Molded perfection: What it takes to restore antique plaster

The ancient building technique of plasterwork is experiencing a modern resurgence, transforming walls and ceilings into elevated aesthetic elements within homes. Jimmy Sanfilippo, through his company Sparrow Plaster and Tile, has been a central figure in bringing specialized plasterwork to Vineyard homes for nearly three decades. His work blurs the lines between trade and art, emphasizing functional, durable, and aesthetically pleasing outcomes. Sanfilippo's approach is distinguished by his willingness to undertake complex, creative, and physically demanding projects, continuously learning and imparting his extensive knowledge to his team. He works with plaster, a delicate mixture of lime, gypsum, sand, and water, which is highly sensitive to environmental factors such as humidity, heat, and air circulation, as well as the concentration of aggregates and water temperature. These variables become even more critical when working with curved surfaces, domes, barrel vaults, or cast moldings, or when incorporating integral color pigments or marble-like Venetian finishes. Sanfilippo prioritizes high-quality, time-intensive jobs using superior and often rare materials. He transitioned from drywall in the mid-eighties as he found it becoming too generic. His specialization lies in the esoteric aspects of artisanal wall surfaces, particularly plastering over wirework for complex shapes like barrel vaults and domes, which cannot be achieved with Sheetrock. This process involves multiple layers, each requiring precise and consistent curing to prevent future cracks, making meticulous preparation essential before mixing the plaster. Teamwork is fundamental to Sanfilippo's plastering projects. He divides areas into sections, assigning each to a worker, and the crew collaboratively determines the exact amount and consistency of plaster needed for each section, accounting for individual working styles and area specifics. This collaborative approach ensures a cohesive and beautiful final product, fostering a sense of shared accomplishment rather than competition. Plasterwork offers significant longevity due to its material durability and its ability to expand and contract with environmental changes, making it resistant to seasonal shifts and humidity. Aesthetically, a hand-tooled plaster ceiling or wall imparts a distinct, handcrafted quality that integrates seamlessly with other artisanal elements like handmade floors and custom woodworking, creating a unified sense of craftsmanship within a home. While much of his work is on Martha's Vineyard, Sanfilippo also undertakes projects in New York City, drawn by innovative architectural designs that challenge his skills. He has collaborated with restaurateur Keith McNally on several projects, including Pravda and Pastis, and McNally's Vineyard home. A notable project for McNally involved creating a unique layered plaster surface that was smooth yet revealed rougher inner layers, designed to absorb color washes differentially, resulting in a distinct visual and tactile effect. Sanfilippo stresses the importance of clients articulating their aesthetic preferences, often asking them to provide examples from magazines or descriptions of their existing decor to ensure the plasterwork complements the room's overall character, considering factors like rugs, furnishings, and room temperature. Historically, plastering is an ancient practice dating back nearly ten thousand years, used for protection, insulation, and sanitation. Early civilizations, including those in India, China, Jordan, and ancient Egypt (the pyramids were plastered), utilized it. Limestone in plaster acts as a mold inhibitor, a property leveraged by early Europeans to protect their walls. Even the indigenous people of Martha's Vineyard used a form of clay-concentrate mud plaster for their wetus, demonstrating the timeless principle of building with earth materials. Sanfilippo's journey into plastering began in his father's drywall business, where he developed a foundational understanding of construction. He later advanced his skills through an industrial arts program and eventually transitioned from drywall to plastering, taking a pay cut to learn and refine his craft, ultimately achieving mastery. His philosophy, as encapsulated by a shared quote, emphasizes that true artistry in his trade emerges when one works not only with hands and head but also with the heart. #Plasterwork #ArtisanalCraft #HomeDesign #InteriorFinishes #ArchitecturalDesign #BuildingMaterials #HistoricTechniques #CustomHomes #Craftsmanship

Plaster, an ancient building material composed of lime, sand, and sometimes fibers, has been utilized for centuries, adorning structures from ancient Egyptian pyramids to Greek temples. Despite its susceptibility to cracks and bubbles, plaster remains a durable and aesthetically pleasing wall coating. Its popularity peaked in the early 1900s, featuring prominently in historical homes built before World War II, prior to the widespread adoption of drywall panels in the 1950s. Today, plaster is experiencing a resurgence, appreciated for its beautiful texture that adds depth, interesting highlights, and a sculptural effect to rooms. This renewed interest is fueled by technological advancements in plaster variations and its eco-friendly properties. Modern homeowners and designers are increasingly turning to plaster to infuse artistic flair into their wall spaces, with a wide array of color palettes and texture options available, akin to paint colors. Various types of plaster exist, including tadelakt, slaked lime, and Venetian plaster. While gypsum and other cement-based plasters are more affordable, they necessitate professional application and may not be suitable for all surfaces. Venetian plaster, though higher in price, offers stunning visual effects. Clay-based plasters, while softer, are not recommended for wet areas like kitchens and bathrooms. Proper care is crucial to prevent significant and costly plaster repair. This guide provides five key tips to minimize damage and maintain plaster walls. First, it is essential to recognize the signs of damage. Cracks appearing near door openings, wrapped doorways, hallways, beams, or corners typically indicate stress cracks due to foundation or structural shifting. Water damage, often caused by leaky roofs or pipes, manifests as separation of plaster from the lath, forming bulges, or in plaster-over-drywall applications, as soft areas with brown-tinted stains. Ideally, such defects should be repaired by a professional specializing in the specific type of plaster, as repairs are usually visible unless the entire wall is skim coated. Second, promptly repairing cracks is vital. Unlike drywall cracks, filling hairline cracks in plaster is not straightforward, as sealing agents often bubble up. A more involved trenching process is required: the crack should be cut out deep enough to reach the substrate using a utility knife held at a 90-degree angle, creating a V-shaped trench. Before beginning, it is crucial to ensure proper ventilation with a box fan and a MERV 13 or HEPA filter, and to wear a dust mask, gloves, and safety glasses, as historical plaster may contain harmful components. Children and individuals with respiratory issues should avoid the area. After trenching, a fast-drying patching compound, such as USG Easy Sand 45, is applied to fill the cracks flush, allowed to dry and shrink. Mesh tape is then placed over the repaired area, followed by a thin coat of joint compound or the patching compound. Once dry, the exterior side of the tape is feather-coated approximately six inches wide using a putty knife, ensuring it is flush with the tape and wall. Any heavy pieces are removed before the final coat. The key is to apply thin coats, as adding more compound is easier than sanding. The final thin coat is sanded as needed once dry. Third, correctly hanging art and shelves is paramount. Plaster walls can be challenging for hanging objects due to the bounce-back effect from the underlying lath, which can cause significant wall damage or paint bubbling. To prevent this, an anchor-and-screw system is recommended for heavy items, with molly bolts or toggle bolts providing superior support. Locating a stud using a stud finder is also advisable. Pre-drilling is essential when using nails, with a drill bit 1/32-inch to 1/16-inch smaller than the nail. The drill bit should be angled at 45 degrees, and the nail gently drilled in. A small amount of caulk or construction adhesive can be applied to the hole to secure the nail, allowing it to dry before hanging. Alternatively, utilizing existing picture molding or installing a modern wire system can avoid nailing into plaster altogether. Fourth, regular touch-ups can extend the life of plaster walls. If plaster is in good condition but has a shiny, cracked appearance, repainting with a matte finish paint can minimize defects. Before repainting, it is important to determine the existing paint type; if oil-based, an appropriate primer is necessary before applying water-based paint. Finally, careful cleaning is crucial. Plaster walls should be cleaned delicately due to their texture and susceptibility to cracking. Vacuuming with a dust-brush attachment is the first step. For dirtier areas, a warm, damp cloth with a mix of water and dish soap can be used, taking care not to scrub vigorously to avoid damaging the texture or finish. #PlasterWalls #HomeMaintenance #WallRepair #InteriorDesign #DIYHomeImprovement #HistoricHomes #WallFinishes #CrackRepair #HomeCare

Jeff Poree, a fifth-generation plasterer and owner of Jeff Poree Plastering, exemplifies dedication to his craft despite the physical demands of his work at 69 years old. He expresses no intention of retiring, with his company currently managing ten projects. Poree's extensive experience and the legacy of his family's craft are rooted deeply in New Orleans, where his company is renowned for its expertise in ornamental exterior and interior plaster, artistic molds, and specialized finishes, including Venetian and exotic techniques. The New Orleans Master Crafts Guild, through its founding director Jonn Ethan Hankins, recognizes the Poree family's exceptional skills. Jeff Poree Plastering operates a substantial 15,000-square-foot casting shop, employing 32 individuals. This team includes apprentices who learn foundational plastering skills like creating smooth walls, as well as gifted artisans specializing in intricate decorative elements such as ceiling roses, lions, and gargoyles. The company also maintains a full-time art department capable of restoring damaged pieces using fragments, photographs, or drawings, aiming to return historic works to their original state. Christopher Caravella Jones, a long-time employee, highlights the honor of restoring historical works. Architect Robert Cangelosi, Jr., president of Koch and Wilson, has frequently collaborated with Poree's company on numerous projects, including significant historical sites like the Napoleon House and various private residences in the Garden District and French Quarter. Cangelosi commends Poree's company for its experience and expertise in complex historic plastering and stucco restoration, emphasizing its role in preserving New Orleans' heritage for future generations. This underscores the critical role Poree and his team play in maintaining the architectural integrity of the region. Poree is also committed to preserving the craft of plastering by educating the next generation. For the seventh consecutive year, he is scheduled to present at The New Orleans Jazz & Heritage Louisiana Folklife Village. Furthermore, he actively trains apprentice plasterers, with the apprenticeship program spanning three years. Poree is nearing completion of his sixth apprenticeship class. Hankins notes that Poree, who trained under previous generations of master plasterers, is now considered the leading authority in the field and bears the responsibility of passing on these centuries-old, specialized skills to ensure the trade's continuation. Poree, described as humble and soft-spoken, expresses gratitude for having worked with older craftsmen and for the opportunity to share his knowledge with aspiring plasterers. #PlasterMaster #HistoricPreservation #NewOrleans #Craftsmanship #Apprenticeship #ArchitecturalRestoration #JeffPoreePlastering #OrnamentalPlaster #HeritageCrafts

This article discusses the identification, survey, and assessment of fibrous and traditional lime-based plasterwork in buildings, particularly in light of recent guidance following the collapse of a decorative plaster ceiling at the Apollo Theatre in Westminster in 2013. The Association of British Theatre Technicians (ABTT) published guidance in 2015, followed by Historic England's interim guidance in 2019, to assist conservation professionals and building managers. Fibrous plasterwork, a lighter, quicker, and cheaper alternative to traditional lime-based plaster, gained popularity in the mid-to late 19th century. While often associated with public buildings, its presence is increasingly noted in private houses from the late 19th and early 20th centuries, necessitating surveyors' ability to identify its type and appraise defect risks. The primary method of fixing fibrous plasterwork, known as wadding, involves hessian ties soaked in plaster of Paris. Post-Apollo Theatre collapse investigations revealed that wad ties are vulnerable to environmental conditions, dampness, damage from interventions, and additional loading. Historic England identifies wadding as a significant risk to fibrous plaster integrity. The ABTT guidance, largely incorporated into Historic England's publication, emphasizes regular inspections for fibrous plaster ceilings, especially those supported by unreinforced hessian wads, which are considered deleterious and likely to require reinforcement to prevent collapse. If areas cannot be inspected, the use of unreinforced wads should be assumed. The guidance from both ABTT and Historic England recommends that competent structural engineers inspect supporting structures, and competent plaster inspectors assess plaster parts. Inspections should occur from both above and below, examining surrounding fabric for water ingress and structural movement. A baseline survey is crucial to document construction, including all supports, to inform repairs and future asset management. This may involve adding or replacing support ties, removing debris, reducing loads, consolidation, or replacing ceiling sections. Baseline surveys also dictate the timing of subsequent inspections, with regular checks for changes like cracking and staining required between major inspections. The article extends these principles to traditional lime-based plasterwork, which was more common in British buildings until the mid-20th century and shares similar vulnerabilities. Traditional decorative ceilings, applied to timber laths, form plaster nibs or rivets for mechanical keying. These can be damaged by loading, alterations, insulation upgrades, or vibrations. Inspection should cover timber laths, ties, connections, and surrounding fabric for water ingress. A close inspection of the underside of the ceiling is necessary to record defects such as cracks, detachment, and surface disruption. Accurate recording of construction methods and defects informs repairs and monitoring. Retention and repair of traditional lime-based plasterwork is the preferred approach, especially in significant buildings, with wholesale replacement being a last resort. Guidance from English Heritage, Historic Environment Scotland, and Cadw should be followed for repairs. Key recommendations for working with plaster include identifying plaster type, assessing fixing methods, evaluating surrounding fabric, adopting a conservative repair approach in significant buildings, encouraging training for non-conservation professionals, and implementing regular inspections based on baseline surveys. #FibrousPlasterwork #TraditionalPlasterwork #BuildingConservation #HeritageBuildings #BuildingSurveying #CeilingCollapse #HistoricEngland #MaintenanceAndRepair #PlasterInspection

Cultured marble, a composite material comprising polyester resin, catalysts, fillers, and pigments, is commonly used for bathroom vanities and countertops due to its smooth, glossy gel-coat surface. Over time, however, these surfaces can develop fine scratches from normal use or improper cleaning agents, diminishing their aesthetic appeal. Traditional abrasive cleaners are typically avoided as they can exacerbate scratching. For minor scratches, a product like Gel-Gloss Kitchen & Bath Polish can be applied. This product is primarily composed of water (80-90%) and fine quartz particles (10-20%) and is intended to coat the surface to restore its shine. An alternative, Original Gel Gloss RV One Step Polish and Protector, shares the same formulation and is suitable for countertops, offering UV inhibitors for added protection. The manufacturer, TR Industries, recommends applying the liquid with a clean microfiber cloth and buffing it with another clean cloth. For older, more stubborn scratches, an orbital buffer may be necessary, with multiple applications suggested for enhanced protection and shine. Over-application of Gel-Gloss can lead to a foggy appearance, which requires removal with soap, water, and mineral spirits. For more significant scratches, a more intensive restoration process is recommended, as advised by Luke Haas, president of Elite Marble Company and a board member of the International Cast Polymer Association. His company utilizes a two-step approach involving sanding and buffing, similar to automotive paint restoration techniques. The initial step involves sanding the affected areas with 600- to 800-grit sandpaper. If performing this manually, it is crucial to progress to finer grits, such as 1,000 and 1,200, to ensure a smooth transition and minimize visible sanding marks. Wet-dry sandpaper or sanding sponges, like 3M Sanding Sponges (ultrafine and microfine), are suitable for this purpose. Following sanding, an automotive buffing compound is applied to remove the scratches left by the sandpaper and restore the surface's luster. While professional use might involve products like Aqua Blue 100 Fast-Cut Compound, consumer-grade options such as Turtle Wax T-241A Polishing Compound & Scratch Remover are readily available at auto-parts stores or hardware stores. It is important to distinguish between 'rubbing compound,' which is more aggressive and can potentially substitute for sandpaper, and 'polishing compound,' which is used for the final buffing stage. Regardless of whether a rubbing compound is used, it must be followed by a polishing compound to achieve the desired finish. For increased efficiency and a more even finish, particularly on larger areas, a lightweight, one-hand orbital buffer (e.g., Ryobi 0.5 amp corded six-inch orbital buffer/polisher) is recommended over larger, two-handed models. Prior to sanding and buffing, it is advisable to leave faucets in place but protect their bases with painter's tape to prevent accidental damage. The final step involves applying Gel-Gloss to seal the surface and enhance its newly restored gloss, providing a like-new appearance to the cultured-marble countertops. #CulturedMarble #CountertopRestoration #HomeImprovement #DIYHomeRepair #SurfaceCare #ScratchRemoval #GelGloss #AutomotiveBuffing #HomeMaintenance