How Are Tin Ceiling Panels Manufactured?
A Historic Craft
Tin ceilings once graced most commercial buildings and many great houses. They were a phenomenon of industrialization and gained popularity in the nineteenth century due to their fireproofing properties. Ceilings fashioned of tin or steel plate panels, nailed to furring strips, were less expensive than the traditional plaster or wood and could be easily repaired or replaced. Their only drawback was an unfortunate tendency to rust along seams and high-relief details, a problem solved with the use of new materials.
Materials and Methods
Historically, tin ceiling panels were made of tin-plated steel, copper or copper alloyed with tin. The metal was rolled very thinly between large, heavy rollers and cut into large pieces, sized according to pattern. A thin sheet was then laid in a compression press to create raised patterns. Historic patterns came in four-by-two and two-by-two foot panels or in trim, cornice and ornate ceiling rose patterns. The stock patterns that plasterers had fashioned for hundreds of years could be recreated in identical, light and easy to apply pieces that essentially fireproofed a ceiling, an important consideration in the days of balloon construction before fire breaks were required in building codes. Panels were nailed to furring strips, or "battens," with round-topped nails in strips or window-pane patterns across a ceiling. Panels and trim were also manufactured for walls and wainscoting. Tin panels and trim was cut to fit using tin snips.
New Alternatives
Modern tin ceilings are tin in name only. The old materials have been replaced with lighter ones that can be rolled a bit thicker--about one-fiftieth of an inch. Modern manufacturers, some of whom have been in business for more than 100 years, still use the same method of rolling and pressing, and many pride themselves in using the same press plates as were used in the nineteenth and early twentieth centuries. The development of aluminum alloys has replaced the old steel panels to make modern panels reliably rust-resistant. Copper and bronze alloys are still available. Powder coatings can replicate verdigris and other antique finishes and have eliminated the need to paint with the old oil-based paint before hanging. Modern ceilings are hung using the batten system or "T-rail" suspension grids like the ones used for suspended ceilings. In addition to the old pressed metal, new materials such as polyvinylchloride (PVC), vinyl and urethane foam can be fabricated using molds. These materials make possible a whole new variety of pieces, including pre-made corners, corbels and custom details. Color is often included as part of the material for these pieces, making painting or powder-coating unnecessary. Old plaster details can be replicated by using a latex reverse mold process.
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