Cutting a Giant Granite Boulder with Skill
Masonry is one of the oldest professions in the world. In fact, there are remnants of buildings that are many thousands of years old, built with masonry. Today though it’s an easier job. We have powerful vehicles and machinery that can help both transport masonry materials themselves and also heavy machinery that can help create the masonry materials. One of the many powered tools that typical contractors like ourselves use every day are diamond saws, both powered by electricity and or gas. We also use machinery to lift and support masonry as it’s being placed and or installed.
Believe it or not though, even with some of our modern technological advancements, the work can still be done in a more manual type of approach. Many people are aware, with some notable historical examples, some of the methodologies used for historic masonry construction have already been lost to the intentional destruction of historical libraries and the dark ages. Today we’re going to look at a particular stone cutting technique that was used in historic times, even before mechanical tools were available. In the middle of the stream, in the photo below, the largest boulder was going to be cut into two.
This particular type of process of cutting a large stone is called the plug and feather or feather and wedge method. We say it’s a method of cutting, but it’s not actually cutting, it’s more like a controlled method for splitting a large stone. In a nutshell, the process works like this:
- Drill holes
- Insert feathers
- Hammer in wedges
- Repeat
This nutshell explanation is definitely an intentional over simplification, but we’ll explain with more detail below. In the picture below, you can see the line of small holes drilled into the surface of the stone.
Many small holes are chiseled into the surface of the stone in a line as you can see here the spacing of these individual holes is relatively close. The holes go down into the stone, just a few inches. Holes that are cut like this, in historic times, were cut without the use of a power tool. Today we would use something like a rotary hammer drill or even a rotary type of electric drill with a masonry bit. The modern version is done without lots of manual action and movement. It’s still a tough job, to drill a bunch of holes, even in modern times.
Drilling through stone, even with strong power tools can still wear you out. The tools do most of the work though, in our modern times. To drill these holes today, you basically just have to press the button and hold on really tight. Holding yourself in a position where you’re drilling and controlling the tool while simultaneously placing your weight or strength to push the tool in the stone is a little bit like a plank exercise. Even though there’s not a lot of movement or action, you’re still applying a lot of force and pressure. This is very easy though, compared to the historic methods, yet it’s nonetheless tough work.
The type of drill used was more like what we today would consider to be a chisel. Unlike a typical chisel which has a flat point, this particular type of chisel though has a cross in the middle. As the chisel is hammered downward, it is slightly moved, continuously between each strike. That process leads to the creation of holes. You can probably tell, it is a lot more work than using a power tool from our modern times.
After the holes are created, feathers are inserted into two opposite sides of the holes. All of the feathers are set, into each hole, facing the same direction. This leads the force or pressure to push in the same direction. The feathers are like thin iron or steel sleeves to resist and or aggregate the force of the wedges that are next inserted between the feathers.
Two of the holes are shown in the picture below, more closely. Although they were created without the aid of modern equipment, they are cut or drilled into this stone in a very clean, even manner. The point is, even without today’s power tools, the work could still be done relatively neatly.
Our company, Dupont Tuckpointing and Masonry, specializes in masonry restoration, historic brick repointing, and tuckpointing services in the Washington D.C. area. These buildings are uniquely historic, and their preservation requires skilled masons who are technically trained in the best practices and knowledge of proper restoration techniques.
We understand the significance of maintaining the architectural integrity of these historic structures, and our team of experienced professionals is dedicated to delivering exceptional craftsmanship. Whether you require masonry restoration, tuckpointing, or brick repointing services, we are here to help.
At Dupont Tuckpointing and Masonry, we take pride in our work and strive to ensure that every project is executed with the utmost care and attention to detail. We are committed to preserving the rich heritage of Washington D.C.’s built environment for generations to come.
If you have any questions or needs regarding masonry restoration, historic brick repointing, or tuckpointing services, please do not hesitate to reach out to us. We would be delighted to assist you and provide you with the expertise and quality workmanship that your historic property deserves.
You can reach us by telephone at (202) 796-7644 and you can reach us by email from the contact form on our website at https://duponttuckpointingmasonrydc.com/contact-us/.
