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New Manufacturing Capability Expedites Historic Restoration Mortar Deliveries

Cathedral Stone Products, Inc., the exclusive US manufacturer of Jahn restoration mortar products, has completed the installation of its all new manufacturing and testing laboratories at Company headquarters in Hanover, MD.

Until now, Jahn restoration mortar products were formulated and shipped from Jahn's headquarters in Germany causing high transportation costs, delays and other inconveniences. With the new Hanover plant coming on-stream, orders can now be shipped within 24 hours, or in rare cases, 48 hours.

Cathedral Stone Products offers a full line of standard Jahn mortar mixes that are pre- engineered for long life and "breathable" compatibility with many different surface compositions such as, cement, limestone, brick, brownstone, terra cotta or stucco.

Architects and engineers seeking a custom mortar mix for a specific application send a sample of the exterior facing material taken from the building. Following careful analysis in the Cathedral Stone lab, mix proportions are adjusted to match critical physical properties such as porosity, tensile strength, bending and compression, and expansion/ contraction moduli. Color matching by the lab experts at Cathedral Stone is another way Jahn repair mortars assure the building looks right when the job is completed.

Custom mix formulas are then programmed into their new manufacturing system via Cathedral Stone's proprietary software which interfaces with PLC controllers to precisely control the process. The pre-measured components are then vacuum delivered from the hoppers to the mixer where they are weighed on close tolerance scales and packed in 44 lb. buckets, or customer specified packaging.

To assure QC, remains from each order are always mixed, cured and tested before the product is shipped. A hardened sample block is retained by Cathedral Stone with the lot number noted to assure repeat orders are formulated to exactly match the color and other properties of the original order.

In this manner, Cathedral Stone can guarantee batch-to-batch consistency of any custom mortar mix. Cathedral Stone Products has been in operation since 1982 and has provided Jahn products for the restoration of the Empire State Building, the Ellis Island Immigration Museum, the White House, as well as numerous other historic public buildings and churches around the country.

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