Galvanized

the branch studio fountain 2016Every winter, the Branch Studio fabricates a new fountain or two. Some years that fountain is classical in form. Classical garden fountain style interpreted in steel interests me, and our clients. Our fountains come ready to fill, plug in, and turn on. There is something about water in the garden that enchants, so I like to make it easy as possible to have. Some years our winter fabricated fountain is contemporary. We have in the past fabricated an elliptical and rectangular steel fountain with a congested steel rod surface. The rectangular fountain has over a mile of steel rods welded to its exterior, and weighs close to 4000 pounds. Have you seen it?  The elliptical fountain has been placed in a private garden. In the interest of fabricating a one of a kind fountain, our newest contemporary fountain is a shape we have never done before.
The Branch Studio fountain 2016 (3)This winter, our contemporary fountain from Branch is spherical, and features our signature stick like and prickly surface. A pair of steel hemispheres, 64 inches in diameter,  got welded together. We sliced the top third off that welded hollow sphere.  The remaining 2/3rds of a sphere became the armature for this fountain. Owen and Riley, with followup from Sal, spent a good bit of the winter welding sticks of all different sizes to the surface. Our group of companies, Deborah Silver and Company, who designs and installs landscapes, Detroit Garden Works, who retails just about everything beautiful and useful for a garden and landscape, and The Branch Studio, who fabricates whatever garden ornament a gardener or landscape designer might dream up for a project –  hope to help every gardener and landscape designer get where they want to be with their landscape. But in the dead of the winter, we just express ourselves, and keep our fingers crossed there will be a client who hears what we have to say.

The Branch Studio fountain 2016 (1)Branch created this fountain for the garden strictly on speculation. Why would I speculate?  All of the Branch fabricators, and the studio head, Buck, are very creative people. They need a project once in a while that allows them to stretch their wings, and fabricate something new. This is a breath of fresh air for our group. It creates excitement in the studio. And is is good for a client seeking a very unusual and one of a kind ornament for the garden.

The Branch Studio fountain 2016 (2)The Branch group handled the fabrication of this fountain like they were born to make it. Once the stick making had covered the surface, a decision was made to leave the 6″ wide return plain. The contrast of one complex surface to the other plain one is striking and pleasing. The fountain jet will be fabricated next. The jet pipe will mimic the spherical shape and construction of the fountain. Water from the jet pipe splashing over a rod steel covered sphere will be quite musical.  The sound of a fountain is a considerable part of its attraction.

20160419_124028 (2)Clients considering the purchase of Branch containers are concerned about the longevity, and the durability of their resistance to rust, and rightfully so. Everything we manufacture is meticulously hand fabricated with heavy gauge hot rolled steel, with a lifetime of service in mind. The cost of them reflects this. What we do to prevent rust is considerable. All of our containers, fountains, and garden ornament are sent out for galvanizing after it is fabricated. Our galvanizing company has a zinc tank  6 feet wide, 8 feet deep, and forty feet long. This shape has everything to do with the fact that most steel that comes here for galvanizing are steel beams using in the construction of building, bridges, and so on. The plant manager was dubious the day we arrived with our first load of garden containers. 13 years later they know we are as serious about rust prevention as we are about beauty. We pay for galvanizing by the pound.  Our scale at Branch only weighs objects up to 2000 pounds.  This fountain went over the 2000 pound mark.  We won’t know what it weighs until after the galvanizing is complete. The fountain is lifted with a bridge crane via steel straps in preparation for the dip.

20160419_124120This tank holds 824,000 pounds of molten zinc, heated to about 900 degrees. The galvanization process completely immerses the raw steel object in molten zinc, very slowly.  The shock of the heat to the steel is considerable.  Steel which is not thick enough can be damaged by the plating process. The molten zinc coats every surface with a skin of zinc. How much of a skin?  This fountain will weigh 20% more once it is galvanized. This means that a 3000 pound object will emerge with 500 pounds of zinc coating its surface.The fountain was lowered into the tank ever so slowly.

20160419_124757 The shop foreman made a trip up to Branch to inspect what we had a mind to galvanize, before we took the fountain to them. An object of this size and complexity is a once a year project for us. There are logistical issues that need to be addressed in advance. There was plenty of discussion about what it would take to get the fountain to sink slowly and evenly. An object that floats on top of the molten zinc is a problem object. Our big spherical fountain had lots of holes drilled in it, which will be repaired with galvanized steel discs once the galvanizing process is complete. Our garden boxes have loose galvanized plate steel bottoms which are added after the boxes are galvanized. A box with no bottom sinks in the zinc bath.

20160419_124729The fountain took as long to emerge as it did to descend.

20160419_124500A molten zinc tank always has floating hardened zinc and impurities floating on the surface.  Prior to and during the galvanizing of this fountain, the surface of the molten zinc got raked, so those impurities would not be deposited on the surface. Occasionally a glob of something will stick to an object.  If it is chipped off, or ground down too hard, the integrity of the galvanizing might be breached.

20160419_124541If a galvanized object from us develops a small rust spot, it will do so within 2 weeks of being outdoors. That spot can be repaired with cold galvanizing compound. A breach in the galvanizing is a rare occurrence.

20160419_124549The moment any steel object emerges from a zinc bath sports a shiny as silver color. Once that object comes in contact with the air, that shiny surface begins to oxidize, and will become that dull gray color one usually associates with galvanized metal.

20160419_124649The process by which Branch fabricates, finishes, and sells their garden pots, fountains, pergolas and ornament is all about beautiful design and fabrication, and a thoughtful and serious finish that is unlikely to need any maintenance. My thanks to the plant manager for taking these pictures for me.

spherical Branch fountain (2)Back at Branch, the fountain is awaiting our final signature finish, which will give the steel that blue gray patina which is reminiscent of lead. Heather, who handles all of the Branch Studio inquiries, came with me for a look see today.

spherical Branch fountain (1)I am sure this fountain will be up and running soon.

Belgian Stoneware

stoneware 3Rob has been shopping in Belgium for at least 15 years. He has a considerable affection for the topography and natural landscape, as it reminds him of Michigan. The garden ornament has a solid and unaffected feeling about it. Many of the things he buys there have their roots in agriculture-cisterns, troughs, and the like. The pot pictured above comes from a pottery whose work he greatly admires. This will be the third year we have offered these Belgian stoneware garden pots. The come in three colors-taupe, gray, and black. The shapes are simple.  Though the shapes are smooth and graceful, the surface texture is gritty and rough, in a subtle sort of way.

pots 4That gritty texture and surface is typical of stoneware.  The name stoneware comes from the dense and hard quality of the clay body. This clay body, or type of clay from which a pot is made, has natural characteristics that result in pots more like stone than fired earth, or terracotta.  Stoneware pots are fired at a high temperature, and do not absorb water much after the firing. This inclination to repel water after firing makes this type of clay, and this type of pot, perfect for our climate.  Water that is absorbed by a pot which is them subjected to freezing can result in breakage.  Water expands as it freezes. This freezing action can shatter or break a clay pot. Anyone who has ever inadvertently left a machine made Italian terra cotta pot outdoors over the Michigan winter knows from whence I speak.  This stoneware is frost proof- this is great news for anyone who likes terracotta. Clay pots are made the world over. Clay dug from the ground in Philadelphia is very different than the native clay of southern France, or Italy. Not all clay is of a natural stoneware type. Pots made from stoneware clay bodies are of interest to us, and gardeners in our zone.

stoneware 2Some potters mix their own clay, or choose a clay body/mix that has been made available commercially, that suits their interest and intended use.  Porcelain is the material of choice for an artisan interested in a very fine and formal clay that can be thrown very precisely, and very thin. These large thick walled Belgian pots are made to hold many hundreds of pounds of wet soil without complaint. The natural clay is a friendly visual companion to plants that go in that soil. The texture is just enough, and no more. The gritty surface of this stoneware is a result of adding grog to the stoneware clay body. Grog refers to clay which has been fired, and then ground into hard particles of various sizes. Those particles are then mixed into the fresh wedged wet clay body before the pots are thrown.  As wet clay is incredibly heavy, there is a limit to how large and tall a pot can be thrown, before the clay starts to collapse from its own weight. In addition to providing great texture, both visual and tactile, grog helps provide the construction of a big pot with a little structure. The grog particles have been fired.  They will not absorb water, and melt.  Grog stiffens the wet clay, so larger forms can be thrown at one sitting.

Belgian stoneware 8Even so, very large stoneware pots may need to be thrown in stages. The lower portion may need to rest, and begin to harden, as in leather hard, before the pot can be made any taller. This accounts for one reason why large handmade pots are much more expensive than smaller pots that can be made in one sitting or throwing session. Another reason-the volume of clay consumed.  Very large French terra cotta pots are incredibly thick. Thin walled, large pots would not likely survive the heat of the firing. There may be many hundreds of pounds of wet clay in one pot. I would bet that clay bodies are sold by weight, and that weight can make it expensive to ship them. Of course as the water evaporates out of the pot, the weight is much less.  How a pot is dried, and how it reacts to the firing is a topic of much study.  Pots that have taken days to throw that break or explode in the kiln is a big loss in materials and time.  The cost of breakage becomes part of the cost of those pots that survive the firing.  stoneware rock collectionThese stoneware “rocks” are forms that can be used as a sculpture or seat in the garden.  The shapes are all beautiful, and different.  They have an aura about them, as they have gone beyond function to another level.  I am sure every gardener would perceive and use them differently. Nor would they appeal to every gardener.

stoneware 14These pots seemed quite contemporary in form and color when I first saw them, but I have since learned that what they do best is take on the quality and character of their environment.   I have seen them used successfully in modern, and even quite traditional architectural settings. One client with a classic 1920’s English tudor style house has a pair of these pots at the front door.  They look great.  They do not impose, or attract undue attention. They are simply and beautifully made. They look great, planted up. The statement they make when they are empty-sober and strong. I am not surprised that Rob would have them, a third time around. To follow are some of his pictures of the two containers that came in last week.  You can tell from his pictures, how much he likes them.

stoneware rocks

stoneware collection

stoneware 11

Belgian stoneware 6My discussion of the clay is cursory. I am not a scientist, or a potter.  I just love these pots.  If you have a further interest, you can read more about clay at  Hammill & Gillespie

A Quick Look At Some Stick Work

Federal Reserve Building (8)A  client who calls for work after the holidays is unusual, but we were happy to oblige.  We had materials, and there are months of winter yet to come. They had purchased these large scale contemporary birch faux bois concrete planters from Branch over a year ago.  The landscape is dominated by a single river birch.  An arrangement that would feature birch seemed natural.  We had just enough 3″ caliper poles to fill the pair of planters.  Bunches of white lepto came in handy for filling the gaps between the poles. Our last three cases of mixed evergreen boughs were just enough to soften the top of the pot with a thick blanket of green.

Federal Reserve Building (6)The ground plane of the landscape was done with groundcovers of various types in spaces dictated by a pattern of aluminum edger strip, and gravel.  The pattern established is graphically strong.  There were a few areas designated for a seasonal planting.  The concrete boxes had been planted with chrysanthemums for the fall.  What could be done in those areas that would have some height, volume and presence over the winter?  Our solution was to cut up some 1″ and 2″ diameter birch poles into random short lengths. Each piece had a hole drilled all the way through each end. Each of the poles were loosely attached to its neighbor with heavy gauge aluminum wire. The end result-a giant birch garland.

Federal Reserve Building (9)In order to get some height and mass, rolls of grapevine were stretched out and pinning into the soil.  The pinning was easy, as the ground was frozen.

Federal Reserve Building (5)We zip tied the birch garland to the grapevine where it seemed appropriate.

Federal Reserve Building (4)The large size bamboo poles was a vestige of a previous installation-not by us.  The client wanted to leave them in.  That was a good thing, as they were set into metal sleeves placed below ground.  Water had completely filled the sleeves.  The poles were solidly frozen into place by time we got there. I rather prefer the birch poles here.  They look like they belong in a winter garden in Michigan.  There is a certain authenticity to the materials used here.

Federal Reserve Building (3)In the background, the last of our big linden espaliers.  At 9′ wide and 12′ tall each, they mean something in front of this large commercial building.  Properly cared for, they will only get better looking as time goes on.  Funny how some very large commercial spaces devour almost every bit of the land they sit on. It takes the right material and a very strong design to work in a space like this.  I did not do the landscape design here, but I like it.

Federal Reserve Building (1)Hauling around four sets of fresh cut birch garland was the perfect installation for a 12 degree day.  We warmed up in a hurry. Once we were done, all we needed was some snow.  I wonder what it looks like now that we have a good snow cover.

 

The Grapevine Deer

deer 2014 (2)It is a yearly thing at Detroit Garden Works – the arrival of the grapevine deer.  In celebration, we outfitted a window box with all the fruits of the harvest. Cabbage, romanesco broccoli, lime green cauliflower, white onions, pumpkins and gourds. Tieing all of the individual elements together – one roll of grapevine-a material so versatile and appropriate for display in a garden. The window box turned out to be a perfect spot to place a grapevine sculpture of a doe. The two elements compliment one another, and speak to the time of the harvest.  The rolls of grapevine that we stock year round look great in, under or around containers.  They soften and highlight any fall planting. A deft hand can make the wiry dried vines drape gracefully. A tree trunk gift wrapped in  grapevine for the winter is a lovely wrap indeed.  They can provide a support for a more lax growing vine, such as clematis.  The grapevines that hang over our fence are lush in the summer, and so sculptural in the winter.

grapevine deer (1)These grapevine deer are the most beautiful use of grapevine I know. They rank high on my list of beautiful garden sculptures.  This natural material and the natural form it represents fits into the garden effortlessly. Sections of the sinewy vine are woven over welded steel forms.  They are a powerfully sculptural interpretation of the beauty of nature.  Who makes them?  A group of people who most of the year tend a vineyard full of wine grapes. In the fall, when the vineyard work is done, they collect the prunings from the vines, and sculpt.

grapevine deer (3)
The vines of the grapes are quite stiff, and unyielding. Working with them to create a shape is sure to produce blisters-I have first hand experience. It could be that these vines are soaked and softened before they are fitted over the steel form. I do not know their method of construction, but I do know they are beautiful.  I marvel at these gracefully curving forms.  I further admire the perfectly parallel placement of the vines over the form. These vines woven over a form is a study in strength and endurance.  Just like a garden.

grapevine deer (8)It is striking that such a stiff material could be made to convey  such soft and natural natural emotion as a doe tending her fawn. Though  I have plenty of clients whose gardens are under siege from deer, it is hard not to appreciate this pair. These sculptures are not about the trouble that deer in the garden present.  They are about the the presence and beauty of nature.

grapevine-deer.jpgThe standing buck sculpture is tall. The antlers are woven around square pipe that insets into a larger pipe hidden below the surface.  I could see it placed in a field of hellebores, or in a grove of trees.

Dec 23 2010 047One year I took a buck home, and used it in lieu of a Christmas tree. It spent the rest of the winter outdoors in the garden. With a yearly rubdown of a penetrating oil sealer, they last for years outdoors. If you have ever tried to compost grapevine, you know how long it persists, even in contact with the soil. Should the vines ever need replacing, the forms can be sent back for fresh vines.

grapevine deer (5)The sculptures are remarkably stable.  If they do blow over, they are easy to right.  For a completely sturdy installation, it is easy to hook a heavy gauge steel hairpin through the steel loop at the foot.  All of the sculptures are life size.  The standing buck is about 5.5 feet tall, excluding the antlers.

grapevine deer (6)A family

grapevine deer (5)Garden sculpture, properly placed, is all about adding another layer to the experience. Looking for a garden sculpture that will look like it has always been there?  Consider the grapevine deer.  Interested further?  http://www.detroitgardenworks.com/garden-store/statuary/grapevine-deer-2/