Chap. II. TERRA COTTA.

531
its surfaces be not chipped or ruLbed after burning, and each piece should be properly
chambered with cross-pieces.
1839J. The clays best suited for terra-cotta are found in the tertiary beds, or those
occurring above the chalk, and corresponding with the lower Bagshot sands of the
London district. Also those in the oolite and lins formations. It is procurable at Tam-
worth in Staffordshire; Watcombe in Porsetthire ; Poole in Dorsetshiie; Evt-rton in
Surrey; Ruabon in North Walts; in Cornwall, and in Northamptonshire. The cLiy
should be as free from iron and limestone as possible, and should be cleansed from all
impurities. Natural terra-cotta c ay contains 60 to 65 parts of silica to about 28 parts
of alunjina. The Poman nidterial consisted usually of the following ingredients
:
Si.icii, 7145; alumina,
225;
protoxide of iron, 12; protoxide of manganese, 17;
lime, 8-14
; soda, 16'62; magnesia, a trace. Sand is an essential ingredient, and should
be free from iron. The chief materials constituting the paste are clay, sand, Hint, glass,
and phosphate of lime.
1839/t. All clays require careful preparation before use, and their after characteristics
are often as much determined by this as by anything ; the same clay being different under
different treatment. 1st. Kneading, or piigginir, which consists of wrll mixing the clay
and reducing it to a perfect consistency throughout ; this is now done by a pug-mill.
Most clays are too fat, and require an alloy to make them more workable ;
their shrink-
ing is too great, and they are liable to twist and warp in drying and burning, so that
rough stuff or burned clay grnui.d fine is added in proper quantities to prevent this, and
it gives the potter more certain command over the clay. When mixed it is raided in a
dry state into the mixers, water is added, and it is then passed through the pug-mills,
when it is ready for use. Someiimes the clay is rendered more homogeneous by being
struck continuously with an iron bar, to assimilate the parts and to expel any air, which
on being expanded bj the heat, of the kiln would shatter the work. 2nd. A ball of this
clay is supplied to the potcer, who proceeds to form the article by hand ;
or it is pressed
into a mould, which is of plaster, when repetitions are requirtd. Care is necessary to
have an equal thickness throughout, to prevent unequal shi-inknge. This thickness is not
much more than one inch. When required of a greater thickness, the blocks are formed
hollow with cross webs to strengthen them. When necessary thete cavities may be filled
with conciete
; this filling also prevents the accumulation of moisture, to which the blocks
would be liable were they left open. 3rd. The article so formed in the rough is
removed to be dried. Drying is evaporating the water, which must be done very
gradually and evenly or there would be a liability to ctack and twist. When nearly as
hard as a piece of soap it is placed on a lathe and smoothed or poli-hed with an iron
tool. If any part is required to be attached to it the part is moulded, and the clay
moistened at the point of junction, and the two luted with a very little soft clay. The
work is now ready to be burnt. 4th. Burning is a process of the utmost importance, as
on it depends the lasting qualities of the material. A chemical action goes on in the firing
which changes the whole nature of the clay ; it never admits of being worked up again,
as in its original state. To accomplish burning successfully requires much experience,
skill, and patience. It is now removed to a kiln or reverberatory furnace, and carefully
packed in fire-clay troughs called siggars, or placed one over the other. When the kiln
is full the doorway is bricked up. and the fires are lighted in the furnace holes around the
kilo. Large articles have to be fired very slowly for four or five days, then for about
forty-eight hours fired sharply until a heat is attained sufFicieat to bake the ware, and to
flux the ingredients of which the body is formed into a vitreous mass without melting
the whole. The intensity usually necessary is stated to be that at which soft iron
would melt. The ai tides have to bo protected from the coal flame by the seggars, or by
being coated with paper and clay, or by a muffle throughout the kiln, as the flame is apt
to crack many clays openly exposed to it, and the vapour of coal is sure to discolour the
ware, generally turning it a foxy red. A kiln of large goods takes about a week to cool.
183nZ. Of late jears terra-cotta has been used extensively for the facings and
dressings of a building in the place of stone. It is generally made of hollow blocks,
formed with webs inside so as to give strength to the sides and keep the work true while
drying, whereas when required to bond with brickwork it must be at least
4j
inches thick.
1839;. The following result of experiments made by Mr. Blashfield for Mr. Charles
Bnrry, were given in a paper by him on Diihcich CilUge, read at the Royal Institute of
British Architects, session June, 1868.
A block of Portland stone about 6 inches cube, bore a erusking weight
equal to per foot super.
___-----
292 tons
A block of Bath stoie, equal to per foot super.
_ . . - l(j4 ,,
A stock brick
,, ,,
- - - - 82
A solid block of Terra-eottri, equal to per foot super.
_ . - 623
,,
A hollow block, slightly made and unfilled
- - - - - 80
>.
The same, but filled with concrete
__---.
163
A hollow block, unfilled, but made with thicker walls - - - 186