Re: A product for re-enameling bathtubs


[ Follow Ups ] [ Post Followup ] [ Clawfoots Clawfoots ] [ FAQ ]

Posted ByVon Obersteiner on September 25, 2003 at 04:45:52:

In Reply to: Re: cast iron bathtub...History you say.. posted byPat O'Connor on February 08, 2002 at 00:47:22:


Dear bath friends,

-would someone be able to tell me a well working product to be successfully sprayed on to heated bathtubs for re-enameling ?

Many thanks

Von Obersteiner

: Hand-decorated cast iron bath made in Britain
: “By 1920, the cast iron single-shell bath, with the rim squared at the four corners so it could be built into rectangular spaces, was in full mass production.”
: As far as manufacturing materials and processes go, as one might expect, cast iron tubs are made from iron. More specifically, cast iron itself is derived from pure iron. What classifies iron to be cast iron is the fact that cast iron has a 2-4% carbon content. In turn the material is often quite brittle and therefore not used structurally. As an example of the difference that the carbon content can make in iron, consider wrought iron (a very soft material) which contains .1% carbon and steel (a structural material) which contains .05% carbon. In addition to iron, the cast iron also contains small amounts of silicon and other elements.
: “Casting is one of the oldest known methods of forming metal objects.” Apparently, “Cast-iron baths are still produced in the traditional manner, with a little help from electric-powered tools.” The process of producing cast iron bathtubs begins with the manufacture of a mold. Since cast iron baths are normally rather square in shape, “the simplest mold is formed of, first a metal box, in which sand is packed, and which gives it sufficient strength to resist the metal during the pouring process.” Secondly, the sand is packed and this may have to be shaped in a number of ways according to the complexity of the tub. It is also necessary to insert into the mold a part, also make of sand, known as a core. That forms the basin of the tub. Lastly, the mold is closed by the top of the casting box. Generally the mold is make in two halves which are brought together to make the complete casting. Before the mold can be run with molten iron, the mold must be equipped to allow air and gasses to escape without injury to the casting. “Each mold has in consequence at least two apertures [openings]; one, for entry, is used for pouring the metal, while the other acts as a vent and a channel for exit.” The next stage of the process is the running of the metal into the molds. In mass-production, there is a huge ladle that holds the iron.


: Pouring heated iron from a ladle
: The ladle is kept at the required temperature and tapped automatically as the molds are passed underneath. Then the process is halted until the tubs are eventually turned out from the mold and are ready for a finish to be applied.
: The most common finish on cast iron bathtubs is a baked enamel finish. A thick coating of porcelain enamel made from powdered colored glass is applied to the tub. Then the bath is placed in an enameling oven where it is subjected to about 1800 degrees of heat. While the tub is inside the oven, the powdered glass becomes fused to the inside surfaces of the bath. “The result is a bath with a thick, smooth, glazed coating which has very good resistance to staining and general wear, but which can be chipped under heavy impact.”
: Cast iron bathtubs are not materials of construction readily known to cause a significant amount of toxicity to installers or users. The only main concern to installers is the fact that cast iron bathtubs are extremely heavy compared to bathtubs made of other materials. While examining the Kohler company brochures, I found that typically cast-iron tubs (just the basin itself) ranged in weight from 350 to 450 pounds, whereas a newer material such as an acrylic basin weighed from about 80 to 100 pounds. Yet another material, vikrell, typically weighed only about 50 to 60 pounds. As one can see, there is quite a difference between the weight of cast iron and the other available materials. As far as toxicity to users, the material itself could possibly be hazardous. “Lead poisoning is currently considered the number one environmental health danger for children by the Centers for Disease Control.” When testing cast iron tubs for lead content, it was found that 77% of the cast iron tubs tested positive. However, “this source of lead most likely represents a significant exposure to only very young children with their high level of hand to mouth activity and propensity to ‘drink’ the water during bath time.”
: The only other toxicities would mostly come into play with elderly people or young children. Cast iron is not only a heavy material, but also a material that is hard to the touch, as one salesman at Familian Bath-Kitchen Center in Santa Maria, CA informed me. When I asked which of the baths on display were cast iron, he made a sarcastic comment when he said that whichever ones hurt my knuckles when I knocked on it, was the cast iron one. Of course he was right (I knocked softly, mind you). With that in mind, cast iron tubs have the possibility of being harmful if one (typically the elderly or young children) was to slip and fall while standing up in that type of tub. The enameled finishes applied to cast-iron tubs make that possibility very great due to the fact that the enamel is typically smooth and slick. However, certain precautions could be made to reduce those risks of owning a cast iron tub. One can apply non-slip strips and mats to the bottom of the tub or even purchase a simple grab rail to attach to a nearby wall to make entering or exiting the bath safer for everyone.
: Moving onto the advantages of cast iron tubs, one of the fundamental advantages that manufacturers boast about is the material’s great resistance to staining and general wear due to the thick, smooth, baked enamel fused on top of the cast iron. Cast iron tubs are also known for their rigidity, stability, and durability. As Kohler proclaims in a brochure “Solid cast iron construction stands firm against dents while minimizing disposal noise and vibrations. The thick enamel coating of Kohler cast iron is ‘fire polished’ for a deep, glossy color and exceptional acid resistance. The unequaled thickness of Kohler enamel provides outstanding protection against chipping and scratching.”
: Cast iron baths were also often put upon legs and called claw-footed or simply footed tubs. Nowadays, the advantage to that type would be that it could provide an

: A claw foot cast iron bathtub at Central Coast Plumbing in Atascadero, CA
: antique look to a bathroom. Additionally, the lifespan of cast iron bathtubs is up to about 50 years. Should one obtain an actual antique cast iron tub that needs refinishing, it is perfectly possible to repaint the baked enamel finish, or even enlist in refinishing companies that are available for scratched, chipped or stained enamel. “The process of refinishing bathtubs has been in existence for over 50 years. There are currently over 2,500 companies in the United States and 1,500 in Canada in the business.” Simply look in the Yellow Pages under "Bathtub and Sink Repairing and Refinishing" and you will find places in your area that specialize in refinishing. “Although it [refinishing] is sometimes referred to as "reglazing," it does not actually replace the original porcelain enamel surface of the tub. Instead, it uses a very robust coating (usually a urethane) to recoat the surface of the tub. Present day coatings should be expected to last 8-10 years, after which they will have simply begun to lose their gloss. At that time, the tub can easily be re-sanded and re-coated, for another 8-10 year cycle of life. Typical guarantees run from 5 to 10 years. Refinishing is a very economical alternative to replacement. Replacement of a tub can cost from $2,000 to $4,000. Refinishing, on the other hand, costs on the average $200 to $400, one-tenth of replacement. The refinishing process usually is done by preparing the tub surface by wet sanding, followed by multiple cleaning and preparation steps. Then an adhesion promoter is applied (either an acid etch or a chemical bonding agent, in the case of porcelain tubs). The next step is to apply multiple coats of a high quality urethane to the surface. The normal standard colors available are white and almond, although many suppliers of refinishing coatings have American Standard and Kohler standard colors in stock. Also, custom colors are available; just ask your Refinisher to see his repertoire. Normal cure times run from 24 to 48 hours, after which the tub can be restored to normal use. Many refinishers can also perform spot repairs of chips and do color matching of small areas that have been damaged.” Refinishing also offers a solution to the lead problem mentioned earlier. “Unique Refinishers has confirmed that refinishing Lead Check positive tubs eliminates the leaching of lead by encapsulating the tub.”
: Another apparent advantage of cast iron tubs is that a deep cast iron tub will retain the heat of the bath water for much longer than any other type of bathtub. They “are comfortable too - often deep enough for total submersion, a feat that is practically impossible in a modern shallow acrylic dish.” Like other types of bathtubs, cast iron tubs are not limited in the selection of colors either, although the more abstract the color, the more it will cost you.
: Regrettably, cast iron bathtubs also have quite a few disadvantages which often include cost, weight, size, and limited availability. Cast iron tubs are often more expensive because they are more expensive to produce than tubs made out of the other available materials. I found out specifically that cast iron tubs are more expensive while looking through Kohler’s 1996 Fixtures Suggested List Price Book in the Media Resource Center at Cal Poly (keep in mind that Kohler tends to have higher prices than other manufacturers). The most expensive line of cast iron bathtubs were the whirlpool systems.

: Two examples of whirlpool bathtubs at Familian Bath and Kitchen in Santa Maria, CA
: The best line (System III) ran anywhere from $4,000 to $6,000. The same types of tubs made from acrylic were typically $3,000 to $5,000. The System II tubs ran from about $2,000 to $3,000. Their acrylic counterparts ran about $1000-$2,000. Those prices don’t even include the required accessories (the jets) which run about another couple of hundred dollars. For Kohler claw-footed tubs, they ranged in price from about $3,000 to $4,000. The feet also cost about an extra $2,000 for all four together (also dependent on what material they are made out of). I found acrylic clawfoot tubs at PlumbingStore.com for around $2,000. As for square, cast iron, recessed baths, they ranged anywhere from $400 to $2000. The square, acrylic, recessed baths ranged anywhere from $200 to $1000. Additionally, for each type of tub, faucets often have to be purchased separately.
: As mentioned earlier, cast iron tubs are often significantly heavier than tubs made of other available materials. Typical baths today are made of acrylic (typically reinforced with fiberglass), fiberglass, or even enameled steel. Even though the materials are different, the tubs usually look the same on the outside. In further comparison, acrylic

: A cast iron bath (left) and an acrylic bath (right) at Familian, Santa Maria and Pacific Coast Kitchen and Bath, SLO
: and fiberglass have a wider variety of colors and shapes available, can easily incorporate molded seats and backrests as well as inset trays for soap and face cloths, are resistant to chipping, and are warm to the touch. Enameled Steel tubs are lightweight and more prone to chip than cast iron, especially during installation, but have a lower cost and a lighter weight. Cast iron tubs also, to me, seem to not be available as much as other types. I visited three plumbing fixture retail stores, Familian Bath and Kitchen in Santa Maria, Central Coast Plumbing Supply in Atascadero, and Pacific Coast Kitchen and Bath in San Luis Obispo. At each place they had more acrylic or fiberglass tubs than cast iron tubs. Additionally, only one place had a claw-foot tub for sale.
: When buying a cast iron tub, one can’t simply say, “I would like to purchase a cast iron tub, ring me up please”. There are many factors involved when purchasing a cast iron tub. Some common decisions might include shape, size, brand, color, and accessories. Starting with shape, there are usually three general shapes to choose from. The recessed, freestanding, and claw foot styles. There are also usually quite a few sizes


:
: Example of recessed cast iron bathtubs at Central Coast Plumbing and Pacific Coast Kitchen and Bath
: to choose from. Typically the claw foot style is deeper than the other types. However, the size of claw foot tubs also depends upon the style that is desired. Some common styles include the Slipper, Double Ended, Traditional, and the Classic. Lengths are usually 60” or 68”, although quite a few styles are available in both. Kohler also offers a few that are 72”.


:
: Specifications for a typical Slipper Tub
: Keeping with the idea of making decisions, there are a variety of companies that sell cast iron tubs. One of the prominent manufacturers that I have come across is Kohler, which is based in Kohler, Wisconsin. Kohler seems to carry the widest variety of sizes, styles, and colors for cast iron bathtubs. Another manufacturer that was prominent when cast iron tubs first began to be produced was American Standard.
: As far as color goes, it has come a long way. The early baths usually only came in one color: white. That was because white was the color of sanitation and cleanliness. Later on, our views and technology expanded and manufacturers were able to offer a wide variety of colors. “The first tentative experiments in colored fixtures at the end of the 1920’s were all in pastel tones…these were joined by more intense colors during the 1930’s.” Nowadays, “white is the cheapest ‘color’, then the familiar pastel pinks and blues. More adventurous colors - Pampas and Avocado, for example, sometimes referred to as Group II - are more expensive, and special ‘fashion’ colors cost even more.” In the United States, each of the major manufacturers has an individual color range due to the fact that there are not industry-coordinated colors. Kohler, for example, carries fifteen “full line” colors that include the whites, tans and pastels. There are then nine “high fashion” colors that include the darker or more abstract colors. The final category contains five “limited edition” colors that are typically a speckled combination of two colors. Also, each consecutive color line adds more money to the final cost of the bathtub.
: When purchasing a tub, one must also consider accessories that are required to accompany a bathtub. Those include, but are not limited to, faucets, drains, accessory racks, or even in the case of claw foot tubs: feet. I have found that claw foot tubs have very unique accessories available to them. Because they are freestanding, they require a totally different type of faucet setup and water supply setup. Feet also have to be bought separately, and there are many styles and materials to choose from. Also, because soap dishes are not built into the footed tubs, it may be necessary to purchase a caddy that spans across the opening of the tub.

: A bathtub caddy and water supply lines
: Overall, cast iron bathtubs are not just to be thought of as the antique claw-footed tub your great-grandmother had. Cast iron tubs have changed with the times and are now available in a variety of shapes, sizes, colors, and styles. When purchasing a bathtub, one must consider all possibilities. There are not only choices to be made about the looks of the bathtub, but also about what material it should be made out of. Cast iron has its advantages, but like many products it is also has its disadvantages. One must decide based upon those criteria as well as what materials the bathtub will interact with. Are there tiled floor? Or perhaps carpet? Is the bathroom small or large? Are there other fixtures that the tub must match? A bathroom is a very private room in the home, yet one that will often be visited by guests. What message do you want to convey to those who step through your doors? Basically, cast iron bathtubs are yet another material of construction that has the possibility of being chosen in any random décor.

:
: Bibliography

: Conran, Terence. The Bed and Bath Book. New York: Crown Publishers Inc., 1978.

: Cowan, Thomas. Beyond the Bath - A Dreamer’s Guide. Philadelphia: Running Press,
: 1983.

: Fisher, Charles. The Well-Appointed Bath. Washington, D.C.: The Preservation Press,
: 1989.

: Gloag, John. A History of Cast Iron in Architecture. London: George Allen and Unwin
: Ltd., 1948.

: Mazzurco, Philip. Bath Design - Concepts, Ideas, and Projects. New York: Quarto
: Marketing Ltd., 1986.

: Shepard, Richard. Cast Iron in Building. London: George Allen and Unwin Ltd., 1945.

: Winkler, Gail Caskey. The Well-Appointed Bath. Washington, D.C.: The Preservation
: Press, 1989.

:
: www.kohlerco.com





Follow Ups



Post Followup

Name:
E-Mail:

Subject:

Comments:

Optional Link URL:
Link Title:
Optional Image URL:


[ Follow Ups ] [ Post Followup ] [ Clawfoots Clawfoots ] [ FAQ ]