When walking in the country one day
I came to a beautiful pond by the side of the road.
The water was almost as clear as air, and as I looked
down into it, I could see that the bottom was made
of granite. The farther shores were cliffs of
clean granite thirty or forty feet high and coming
down to the water’s edge. The marks of tools
could be seen on them, showing where blocks of stone
had evidently been split off. I picked up a piece
of the rock and examined it closely. It proved
to be made up of three kinds of material. First,
there were tiny sparkling bits of mica. In some
places there are mica mines yielding big sheets of
this curious mineral which is used in the doors of
stoves and the little windows of automobile curtains.
With the point of a knife the bits in my piece of
granite could be split into tiny sheets as thin as
paper. The second material was quartz. This
was grayish-white and looked somewhat like glass.
The third material was feldspar. This, too, was
whitish, but one or two sides of each bit were flat,
as if they had not been broken, but split. This
is the most common kind of granite. There are
many varieties. Some of them are almost white,
some dark gray, others pale pink, and yet others deep
red. It is found in more than half the States
of the Union.
This quarry had been given up and
allowed to fill with water; but it was a granite country,
and farther down the road there was another, where
scores of men were hard at work. This second quarry
was part-way up a hill; or rather, it was a hill of
granite which men were digging out and carrying away.
When they began to open the quarry, much of the rock
was covered with dirt and loose stones, and even the
granite that showed aboveground was worn and broken
and stained. This is called “trap rock.”
The easiest way to get rid of it is to blast with
dynamite and then carry away the dirt and fragments.
Next comes the getting out of great masses of rock
to use, some of them perhaps long enough to make the
pillars of a large building.
Now, granite is a hard stone, but
there is no special difficulty in cutting it if you
know how. In the old days, when people wished
to split a big boulder, they sometimes built a fire
beside it, and when it was well heated, they dropped
a heavy iron ball upon it. King’s Chapel
in Boston was built of stone broken in this way.
To break from a cliff, however, a block of granite
big enough to make a long pillar is a different matter,
and this is what the men were doing. First of
all, the foreman had examined the quarry till he had
found a stratum of the right thickness. He had
marked where the ends were to come, and the men had
drilled holes down to the bottom of the stratum.
Then he had drawn a line at the back along where he
wished the split to be, and the men had drilled on
this line also a row of holes. Next came the
blasting. If one very heavy charge had been exploded,
it would probably have shattered the whole mass, or
at any rate have injured it badly. Instead of
this, they put into each hole a light charge of coarse
powder and covered it with sand. These were all
fired at the same instant, and thus the great block
was loosened from the wall. Sometimes there seems
to be no sign of strata, and then a line of horizontal
holes must be drilled where the bottom of the block
is to be. After this comes what is called the
“plug-and-feather” process. Into
each hole are placed two pieces of iron, shaped like
a pencil split down the middle. These are the
“feathers.” The “plug”
is a small steel wedge that is put between the iron
pieces. Then two men with hammers go down the
line and strike each wedge almost as gently as if
it was a nut whose kernel they were afraid of crushing.
They go down the line again, striking as softly as
before. Then, if you look closely, you can see
a tiny crack between the holes. There is more
hammering, the crack stretches farther, a few of the
wedges are driven deeper and the others drop out.
The block splits off. A mighty chain is then
wound about it, the steam derrick lifts it, lays it
gently upon a car, and it is carried to the shed to
be cut into shape, smoothed, and perhaps polished.
In almost every kind of work new methods
are invented after a while. In quarrying, however,
the same old methods are in use. The only difference
is that, instead of the work being done by muscle,
it is done by compressed air or steam or electricity.
Compressed air or steam works the drill and the sledgehammer.
The drill is held by an arm, but the arm is a long
steel rod which is only guided by the workman.
Not the horse-sweep of old times, but the steam derrick
and the electric hoist lift the heavy blocks from
the quarry. Polishing used to be a very slow,
expensive operation, because it was all done by the
strength of some one’s right arm, but now, although
it takes as much work as ever, this work is done by
machinery. To “point” a piece of
stone, or give it a somewhat smooth surface, is done
now with tools worked by compressed air. After
this, the stone is rubbed by machinery,
of course with water and emery, then by
wet felt covered with pumice or polishing putty.
A few years ago two young Vermonters invented a machine
that would saw granite. This saw has no teeth,
but only blades of iron. Between these blades
and the piece of granite, however, shot of chilled
steel are poured; and they do the real cutting.
Granite has long been used in building
wherever a strong, solid material was needed; but
until the sand blast was tried, people thought it
impossible to do fine work in this stone. There
was a firm in Vermont, however, who believed in the
sand blast. They had a contract with the Government
to furnish several thousand headstones for national
cemeteries. Cutting the names would be slow and
costly; so they made letters and figures of iron,
stuck them to the stones, and turned on the blast.
If a sand blast is only fast enough, it will cut stone
harder than itself. The blast was turned upon
a stone for five minutes. Then the iron letters
were removed. There stood in raised letters the
name, company, regiment, and rank of the soldier,
while a quarter of an inch of the rest of the stone,
which the iron letters had not protected, had been
cut away. By means of the sand blast it has become
possible to do beautiful carving even in material
as hard as granite.
Granite looks so solid that people
used to think it was fireproof; but it is really poor
material in a great fire. Most substances expand
when they are heated; but the three substances of which
granite is made do not expand alike, and so they tend
to break apart and the granite crumbles.
A marble quarry is even more interesting
than a granite quarry. If you stand on a hill
in a part of the country where marble is worked, you
will see white ledges cropping out here and there.
The little villages are white because many of the
houses are built of marble. Then, too, there
are great marble quarries flashing in the sunshine.
Sometimes a marble quarry is chiefly on the surface.
Sometimes the marble stretches into the earth, and
the cutting follows it until a great cavern is made,
perhaps two or three hundred feet deep. A roof
is often built to keep out the rain and snow.
It keeps out the light, too, and on rainy days the
roof, together with the smoke and steam of the engines,
makes the bottom of the quarry a gloomy place.
Everywhere there are slender ladders with men running
up and down them. There are shouts of the men,
clanking of chains, and puffing of locomotives.
Marble is cut out in somewhat the
same way as granite, but a valuable machine called
a “channeler” is much used. This machine
runs back and forth, cutting a channel two inches
wide along the ends and back and sometimes the bottom
of the block to be taken out.
Marble is so much softer than granite
that it is far more easy to work. Cutting it
is a simple matter. The saw, which is a smooth
flat blade of iron, swings back and forth, while between
it and the marble sand and water are fed. It
does not exactly cut, but rubs, its way through.
The round holes in the tops of washstands are cut by
saws like this, only bent in the form of a cylinder
and turned round and round, going in a little deeper
at each revolution. A queer sort of saw is coming
into use. It is a cord made of three steel wires
twisted loosely together. This cord is stretched
tightly over pulleys and moves very rapidly.
Every little ridge of the cord strikes the stone and
cuts a little of it away.
There are varieties of marble without
end. The purest and daintiest is the white of
which statues are carved; but there are black, red,
yellow, gray, blue, green, pink, and orange in all
shades. Many are beautifully marked. The
inner walls of buildings are sometimes covered with
thin slabs of marble. These are often carefully
split, and the two pieces put up side by side, so
that the pattern on one is reversed on the other.
Certain kinds of marble contain fossils or remains
of coral and other animals that lived hundreds of
thousands of years ago. In some marbles there
are so many that the stone seems to be almost made
of them. When a slab is cut and polished, the
fossils are of course cut into; but even then we can
sometimes see their shape. One of the most common
is the crinoid. This was really an animal, but
it looked somewhat like a closed pond lily with a
long stem, and people used to call it the stone lily.
This stem is made up of little flat rings looking
like bits of a pipestem. The stems are often broken
up and these bits are scattered through the marble.
The animals whose shells help to make marble lived
in the ocean, and when they died sank to the bottom.
Many of the shells were broken by the beating of the
waves, but both broken shells and whole ones became
united and hardened into limestone, one kind of which
we call marble. Common chalk is another kind.
Blackboard crayons are made of this: so are whitewash
and whiting for cleaning silver and making putty.
Another stone that builders would
be sorry to do without is slate. This, too, was
formed at the bottom of the sea. Rivers brought
down fine particles of clay, which settled, were covered
by other matter, and finally became stone. It
was formed in layers, of course, but, queerly enough,
it splits at right angles to its bottom line.
Just why it does this is not quite certain, but the
action is thought to be due to heat and long, slow
pressure, which will do wonderful things, as in the
case of coal. This splitting is a great convenience
for the people who want to use it for roofing and
for blackboards. Blocks of slate are loosened
by blasting, and are taken to the splitting-shed.
Splitting slate needs care, and a
man who is not careful should never try to work in
a slate quarry. The splitting begins by one man’s
dividing the block into pieces about two inches thick
and somewhat larger than the slates are to be when
finished. The way he does this is to cut a little
notch in one end of the block with his “sculpin
chisel” and make a groove from this across the
block. He must then set his chisel into the groove,
strike it with a mallet, and split the slate to the
bottom. This sounds easy, but it needs skill.
Slate has sometimes its own notions of behavior, and
it does not always care to split in a straight line
exactly perpendicular to the bottom of the stratum.
The man keeps it wet so that he can see the crack more
plainly, and if that crack turns back a little to the
right, he must turn it to the left by striking the
sculpin toward the left, or perhaps by striking a
rather heavy blow on the left of the stone itself.
Now the chief splitter takes it, and with a broad thin
chisel he splits it into plates becoming thinner at
each split. The second assistant trims these
into the proper shape and size with either a heavy
knife or a machine. Slate can be sawed and planed;
but whatever is done to it should be done when it
first comes from the quarry, for then it is not so
likely to break. It would be very much cheaper
if so much was not broken and wasted at the quarries
and in the splitting. It is said that in Wales
sometimes one hundred tons of stone are broken up
to get between three and four tons of good slate.
Within the last few years the quarrymen have been
using channeling machines and getting out the slate
in great masses instead of small blocks. This
is not so wasteful by any means; but even now there
is room for new and helpful inventions.