GFRC at Buffalo Plastering & Architectural Casting
at Buffalo Plastering & Architectural Casting
Buffalo Plastering & Architectural Casting, Inc. - Official Website
Using quarried stone as a building material
is expensive. Less expensive substitutes have always been
popular. For example, "in the eighteenth century, sand
impregnated paint was applied to wood to look like quarried
stone" (Pieper, 2011).
GFRC: At Buffalo Plastering & Architectural Casting, Inc., a substitute for exterior stone architectural sculpture and restoration is a concrete substitute: GFRC - Glass Fiber Reinforced Concrete.
Plaster Systems: The substitute for interior stone architectural sculpture and restoration is a plaster substitute: plaster systems - plaster reinforced with materials like burlap, horsehair, polymers, or fiberglass.
All the photographs below were taken at Buffalo Plastering in December 2011 with the assistance of the two partners, Gary Bolles and Leo Lysy.
1. Providing the model
The client provides the architectural sculpture or restoration model in many possible forms, including:
Providing the model: Sculptor Leo Lysy created this clay model based on a photograph that the client provided. The next step will be to make a rubber mold of the clay sculpture.
Providing the model: Poster.
The client, Mark Croce of Statler City, provided the original image in the metal lion's head (in lower right). The image was enlarged as a clay sculpture - also illustrated in the poster - by a Buffalo Plastering sculptor.
Not illustrated in the poster: A rubber mold was then made and a casting was made from the mold.
Here's the cast sculpture destined for the Statler City main lobby koi pond:
2. Creating a mold
Most molds are created from rubber.
Creating a mold: Rubber mold of a Corinthian pilaster for a Lafayette Hotel architectural restoration. Detail in next illustration:
Creating a mold
Creating a mold: Rubber mold and plaster sculpture. A series of this sculpture will be used in interior restoration in the Lafayette Hotel.
Creating a mold: Instead of a rubber mold, computer-generated shapes were rendered in brass and used as a "running mold."
3. Casting interior plaster systems: reinforced plaster
In contrast to concrete which is used for exterior pieces, interior pieces at Buffalo Plastering are cast in a plaster system - reinforced plaster.
Reinforced plaster: A roll of burlap to be used as plaster reinforcement for interior plaster systems.
Reinforced plaster: Glass fiber rods to be used as plaster reinforcement for interior plaster systems.
Buffalo Plastering fabricates columns, cornices, domes, architectural and religious sculpture in both interior and exterior materials that replicate terra cotta, limestone, marble, or travertine.
Applying finishing touches: After casting, a sculptor may use a chisel to clean up the piece.
5. Examples of cast plaster systems
Examples of Buffalo Plastering's work on Buffalo Architecture and History Website: