Posts Tagged ‘Cast Metal’

Light Fixtures: Standards and Labeling

Friday, August 27th, 2010 by David Baird

Light fixtures have  always been an important part of our business at Historical Arts and Casting, Inc. We have built thousands of them over the years, and most of these fixtures are small quantities of custom lights specifically designed for discriminating clients.

I am often asked about the testing requirements through which our lights are required to pass. Are they UL approved? And what are the standards?

Underwriters Laboratories (UL) is an organization that has established a set of standards for quality and safety of electrical appliances that is universally accepted throughout the United States. These standards require that fixtures be manufactured in such a way that they are structurally sound, and that they are wired in a manner that will be safe for the public to use and maintain without the danger of electrocution.

Bronze Chandeliers - 800 North Capitol, Washington DC

Bronze Chandeliers (LF018) - 800 North Capitol, Washington DC

A UL label certifies that a light fixture passes these standards and that Underwriter Laboratories certifies that the manufacturer also is responsible for any liabilities associated with the fixture. To obtain one of these labels, the fixture must pass certain tests, and the company is subject to periodic inspections by UL representatives. In addition a fee is charged  by UL per label. Each label is identified with an individual certification number. Typically a certification number identifies a specific type of fixture that meets these strict standards. Therefore each different type of fixture is subject to this labeling fee and newly numbered label.

For a company like HACI, that builds small quantities of hundreds of different fixtures, this labeling procedure could be a challenge, even though the actual electrical components of each fixture are essentially the same.

Our approach was to contract with  TEi-Listing Services, a testing laboratory, who certifies that our fixtures meet UL standards, and provides a numbered label that covers all of our fixtures under one “umbrella”. This label is accepted nationwide just as the UL label is.

Bronze Light Post - Kansas City Library - Kansas City, MO

Bronze Light Post (LF157) - Kansas City Public Library - Kansas City, MO

The standards to which we build our lights actually exceed those required by UL in many instances. All of our fixtures are built of cast metal, be it aluminum, bronze, or iron. All of the fasteners are brass or stainless steel, so there is no danger of corrosion. They are rated for “Wet Location” which is the toughest standard, which means that the lights are designed with adequate weep holes to allow moisture to evacuate. The light sockets are nickel plated porcelain sockets, wired with double insulted THHN wire. All of the components are UL rated, and are purchased from a reliable distributor.

Each completed fixture must pass a dielectric withstand test, which means that a 120 volt fixture is submitted to  1500 volts through the wires to insure that there are no short circuits. Each fixture has a common, neutral, and ground wire.

Bronze Hanging Lamps (LF142) - Private Residence, Naples, FL

Bronze Hanging Pendants (LF142) - Private Residence, Naples, FL

In addition all of the structural hard points, such as hanging loops or hanging pipes, are fastened with stainless steel components.  Glass is typically glazed with Dow Corning 795 Silicone caulking expertly finished, and finally the fixture is tested with lighted bulbs before packaging.

Aluminum and iron fixtures are painted with PPG CONCEPT high performance automotive paint, and Bronze fixtures are colored using a variety of statuary or hand grained patinas sealed with a coat of wax.

At Historical Arts and Casting we are proud of our work, and honored to have our fixtures adorning some of the most prominent buildings in the nation.

Gas Lighting

Wednesday, May 19th, 2010 by David Baird

For many years Historical Arts and Casting has been manufacturing light fixtures. For the most part, these fixtures are of a historical flavor. Comprised of many intricate sculptural cast components all assembled together to create a reality that once began in an architect’s imagination.

Gas Pedestal Lantern - Ohio State House, Columbus, OH

Gas Pedestal Lantern - Ohio State House, Columbus, OH

To date I have supervised the construction, wiring, and glazing of thousands of beautiful light fixtures most of which were custom designed for prominent residences and commercial buildings around the world.

Each fixture is crafted of heavy cast metal components in many alloys including bronze, aluminum, or cast iron.  Bronze may be chosen because of color, or perhaps the client desires a polished fixture, or maybe an antique verdigris bronze light. Aluminum is used where weight may be a factor, or for more economical pricing. Cast iron is generally used to create the look of a wrought iron fixture that fits in a setting of historical significance.

It is not uncommon for us to duplicate existing light fixtures that match exactly in appearance. It is also common practice to restore existing light fixtures with all new finishes, glass, and wiring as well as replacing all broken or missing parts with new ones.

Recently we have seen a trend towards automated gas lamps. Many of our ornate electrical fixtures can be readily converted to natural gas. I have to admit that I mention these conversions with a little trepidation because they can be very challenging to build and set up.

For a brief explanation  let me take you back in history to the late 1800’s when gas light was popular.

Gas Torchere - Private Residence, Palm Beach, FL

Gas Torchere - Private Residence, Palm Beach, FL

Gas lamps were revolutionary in that they could bring bright light into your home at any hour of the day. They were affordable by many, and were relatively safe. There was, however, the occasional fire or explosion, not to mention asphyxiation due to the natural gas from time to time. These lights also required frequent cleaning and maintenance. They also needed to be hand lit with a match. All of this unpredictable “Fire” was the down side!

Open flame gas lamps have a unique ambiance that cannot be beat, and are extremely attractive on a beautiful home. It is therefore understandable why they are desirable today. Many but not all of the undesirable features have been overcome. Making them much more practical today then they were over one hundred years ago. HOWEVER, there are still a few concerns that the prospective gas lamp owner should be aware of.  First, they are not very bright by comparison to electric lamping.   Second, they still require some cleaning and maintenance to be reliable. And third, they can be a little finicky to adjust.

David Baird adjusting the flame.

David Baird adjusting the flame.

At Historical Arts and Casting, we manufacture the fixture bodies in our facility, but we buy the gas modules from an outside source, and install them into our fixtures. We have had a good working relationship with KNIGHTRONIX , the inventors and manufacturers of an ingenious gas light igniter. This is the safest and most reliable unit that we have seen.

The KNIGHTLIGHTER is composed of a self contained gas solenoid, and electronic igniter, with an ion flame sensor, all in one tiny little package. It runs on 24vac and can be configured with an automatic daylight sensor. It can alternately be set up to ignite from a light switch or a Lutron automated timer system.

Knightronix ignighter being tested in a light fixture that will be installed in a private residence in West Palm Beach, Florida.

Knightronix ignighter being tested in a light fixture that will be installed in a private residence in West Palm Beach, Florida.

The KNIGHTLIGHTER will ignite a gas light in a fashion similar to a furnace igniter. It strikes an arc to light the flame. If, for some reason, the flame does not ignite, the control unit will make several more attempts before safely shutting down the system. It will also reignite a flame blown out by the wind. Once installed and set up correctly we have seen years of trouble free service. NOTE: periodic cleaning and maintenance of the fixtures is still required. I would also add that this application is not recommended for interior use. My hat’s off to Arnie Knight, the inventor of this great little device.

Electric or natural gas, Light fixtures are still an important part of any man’s personal castle!

Macfarlane’s Casting Catalog – An Exceptional Design Resource

Friday, May 14th, 2010 by Chad Thorell
MacFarlane's Castings Volumes 1 & 2

MacFarlane's Castings Volumes 1 & 2

Sometimes my life seems to be driven by electronic devices.  Computerized calendars provide “handy” reminders of things that “must” be done.  Email and telephone service follow me wherever I go and I am constantly barraged by digital media through the television, radio and internet. Don’t get me wrong, technology certainly has boundless benefits and creates efficiencies that would otherwise be impossible to achieve. But, as often as I can, I like to try and turn it off and pick up a book to read. For me, the more pictures a book has, the better. This may have a lot to do with the audience to which I am usually reading – a 3 year old daughter who loves ponies and rainbows.

Today, however, I would like to introduce you to a different kind of picture book. The book is entitled “MacFarlane’s Castings.” It is a two volume illustrated catalog of the metalwork that was created by Walter MacFarlane & Company. It depicts the growth and emergence of the foundry industry, during the industrial revolution. The casting process was being refined and beautiful ornamental metalwork became much more prominent.

The MacFarlane's factory (left and showroom (right).

The MacFarlane's factory (left) and showroom (right).

MacFarlane’s foundry was located in Glascow, Scotland and created a tremendous amount of the cast iron metalwork that decorated Europe. They were on the leading edge of metalworking during the late 1800’s. At the height of their business in 1903 the foundry and production plant had expanded to cover nearly 24 acres. Walter MacFarlane had trained as a jeweler in his youth and seems to have applied the techniques of quality, design and detail to larger scale ornamental metal. Thus, he created jewelry that seemed larger than life.

Catalog page showing light fixtures.

Catalog page showing light fixtures.

This catalog is an amazing collection. Its 600+ pages are filled with thousands of detailed drawings. It explores what was accomplished in cast architectural metal a century ago and inspires us with new possibilities. Historical Arts & Casting, Inc. acquired a rare original copy of this treasure and a few years ago decided to reprint it and make it available to architects and designers throughout the world. If you would like more information or would like to purchase a set of the “Macfarlane’s Castings” catalog, please contact our office. It is truly an exceptional design resource.