A04_SOW.docx

Scope of Work for Stone Repair of Monuments at Gettysburg National Military Park The Battlefield at Gettysburg has almost 1400 monuments, most of which are around 130 years old. The majority of these are carved from granite, although other materials such as bronze and marble are also found. Most monuments are in good condition, but some have suffered various types of damage since they were first installed- pieces broken off from storm damage, accidents, vandalism, and some stone has simply deteriorated from being exposed to the elements.

The monuments to be repaired are:

1. 5th New York Cavalry

2. New Hampshire Sharpshooters

3. 13th New Jersey Infantry

4. 8th New York Cavalry

5. 1st Maryland Cavalry

6. 1st Maryland Infantry Eastern Shore

7. 78th & 102nd New York Infantry

8. 6th WI Right Flank marker

9. 40th New York Infantry The National Park Service has identified these nine granite monuments as damaged and in need of repair. The repairs are predominantly “Dutchman” type repairs, wherein damaged stone is “surgically” removed and new stone is installed in its place. The goal is to repair the monuments while leaving as much of the original stone in place as possible, as well as to leave a repair that is as close to invisible as possible with good longevity of the repair. When completed, each repair should be practically indistinguishable from the original, save for the cleaner and brighter appearance of the new stone.

A stone dutchman repair is a replacement of damaged, degraded, or broken stone with new stone, per ASTM C1722-18, 3.2.4. The repairs that are called out for each of the monuments have been established as technically viable but with high complexity. Each dutchman repair is intended to encompass the full extent of damaged stone without compromising the structural integrity or current appearance of the remain sound stone. Each repair is unique to the monument and element to be repaired and the joint location has been chosen to present the most unobtrusive result. There are a select number of joint types called out for use in this project. No deviation from specification is permitted without written approval above and beyond the normal approval process.

The exact type and size of Dutchman needed varies from monument to monument. All will require sculpting of various elements such as horse’s ears, sword scabbards, bills of caps, etc., Experience with sculptural repair, historic stone preservation, and repair methods is required. Exact scale models will be made for approval in the case of broken sculptural elements. The model making should leave no trace on the existing stone substrate. The use of stone sealers, or water repellents are not permitted in the protection of the stone. Models are required for every dutchman in this contract. Initial models are made on site from clay or plasticine, taking care not to stain the stone if using an oil-based modeling clay. These are then to be cast in plaster for use as guides in carving after being submitted to NPS for approval. The mold making process should not leave any residue on the surrounding stone. A list of approved compounds can be found attached.

NOTE: Each monument depicts the original sculptures chosen model/subject matter to work from and not necessarily historically accurate depiction of the memorialized unit’s kit. The original model, models kit, tack, uniform, and firearms may vary based on availability after the wars end and possibly other factors.

Only the use of approved reference materials is permitted for these monuments. These are provided in this document and apron request from the NPS. Each monument repair calls out the appropriate subject matter references.

The extent of the material to be removed for each repair is pre-defined and not subject to any deviations. Should the contractor find cause to expand or change the pre-defined demolition constraints this must be submitted for approval. In the demolition process, special care must be taken not to damage, mark, mar, or abrade the existing stone substrate. No “over-cuts” from a grinder or other cutting tool are permitted.

The correct new replacement stone for each monument will be provided by NPS. NPS takes responsibility for the correctness of stone for each monument. The responsibility of grain and bedding orientation falls on the contractor. Dutchman carved and installed in the wrong orientation are subject to removal and repair are the contractor’s cost.

New stone is attached to existing stone using appropriately sized stainless steel or titanium rods or pins and color matched UV stable stone epoxy per ASTM C1722-18, 8.3. See attachment “A”.

Approval from NPS representative of proposed extent of demolition is required before any stone can be removed. Depth of pocket for every dutchman is to be determined for each repair individually. No material is to be removed beyond the approved limits- no grinding, sanding or other blending on existing stone is permitted.

The models should reflect the finished stone in size and shape. Surface finish of model can vary from final finish of stone, since separate surface samples will be submitted separately.

Any original tooling or chisel marks on the original piece/stone are to be duplicated on the finished stone. The final finish should blend seamlessly with the existing stone. Samples of the finished tooling to be used are required for submittal and approval.

There are several different types of surface finishes that will be used on these repairs, all but one qualifies as a “Hand chiseled” finish. A 2” x 3” sample is required for each monument in the respective stone types. These are part of the approval process and are as follows:

The “Hand chiseled” finish (Not required to be produced by hand as some repairs would be subject to micro cracking from use of a pneumatic chisel.) varies from monument to monument and should be matched specifically to the individual. This can be achieved in a variety of ways but must be appropriate and feasible for each type of repair.

A polished surface. This polish should not be done with a pressure polishing machine but instead done by “hand” with a hand-held tool.

The final stone Dutchman should follow the approved model. Any variations in size and shape will require additional approval from the NPS representative and must be proposed before execution.

The approval process for each of the stages should consist of a physical example for approval as well as a document describing the portion of the project that is ready for approval and the way in which the work will be completed. This document should include photos of physical example, original and any supporting information that may be necessary. NPS Will issue a written approval of the submission or will submit an RFI when needed.

The stages that require approval are:

Contractors’ qualification – Attachment B for reference.

Demolition constraint approval Model approval Finished surface approval.

Epoxy type and pin location/size approval Dutchman approval Installation inspection Pointing inspection Once each approval is given then work on the next stage of the project may commence.

IE: models are approved by NPS, the stone replacements are made using previously made plaster model as a guide. Finished pieces must match approved models.

Approval of all new carved stone dutchman pieces required before installation. All models and documents produced in the approval process and during the repair work are subject to and property of NPS. All models shall be the property of the NPS and considered part of the finished product.

A pre-approved list of consumables is attached, ATTACHMENT A.

Work is not considered completed until it has been approved by NPS representative at Gettysburg.

All scaffolding, air compressors, generators, water, tools, safety equipment, and any other items needed for the satisfactory completion of the job are the sole responsibility of the contractor.

All scaffolding and site work must conform to OSHA standards. No scaffolding may touch, rest upon, be attached to, or otherwise contact or harm the monument.

The standard repair process for these dutchman is as follows except when noted in the description of each repair called-out below.

1. Demolition layout – The size of the planned repair must be physically drawn or marked out on each stone in a non-permanent manner. This outline will match or be smaller than the demolition constrains set forth for the repair. The depth of the repair and the dutchman joint type specifications requirements are included in this submission.

Submission for approval at this stage is required.

2. Modeling process can then be started before the demolition occurs. If there is enough broken stone left on the existing repair for clay to be applied without clay/modeling material contacting the stone that will remain intact, then modeling may be done directly on the monument. If there is not enough broken stone left on the monument to safely use a modeling making material that will stain, then there are a couple of options: first, a non-marking or non-staining material can be used. Second, a protective barrier can be used to prevent staining. Approved materials for this barrier are listed in the attachment of approved materials at the end. Third, the model must be made “off the stone”.

3. Casting - After the initial model is complete, then a mold of the model in place on the original monument can be made. This step serves to preserve the information contained in the broken portions of the stone that will be removed in the next step. It also forces the model to conform to the remains of the broken stone, limiting some of the potential for deviation from the original in the repair. The cast from the mold will serve as the base for the model for the dutchman.

An informal checking to view the first part of the model and give the “go ahead” for demolition is needed at this stage.

4. Demolition can then commence following the approved prescription previously approved and following any tool restrictions that are in place.

A tool use restriction on specific repairs is implemented when the repair is being done on a sensitive area. The cause can vary from a free standing or unsupported element to previous damage that makes the object less stable. The use of impacting tools is forbidden under the restriction. Rotary/grinding tools that emit low vibration are permitted. This restriction applies to the demolition, dutchman carving and installation of this repair/dutchman. Use of these tools will result in contract termination. Some examples of tools not permitted under this restriction are “F&K” Frolich and Klupfle, Cuturi, Milani, “T&H” Trow and Holden air hammers, or any other pneumatic piston hammering tool, “SDS”, “SDS Max”, “SDS Plus” hammer drills, demolition hammers and breakers. This is not a comprehensive list and if there is a question about a specific tool not listed here guidance is available from the NPS.

5. Modeling, the casting of the model must now be added to. The new information from the demolition must be incorporated in the model. This may involve additional mold making and casting. The resulting model should fit, as the dutchman will, in the recess made from the demolition. The finished surface of the stone does not need to be incorporated into the model. The model will be used as a guide and as a standard by which the dutchman will be assessed. The model will only be approved if it fits the monument physically, contextually, artistically, and historically.

a. To qualify as a good physical fit the model must physically fit into or against the joint on the existing stone. The planes of the model must fully contact the planes of the existing stone. There should be no wiggle or rocking in the joint nor should there be any a gap in the joint.

b. To qualify as a good contextual fit the model must show the elements that match the existing elements on the monument. The details of the elements must be appropriate to the subject matter being recreated. There will be examples for each repair given of the appropriate subject matter references and detailing required.

c. To qualify as a good artistic fit the model must fit in with the artistic style that the original monument was carved in. For example, if a sculptural element is too “realistic” for a stylized element, or vice versa it will not be approved.

d. To qualify as a good historic fit the model must match the historic photos of the intact monument. Even if the photo is of poor quality or is grainy or blurry it can still be used as a guide for the overall size and shape of the model. Of particular importance in all historic photos, regardless of quality of the photo, is the cast of light and shadows on the monument. This can give vital information and there should be care taken to match the photo. A photo of the model in place on the monument may be requested by NPS that is taken at a similar time of day as the historic photo so that the shadows cast can be compared.

Submission for approval at this stage is required.

6. Tooling samples. A 2” x 3” sample of the tooling on and surrounding the area set for repair is required for each monument in the respective stone type(s) that each monument is made from. These can be submitted all together at any point before the carving of the dutchman repair commences or individually in association with each repair process. Historic process replication is not necessary in the production of the tooling finish as it is not practical in all applications of the tooling finish on the repairs.

Submission for approval at this stage is required.

7. Dutchman carving can be done onsite, at the monument, or off site at a staging location of the contractors choosing. The finished surface of the new stone dutchman should be worked so that it matches the finished surface of the monument and the samples submitted, specifically the joint where the new stone meets old. The means by which the surface is produced is not limited to the method originally used on the monument since there may be reason to limit vibration caused by impact tools on some repairs.

8. Dry fit and pin location planning. Once the dutchman is carved it can be test fit/dry fit into the pocket made previously. Any trimming to accommodate full contact in the joint should be done before the approval request. The dutchman should fully contact the joint of the original stone. There should be no rocking or wiggling against the joint plane. The joint around the dutchman should be as tight as possible, smaller than 1/16”. The pin location should be marked out on both the dutchman and the original stone. No through or face pinning is acceptable. Length and angle will also be specified at this time for approval before drilling and installation. The pin should be set at an angle from the center of the dutchman portion with the greatest mas through towards the part of the existing stone that has the greatest mass closest to the repair, bisecting only one joint. The pin should be as close to the center of the mass of the dutchman as possible.

Submission for approval at this stage is required.

9. Installation can commence after approval of the dry fit of the dutchman. The hole for the pin may now be drilled and the pin test fit. The UV stable epoxy can also be tinted to match the stone coloration and the monument can be prepared for the installation. Epoxy requirements and a pre-approved list is contained in attachment A. There should be suitable protection of the monument during the installation process. Any damage, drips, staining, unsanctioned “redressing”, marring, or marking of any element on the monument will be cause for back-charges for the cost of repairs and may result in contract termination. Care should be taken in the planning of any bracing, clamping, or other means of securing and applying pressure to/of the dutchman during installation. The epoxy should be applied to both sides of the joint. Care must be taken to ensure that the hole drilled for pins and all mating surfaces are completely dust free. An area free from epoxy should be left at the edge of the joint to accommodate space for pointing. Epoxy should be applied to the inside of the pin holes in both the dutchman and the original as well as to the threads of the pin.

10. Pointing of the installed dutchman elements should be done with a color-matched lime-based mortar. Requirements and a list of pre-approved mortars is called out at the end in attachment A. There should be suitable protection of the monument during the installation process. Any damage, drips, staining, unsanctioned “redressing”, marring, or marking of any element on the monument will be cause for back-charges for the cost of repairs and may result in contract termination.

Submission for final approval at this stage is required for repair completion.

The following are individual repair details.

5th New York Cavalry The 5th NY Cavalry monument is located about 0.3 miles from the nearest road up a rocky foot path. All equipment will need to be brought in on foot or with an ATV. No access is possible for standard sized vehicles.

Damage

1. Scabbard tip missing.

2. Saddle blanket back corner.

3. Horse ear damaged.

4. Kepi bill edge chipped and spalling.

5. Boot spur.

6. Boot toe, stirrup, and leathers.

5th New York Cavalry cont.

The Photos here with red, mark out the exact area that is to be worked with, demolition, and repaired. No encroachment into any other area is permitted without prior written approval in the form of a change order submitted and approved. Also included in this brief are reference photos of the objects to be repaired and all historic photos showing an intact monument.

1. The scabbard tip repair will have a lap joint attachment style with a pin. The demolition constraint should not be exceeded. As with all repairs, the demotion boundaries will be marked in-situ and approved. Enough material must be removed so that the new stone dutchman will contact both the horse body and the remaining scabbard. The pin should be placed vertically through the scabbard potion of the joint. Pin size should be ~ 1/8” D Threaded rod.

There is a tool use restriction on the scabbard repair. The use of impacting tools of forbidden. Rotary/grinding tools that emit low vibration are permitted. This restriction applies to the demolition, dutchman carving and installation of this repair.

2. The saddle blanket repair will be a lap joint attachment with a pin. The new stone dutchman will resemble a triangle when complete. If the background/body of the horse are protected, then the model may be made directly on the broken stone and cast for approval. It is possible to see the “shadow” of the original outline of the blanket in the surface of the background stone. This “shadow” and the existing edges of the blanket can be used as a guide for the size of the model. The standard repair process, as called out, should then be followed.

5th New York Cavalry cont.

3. The horse ear repair should follow the example given in attachment C. Similarly, this repair will have a complex mortis and tenon joint and a pin. Care should be taken at all the edge vertices to avoid a sharp acute angle which will be friable. This model differs in size and demolition constraint from the example. The top of the dutchman will follow the edge of the ear where it protrudes from the mane.

It was determined that the distance between the bridle and damage was too great to extent the joint to the bridle. The depth of the demolition must be at least ¾” of an inch at any given point and cannot exceed 1 ¼” of an inch. The standard repair process, as called out, should then be followed.

4. Full kepi bill replacement. All of the bill on the kepi is to be removed back until it reaches the cap, forehead, and background of the monument. The dutchman for this kepi bill does not require any pins as it requires a mortise and tenon joint. The minimum depth for the mortise on this dutchman at the center of the left eye is ½” of an inch. The maximum, measured at the same point, is 1 ¼” depth. The internal shape of the tenon will be ovoid in plan, tapering out towards the outside. This is done to diminish the mortis and tenon joint complexity and to protect the edges of the joint on the existing stone thus preventing the possibility of an acute angle that will not survive. This dutchman should NOT extend into the background of the monument and ONLY into the forehead of the soldier.

The background attachment joint will be a blind stop flush/butt joint. The dutchman tenon will not be dissimilar in appearance to one side of a biscuit joint. The standard repair process, as called out, should then be followed.

5. The boot spur repair is a more traditional mortis and tenon joint with a pin. Demolition should follow the constraint above, the outline of the spur strap/leather. The joint will hide along the edge of the strap. The depth of the mortis into the stone should be a minimum of ½” and a maximum of 1”. The pin should be installed horizontally through the joint in the center of the dutchman.

There is a tool use restriction on the spur repair. The use of impacting tools of forbidden. Rotary/grinding tools that emit low vibration are permitted. This restriction applies to the demolition, dutchman carving and installation of this repair.

6. The boot, stirrup, and leathers repair will be a complex dutchman with multiple surfaces that engage with the original. This repair will have one pin set at an angle from the center of the dutchman portion with the greatest mas through towards the part of the existing stone that has the greatest mass closest to the repair, bisecting only one joint. The pin should be as close to the center of the mass of the dutchman as possible.

The demolition constraints show the edge of the joint running along the break on the horse body down and under the bottom of the boot, at the point where the heal starts, and straight up along the visual line of the start of the heal of the boot up until the joint hits the top frame of the boot buckle where it sharply changes plane on a 45-degree angle to hit the outside of the buckle frame on the top right corner. The joint then follows the natural break up until it comes close to meeting the joint along the horse body. Both joints then run vertically along the edge of the leathers and terminate in a horizontal joint in line with the bottom of the buckle on the leathers. The area inside of the demolition constrain will not be recessed but it will be smoothed to make a clean joint. It is vital that the dutchman joints line up precisely and accurately with the complex plane on the existing stone.

Pin placement on this dutchman is crucial and there will need to be separate approval given for the placement of the pin before placement on the existing stone. The long-term integrity and success of this repair depends on how well all the planes of this dutchman meet the existing and particularly on the pin.

There is also a tool use restriction on this repair. The use of impacting tools is forbidden. Rotary/grinding tools that emit low vibration are permitted. This restriction applies to the demolition and installation of this repair but not the carving of the dutchman.

Reference photos of historically accurate subject matter are provided below as well as any existing historic photos of the monument taken before the incursion of the current damage. These are to be used in the model making process. Subject matter reference; Original horse ear photo, cavalry scabbard, Standard US Kepi, McClellan Saddle 1st, 2nd, 4th, & 5th Photos show the undamaged monument.

3rd Photo show the cavalry scabbard.

6th Photo shows the kepi cap reference.

7th the McCellan saddle diagram.

8th Photo shows historic cavalry soldier from the Civil war.

9th Photo shows historic cavalry soldier from the American Indian war.

New Hampshire Sharpshooter

Damage –

1. Broken kepi bill- majority missing.

2. Gun hammer spur partially missing.

The Photos here with red, mark out the exact area that is to be worked with, demolition, and repaired. No encroachment into any other area is permitted without prior written approval in the form of a change order submitted and approved. Also included in this brief are reference photos of the objects to be repaired and all historic photos showing an intact monument.

New Hampshire Sharpshooter cont.

1. Full kepi bill replacement. All of the bill on the kepi is to be removed back until it reaches the cap, forehead, and background of the monument. The dutchman for this kepi bill does not require any pins as it requires a mortise and tenon joint. The minimum depth for the mortise on this dutchman is equal to the vertical measurement of the kepi bill where it meets the cap. The internal shape of the tenon can be ovoid in plan to diminish the mortis and tenon joint complexity and to protect the edges of the joint on the existing stone. Preventing the possibility of an acute angle that will not survive. The minimum depth, as previously defined, is to be measured directly under the cap emblem in the center. The dutchman should extend into the background of the monument and into the forehead of the soldier. Not dissimilar to one side of a biscuit joint. The standard repair process, as called out, should then be followed.

2. Gun hammer “spur” repair will require ~1/16” D titanium threaded rod for the pin extending through the butt joint. The joint between the two stone surfaces should be flat. Both surfaces should have full contact with each other. This dutchman has tool limitations on it as well. No tools that cause impact of any kind are permitted on the repair as it is free standing element. Die grinders, pneumatic rotary tools, and grinding tools are permitted. Care should be taken when executing the demolition on the repair. The repair process, as called out, should then be followed.

Reference photos of historically accurate subject matter are provided below as well as any existing historic photos of the monument taken before the incursion of the current damage. These are to be used in the model making process. Subject matter reference; 1861 Springfield rife, and US Berdan Sharpshooter Kepi.

This monument is carved in a slightly off realist. It can be classified as a stylized caricature. This can be seen in the designed relationship between the foreground and the background, the style of the hands, and the gun. The gun hammer “spur” shares this specific style depiction.

1st Photo shows monument dedicated in 1886 by the State of New Hampshire.

2nd & 3rd Photos show the undamaged Munument 4th & 5th Photos show the hammer of an 1861 Springfield rifle 6th & 7th Photos show the US Berdan Sharpshooter Kepi.

13th New Jersey Infantry

1. Kepi bill missing/filled with cementitious patch.

2. Hammer spur and head missing.

3. Canteen edge with strap.

The Photos here with red, mark out the exact area that is to be worked with, demolition, and repaired. No encroachment into any other area is permitted without prior written approval in the form of a change order submitted and approved. Also included in this brief are reference photos of the objects to be repaired and all historic photos showing an intact monument.

13th New Jersey Infantry cont.

1. The kepi bill repair is a full brim replacement. The dutchman for this kepi bill does not require any pins as it requires a mortise and tenon joint. The model for this dutchman may be made on directly on the broken brim of the bill after the cementitious patch has been removed. After the model is made and approved the mold can be taken of the model. The mold making process shall not leave any residue on the surrounding stone. A list of approve compounds can be found attached. The resulting cast can then be submitted for approval and used for direct carving before being turned over to NPS. In general, attachment B can be used as a guide. However, because the damage extends so far along the brim of the bill the side joint constraint is to far back from the forehead to cut a straight plane between the two side joints. A curved profile is required. Convex in the mortis and concave on the tenon of the dutchman. The depth of the recess should not exceed 1 ½” at any point from front to back. The standard repair process, as called out, should then be followed.

2. The gun hammer repair will be a butt joint and pin repair. The demolition constraint is shown in red. Clay model may be made before demolition on the remaining broken stone. The joint between the two stone surfaces should be flat. Both surfaces should have full contact with each other. The standard repair process, as called out, should then be followed. Pin size will be small ~1/16” D titanium threaded rod.

There is a tool use restriction on the gun hammer spur repair. The use of impacting tools is forbidden. Rotary/grinding tools that emit low vibration are permitted. This restriction applies to the demolition, dutchman carving and installation of this repair.

3. The canteen repair will be a pinned pseudo ball joint repair. Meaning that the dutchman will have a convex attachment plane and the shape to be removed in the existing stone will be concave attachment plane. The standard repair process, as called out, should then be followed.

Reference photos of historically accurate subject matter are provided below as well as any existing historic photos of the monument taken before the incursion of the current damage. These are to be used in the model making process. Subject matter reference; 1863 Springfield Rifle, Smooth sided New York Depot canteen, and US Forage Cap (Bummer) "McDowell" Brim.

1st, 2nd 3rd, & 4th Photos show the undamaged monument.

5th Photo shows the US (Bummer) "McDowell" Brim sharpshooter kepi 6th, 7th, & 8th Photos shows the 1863 Springfield rife.

9th & 10th Photos shows the New York Depot Smoothside Canteen

8th New York Cavalry

1. Kepi bill missing front corner.

2. Ear of horse missing.

3. Scabbard tip.

8th New York Cavalry cont.

The Photos here with red, mark out the exact area that is to be worked with, demolition, and repaired. No encroachment into any other area is permitted without prior written approval in the form of a change order submitted and approved. Also included in this brief are reference photos of the objects to be repaired and all historic photos showing an intact monument.

1. Full kepi bill replacement. All of the bill on the kepi is to be removed back until it reaches the cap, forehead, and background of the monument. The dutchman for this kepi bill does not require any pins as it requires a mortise and tenon joint. The minimum depth for the mortise on this dutchman is equal to twice the vertical measurement of the kepi bill where it meets the cap. The internal shape of the tenon will be ovoid in plan, tapering out towards the outside. This is done to diminish the mortis and tenon joint complexity and to protect the edges of the joint on the existing stone. Preventing the possibility of an acute angle that will not survive. The minimum depth, as previously defined, is to be measured in the center of the cap. The dutchman should extend into the background of the monument and into the forehead of the soldier. Not dissimilar to one side of a biscuit joint. The standard repair process, as called out, should then be followed.

2. The horse ear repair should follow closely the example given in attachment C. Similarly, this repair will have a complex mortis and tenon joint and a pin. Care should be taken at the bottom vertices to avoid a sharp acute angle which will be friable. The model of the ear will differ from that in the example since the style of this monuments horse is drastically different from the example. The existing horse ear should be used as a reference for the style of the ear. The standard repair process, as called out, should then be followed.

3. The scabbard tip repair will have a lap joint attachment style with a pin. The demolition constraint should not be exceeded but does not have to be used as a maximum reference either. Less material may be removed then the allowable amount. As with all repairs, the demotion constraint will be marked in-situ and approved. Enough material must be removed so that the new stone dutchman will contact both the horse body and the remaining scabbard. The pin should be placed vertically through the scabbard potion of the joint. Pin size should be ~ 1/8” D Threaded rod. The standard repair process, as called out, should then be followed.

There is a tool use restriction on the scabbard repair. The use of impacting tools of forbidden. Rotary/grinding tools that emit low vibration are permitted. This restriction applies to the demolition, dutchman carving and installation of this repair. Use of these tools will result in contract termination.

8th New York Cavalry cont.

Reference photos of historically accurate subject matter are provided below as well as any existing historic photos of the monument taken before the incursion of the current damage. These are to be used in the model making process.

This monument is carved in a slightly off realist stylized caricature. This can be seen in the design of the tack, the style of the horse face, and the scabbard. The horse ear specifically should share this specific style depiction. Subject matter reference; Original horse ear photo, cavalry scabbard, Standard US Kepi

1st & 2nd Photos show the undamaged monument.

3rd Photo show the cavalry scabbard.

4th Photo kepi cap reference.

1st Maryland Cavalry Damage –

1. Horse ear missing.

The Photos here with red, mark out the exact area that is to be worked with, demolition, and repaired. No encroachment into any other area is permitted without written approval. Also included in this brief are reference photos of the objects to be repaired and all historic photos showing an intact monument.

1. The horse ear repair should follow the example given in attachment C. Similarly, this repair will have a complex mortis and tenon joint and a pin. Care should be taken at all the edge vertices to avoid a sharp acute angle which will be friable. This model differs in size and demolition constraint from the example. The top of the dutchman will follow the edge of the ear where it protrudes from the mane and head.

1st Maryland Cavalry cont.

Reference photos of historically accurate subject matter are provided below as well as any existing historic photos of the monument taken before the incursion of the current damage. These are to be used in the model making process. Subject matter reference; Original horse ear photo.

1st & 2nd Photos Show the intact monument.

1st Maryland Infantry Eastern Shore

Damage -

1. Full kepi bill replacement.

2. Nose missing back to face- currently filled with cementitious patch.

3. Trigger guard and strap hardware- Forward half of trigger guard is broken, and attachment point of shoulder strap is broken.

1st Maryland Infantry Eastern Shore cont.

The Photos here with red, mark out the exact area that is to be worked with, demolition, and repaired. No encroachment into any other area is permitted without prior written approval in the for of a change order submitted and approved. Also included are reference photos of the objects to be repaired and historic photos showing an intact monument.

1. Full kepi bill replacement. All of the bill on the kepi is to be removed back until it reaches the cap, forehead, and background of the monument. The model for this dutchman may be made directly on the broken brim of the bill after the cementitious patch has been removed. The dutchman for this kepi bill does not require any pins as it requires a mortise and tenon joint. The minimum depth for the mortise on this dutchman at the center of the nose is ½” of an inch. The maximum, measured at the same point, is 1 ¼” depth. The internal shape of the tenon will be ovoid in plan, tapering out towards the outside. This is done to diminish the mortis and tenon joint complexity and to protect the edges of the joint on the existing stone thus preventing the possibility of an acute angle that will not survive. This dutchman should NOT extend into the background of the monument and ONLY into the forehead of the soldier. The background attachment joint will be a blind stop flush/butt joint. The dutchman tenon will not be dissimilar in appearance to one side of a biscuit joint. The standard repair process, as called out, should then be followed.

2. The model for the nose dutchman may be made on the broken nose after the cementitious patch has been removed. The demolition of the nose will be confined to both alar nasal sulci (outside of the nostrils), following along the alar base (or following the edge of the nostril around the bottom), and alarfacial groove (the point where the nostril meets the face), including the nostril sills (the skin that makes up the bottom of the nostril hole) and septum (the vertical tissue between the nostrils), but excluding the philtrum (the grove between the nose and upper lip). The line of the demolition will continue vertically along the medial (towards the center) edge of the levator labii superioris alaeque nasi muscle (the muscle running vertically from the upper lip to the bridge of the nose) and then turning medially (towards the center) along the cephalic (top) edge of the anomalous nasi muscle (the muscle that covers the side of the nose, starting along the ridge of the nose and terminating at the top of the nostril) to the radix or bridge of the nose. The plane created with this line should be as smooth and flat as possible but should deviate concave when necessary. The joint of the dutchman should be a butt joint with a pin. There will a single pin that is situated in the center of the dutchman with the most mass and should remain a minimum of 5/8th of an inch away from the surface of the nose.

There is cementitious patch on the cheek proximal to the background shown in green. This should be delicately removed and assessed. If NPS deems a repair necessary, then this portion of the repair will be incorporated into the nose dutchman repair changing the proximal side of the dutchman. There is also the option for re-dressing the area on the cheek should the repair be more invasive than damage. This re-dress should be done in a historically accurate manner with a chisel.

1st Maryland Infantry Eastern Shore cont.

3. The trigger guard and hardware repair will be complex. The path of the repair follows the guard around the finger and trigger without damaging them and terminating at the attachment points on the stock. A portion of the strap and the attachment hardware that attach to the guard are included. The dutchman is engaged with the gun stock and strap as well as the background with a mortis and tenon joint. The tenon should extend a minimum of ¾” into the background. It should not extend more then 1 ½” deep. The joint between the strap and gun stock should be a butt joint. The standard repair process, as called out, should then be followed.

Reference photos of historically accurate subject matter are provided below as well as any existing historic photos of the monument taken before the incursion of the current damage. These are to be used in the model making process. Subject matter reference; 1863 Springfield, Standard US Kepi, 1st, 4th Photos show the intact monument.

2nd & 3rd Photos show the 1863 Springfield reference.

5th & 6th Photos show the kepi cap reference.

78th & 102nd New York Infantry

Damage-

1. Missing end of rifle barrel.

2. Gun hammer damaged.

The Photos here with red, mark out the exact area that is to be worked with, demolition, and repaired. No encroachment into any other area is permitted without prior written approval in the form of a change order submitted and approved. Also included in this brief are reference photos of the objects to be repaired and all historic photos showing an intact monument.

78th & 102nd New York Infantry

1. This gun barrel repair is a butt joint connection with a 1/8” -1/16” D pin. The demolition must stop at the first band on the barrel. The pin should remain a minimum of ½” away from barrel end. The details shown marked out in blue are not acuity or correct and are only be used to show location. The standard repair process, as called out, should then be followed.

2. The gun hammer repair will be a mortis and tenon joint with a pin repair. The demolition constraint is shown in red. Clay model may be made before demolition on the remaining broken stone. The mortise portion of the joint in the gun stock of the monument will be recessed into the stock with two planes meeting at a 90-degree angle. The tenon will match. The standard repair process, as called out, should then be followed. Pin size will be small ~1/16” D titanium threaded rod. There is a tool use restriction on the gun hammer repair. The use of impacting tools is forbidden. Rotary/grinding tools that emit low vibration are permitted. This restriction applies to the demolition, dutchman carving and installation of this repair.

3. Reference photos of historically accurate subject matter are provided below as well as any existing historic photos of the monument taken before the incursion of the current damage. These are to be used in the model making process.

78th & 102nd New York Infantry cont.

1st – 4th Photos show the 1863 Springfield reference.

5th & 6th Photos show the intact monument.

78th & 102nd New York Infantry cont.

6th Wisconsin Right Flank Marker

Missing length, broken corner.

Full recarve of marker.

This is a full replacement of the original. The stone will be provided by NPS. The bottom 30” will be rock-faced and will be approximately 12”-14” square in plan. The top 12” will be hand tooled to match the original and will be 9” square in plan with a ½” 45-degree bevel on the top edge. The top surface of the marker will be polished. This should not be done with a pressure polisher and instead be done by hand. The lettering in the top surface will not be sandblasted. They will be incised with a chisel and have a “V” profile.

The stone provided will be close to the finished dimensions already. Work will still need to be done to bring it down to size and the material available for rock-facing will be limited.

40th New York Infantry

1. Hammer spur and head missing.

The Photos here with red, mark out the exact area that is to be worked with, demolition, and repaired. No encroachment into any other area is permitted without prior written approval in the form of a change order submitted and approved. Also included in this brief are reference photos of the objects to be repaired and all historic photos showing an intact monument.

1. The gun hammer repair will be a mortis and tenon joint with a pin repair. The demolition constraint is shown in red. Clay model may be made before demolition on the remaining broken stone.

40th New York Infantry Cont.

The mortise portion of the joint in the gun stock of the monument will be recessed into the stock with two planes meeting at a 90-degree angle. The tenon will match. The standard repair process, as called out, should then be followed. Pin size will be small ~1/16” D titanium threaded rod.

There is a tool use restriction on the gun hammer repair. The use of impacting tools is forbidden. Rotary/grinding tools that emit low vibration are permitted. This restriction applies to the demolition, dutchman carving and installation of this repair.

Reference photos of historically accurate subject matter are provided below as well as any existing historic photos of the monument taken before the incursion of the current damage. These are to be used in the model making process.

ATTACHMENT A

Epoxy requirements:

UV Stable – tested for minimum 500 hours of exposure.

Compressive strength 3,000- 13,000psi Flexural strength 11,000 – 13,255 psi Shear – 1,000 – 4,000 psi Pre-approved Epoxies:

Bonstone “Ultimate” modified polyurethane hybrid.

Touchstone Glacier Bonstone “Last Patch™ Gel” Bonstone “Last Patch™ Dymond” Bonstone Fast Set™ 41 is not UV stable and is only approved for use on surfaces that are buried or have no edge exposure. This epoxy is only to be use when setting in cold temperatures is a concern.

Pointing mortar Requirements:

Lime, quick lime or natural hydraulic lime based.

Have small aggregate or be screened down to a small size.

Pre-approved mortars:

St. Asters “Lithomex” Bonstone’s “HRM” Pin requirements:

Rod must be threaded or keyed in some way to facilitate adhesion between pin and epoxy with a mechanical bond addition to the chemical bond from the epoxy.

Rod material must not be prone to redox reactions that cause expansion and must be low on the oxygen reactivity scale/ be semi corrosion resistant.

Pre-approved pin types listed in order of preference:

Titanium Stainless Steel Nickel Aluminum Brass

Casting requirements:

Must not leave any residue.

Must not discolor the original stone monument.

Pre-approved casting systems:

Plaster Smooth-On’s “Super Seal” compatible with polyurethane, silicone, or polysulfide mold rubbers.

Smooth-On’s “Dragon Skin™ Series” only in conjunction with the use of “Super Seal” Smooth-On’s “Rebound 25” only in conjunction with the use of “Super Seal” Clay modeling surface protection:

Plastic wrap Tinfoil Smooth-On’s “super seal” Water based clay.

Attachment B Exhibit A -must show examples of figurative sculpting, figurative carving, Direct carving/ from a model, historic restoration, banker carving/profile carving, and traditional carving techniques and knowledge.

.Attachment C Kepi Bill dutchman example.

Sample of a kepi bill replacement that is not engaged with a background and only engaged with the head.

This kepi bill had a demolition constraint shown here in red. The constraint was chosen for this location in such a way as to hide most of the joint for the new stone dutchman repair in the plane change between the brim and the forehead on the bottom and the brim and the buckle on the top. The location of the side joints was chosen so that they would remain small but not friable. Their location also served to leave a less complex mortis and tenon joint inside because it aloud a flat surface between the two joints.

Here, the model was made direct on the broken bill since the stone it contacted was going to be removed. It was then possible to make a model and cast from the model for approval.

Below, a model and new stone dutchman with centerline.

Attachment C cont.

Here is a sample of what the demolished kepi bill mortis should look like. The flat back makes fitting the new dutchman easier.

Kepi bill dutchman was then dry fitted into place to test the fit and overall shape. Once the fit was approved, the installation could be completed. UV Stable color matched epoxy was used in the joint between the two stones. Complete coverage in the joint on the back was done. The sides, bottom and top were covered as well with a margin at the edge left clear. The goal it to not have any epoxy exposed to light. Color matching and the UV stability is still required for this application so that if the epoxy is ever exposed it will maintain it’s integrity and match the existing stone.

After the new stone dutchman was installed and set, then the repair could be pointed with a lime-based color matched mortar. Since the joint size restriction is a maximum of 1/16” the mortar will have to be screened with a fine screen to remove most aggregate. One final inspection is then done and if the pointing meets with approval the repair is complete.

Attachment D Horse Ear dutchman example.

This is a sample of a horse ear replacement that is not engaged with the background and only with the head of the horse. The approved demolition constrain is shown in red. The area of the dutchman was carefully considered. A smaller sized repair was contemplated but it was determined that this size repair was best for longevity of the repair and for the overall finished appearance as this sizing aloud the joint to hid along the edge of the bridle.

The clay for the model was applied directly to the broken stone since contact point would be removed in the demolition.

A cast was then made and submitted for approval.

The minimum depth was removed for this dutchman along the approved constraint. Care was taken to not leave an acute angle on any edge of the dutchman.

Attachment C cont.

After the demolition was complete another mold was taken so that a model of the full dutchman could be made. This model was also submitted for approval and was used as a working model to carve from.

The new stone dutchman was then carved and dry fitted into the recess. Once the fit was confirmed then the location of the pin was determined and drilled.

The dutchman was installed using a UV stable color matched epoxy continuously covering all of the joints with a margin around the edge left clean and clear for later point. The pin used was threaded stainless steel and set with epoxy.

After the dutchman was installed and set a lime base approved mortar was used to point the joint which did not exceed the maximum dimension of 1/16” in thickness. The mortar was screened for aggregate before use to accommodate.

The repair met with approval after the final inspection.

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