsibility of not only restoring the old parts but also manufacturing the new iron and installation.

One of the key elements of the restoration was the cleaning and painting of the cast iron, which ultimately would provide long-term protection for the iron.  Tnemec Corp. was very helpful in assisting with technical support and providing testing throughout the course of the project.  Their four-part paint system included zinc rich primers, intermediate high build epoxy, and two finish coats of urethane.  Cast iron parts were sandblasted and pre-finished prior to delivery to the job site.  After the installation, additional coats of paint were applied in the field.

The second major consideration during the cast iron restoration was the waterproofing.  The reason for the cast iron failure in the first place was the lack of adequate waterproofing.  We were confident that if we focused on waterproofing issues and thoroughly resolved them we could dramatically increase the life of the cast iron.  When new parts were required, we tried to improve on how they were built, adding flanges and lap joints to improve their ability to shed water.  Thousands of linear feet of vertical and horizontal joints were caulked with Dow Corning’s silicone system.

The last installment will be posted on Monday, May 3rd, 2010. Stay tuned.

Part 1 of 3

Article originally published in the FABRICATOR magazine Nov/Dec 1999 Edition and was written by Robert A. Baird who was the president of Cast Iron Restoration Management and one of the original founders of Historical Arts & Casting, a firm specializing in the design and manufacturing of architectural cast metal ornamentation.

The Rebirth Of A Cast Iron Gem (Part 1 of 3)

A community rallies to the cause of restoring a beloved courthouse.

By Robert A. Baird

Perhaps once in a lifetime one gets a chance to be involved in a project that will change the face of a community, touching the hearts and homes of the local residents and leaving a lasting legacy for years to come.  When that project centers around a craft or skill that one has trained their entire life to perform, an indelible sense of gratification is left to linger.  Such is the case with the restoration of the Mimi County Courthouse and the many people involved in its restoration.

Richard Baird, President of Historical Arts & Casting, Inc., prepares a condition survey of the cast iron prior to restoration.

In 1888, the construction of the Miami County Courthouse was completed.  Commissioned at a cost of $400,000, this Greco-Roman courthouse was different from others built in Ohio during the same period.  Joseph Warren Yost’s ambition design resembled the U.S. Capitol in a smaller scale, with sandstone and limestone walls topped by five domes and four pavilions.  Each pavilion supports heroic allegorical statues, with Justice situated in prominence atop the central dome.  The entire roof system, including the domes and pavilions, was built of riveted iron and clad with an elaborate cast iron skin.  This cast iron construction, indicative of the time period, would become the largest restoration of its type in the country and possibly the world.

The location of the courthouse was determined after years of bickering between two Ohio communities, Troy and Piqua.  What is termed the “Courthouse War,” was won by Troy.  The cornerstone was laid in 1885 with completion in the spring of 1888.  The new courthouse was the pride of the community, rising to a height of 175 feet on the banks of the Miami River.

After 90 years of heavy use, the courthouse underwent an interior restoration in 1982.  By late 1989 the building’s exterior was rapidly deteriorating.  Water penetration into the decorative cast iron accelerated its corrosion, threatening to destroy recently renovated interior courtrooms.

Late in 1989 our firm, Historical Arts and Casting, received a call from John Ruetschle’s office, a local architect that had been given the task to locate consultants with expertise in restoring cast iron structures.  After visiting the site we prepared a comprehensive proposal for the restoration of the cast iron.  Our proposal included detailed measured drawings, a thorough photographic survey, a preliminary specification for restoration work, and an estimated cost proposal to complete the restoration.

The county commissioners were excited about the prospect of doing such a thorough restoration, but were set back by

Once the dome was partially dismantled, it was possible to access the riveted iron framework.

the estimated $4.6 million price tag.  Six years passed while a plan formalized, requiring annual visits to the site to inspect the condition of the cast iron.  Each year the iron was visibly worse, forcing mandatory stopgap emergency repairs.

With tremendous support from local residents, a plan was developed by the Miami County Board of Commissioners to temporarily raise the local sales tax to fund the restoration.  Schools throughout the county became involved with the project by implementing courthouse history and restoration processes into their curriculum.  The students also wrote articles and created artwork published by local newspapers, which also increased public awareness.

Scaffolding surrounds the central dome and southeast corner dome.

In 1995, Cast Iron Restoration Management, a construction management team, was retained by the county to develop and manage the entire restoration program.  They completed all of the construction documents, including drawings and specifications, for the long awaited restoration.  In the spring of 1996, Shook Building Group, a local construction company, was awarded the primary restoration contract.  Costs for the project rose to over $7.2 million as the scope of the project increased.

The restoration program for the courthouse included dismantling the cast iron from the five domes down to the iron structure, restoring the structure, removing all of the applied cast iron ornament on the four pavilions, restoring all of the cast iron, replacing the slate roof, replacing the copper flashing and clad decks, replacing the windows, restoring a four faced clock tower, new exterior lighting, and restoring seven heroic size copper statues.

On the outset of the project, numerous challenges were faced to maintain the two-year construction schedule and keep the courthouse fully functional during the restoration.

Check back next Wednesday (04/28/2010)  for the next installment.