Thanksgiving re-runs: The Peoples' faucetry

This is the fourth in a series of posts on faucet finishes I'm running during my Thanksgiving break. I wrote this series originally in February '09.



So if the higher end of the market uses ancient foundry methods to make objets d'art doing double duty as bath and kitchen fixtures, what's available to the rest of us? You know, the same us who bristle at the thought of an $1800 lavatory faucet.

Well, that's where our pals at Kohler come in with their modern and efficient production methods. Metal casting and finishing have come a long way since the Babylonians figured out how to cast bronze thousands of years ago. When plumbing fixtures are mass-produced now, they are cast in a variety of base metals (usually alloys of brass), then they're plated and finally, they're clear coated to resist corrosion and to make the finish last a lifetime.

All manufacturers have their own, secret alloys and formulas; but the production methods used by all of them are essentially the same. Individual components are cast in a base metal alloy and then polished and cleaned. Then the components are plated with a finish and covered with a clear top coat.

Plating takes two forms these days, and the first method is electroplating. Electroplating was invented in the early 1800s and was in wide-scale use by the middle part of the same century. Electroplating uses electricity to deposit a thin layer of metal on another metal. It's a pretty simple operation now, but figuring it out in the first place represented a huge leap forward.

An electroplating chamber is essentially an electric circuit. An anode is made from the finish metal, in the diagram above that metal is nickel (Ag). The anode's connected to the positive pole of a battery. The target for the electroplating (in the example above, a spoon) becomes the cathode and gets connected to the negative pole of a battery. The anode and the cathode are submerged in a bath of conductive solution and the electricity gets turned on. The electricity flows through the solution to complete the circuit. As the electricity leaves the anode, it takes nickel molecules with it. When the electricity lands on the cathode, it leaves the nickel molecules behind. Ta-dah! We have an electroplated spoon.

There's a second finishing method called physical vapor deposition (PVD). Physical vapor deposition is a marvel of physics and chemistry but I'll spare you another description of a process here. Suffice it to say that in PVD, the conductive solution is replaced with a gas and the whole process takes place in a vacuum. PVD allows a manufacturer more control over the finished product and by adjusting the mixture of gasses in the vacuum chamber, a manufacturer can achieve a number of effects that aren't possible with electroplating.

I bring this up because if you're in the market for a new faucet or two, you will come across the acronym PVD. PVD is never defined and that kind of officious acronym use drives me nuts. So now I know what it means and you do too.

Once the plating's done the fixture gets its final color and finish. If the final finish is something like oil-rubbed bronze, then there's a multi-step powder coating process that follows the plating. If a final finish is something like brushed nickel, then the plated fixture has a texture applied to it. The actual finishes always sit on top of a base of plated metal.

After all that, the fixture gets a clear coat that's usually cured with heat. It's kind of like a clear glaze on pottery, though the temperatures are nearly so high as that. This clear top coat is what allows Kohler to offer a lifetime warranty on their finishes. Oil-rubbed bronze will look like oil-rubbed bronze forever, brass finishes will never tarnish and nickel will never get any more dull than it was the day it was installed.

So when you look at this vibrant brass finish from Kohler, you're not really looking at a brass fixture. If you could see it in microscopic cross section, here's what you'd see.

These same electroplating and PVD methods get used on all mass-market finishes from brushed nickel to stainless steel, from polished brass to chrome. This is not a bad thing. Plated and sealed fixtures last longer and look better longer than their solid-metal counterparts. So remember that you're talking about finish colors, not finish compositions when you leave the high end of the market behind.

Thanksgiving re-runs: Patinas on a budget

This the third in a series on faucet finishes I'm running over my Thanksgiving break. I wrote them originally in February '09.



So for the last couple of days I've been talking about living finishes and patinas and how they fit into the world of plumbing fixtures. To review; copper, bronze and brass as reactive metals --they change color and texture as they react to their environment. That change is called a patina. A patina is what corrosion's called when it's desirable. Think about it. The patina silver develops is called tarnish and it's a badge of shame. Copper does the same thing and people call it verdigris and prize it. Interesting.

Now, in addition to those naturally-occurring color and texture changes, the word patina is also used to describe virtually any color applied to metal. Although that word tends to be reserved for colors that mimic a naturally-occurring patina. Make sense?

So, if this is what bronze ingots look like,

And this is true brushed bronze that would end up being used on a $1900 lavatory faucet,

(Plinth, by Paul Martin Wolff)

what are you supposed to do when you have a budget?

Enter our friends at Kohler.

This is a $300 lavatory faucet, the Fairfax single control, and it's being shown here in Kohler's finish, brushed bronze.

Now, when Kohler refers to one of their fixtures as having a brushed bronze finish, they are talking about its color. When Rocky Mountain Hardware talks about brushed bronze, they're talking as much about the composition of the faucet as they are the color of it.

True bronze made by somebody like Rocky Mountain is a labor-intensive process and bronze is a notoriously finicky metal. Not only that, Rocky mountain is a bronze foundry and they make their bronze fixtures and hardware using sand casting and the lost wax method. Surely you remember the lost wax method from grade school social studies. That's right, Rocky Mountain does things the way the ancient Babylonians did and they charge accordingly. I'm not knocking Rocky Mountain for a second here either, seeing the fruits of their labor makes me weak in the knees. It's really beautiful stuff and it's intended to be a once in a lifetime purchase.

But love it though I do, I can't afford to throw thousands of dollars around on lavatory faucets and that's where our friends at Kohler come in again.

Kohler doesn't make that brushed bronze Fairfield single lever lavatory using methods handed down from the ancient Babylonians. But what they do make is beautiful enough.

Large scale plumbing manufacturers cast a faucet from a base metal; usually brass, zinc or a combination of the two. The base metal faucet is polished and then electroplated. Once it's electroplated they then apply a patina and then finally, they seal the color with a clear top coat. As soon as that fixture leaves Kohler's production floor it's locked in time. It will not continue to change. It won't evolve into another color. In fact, it's guaranteed not to change for life.

So if this is Rocky Mountain Hardware's deck-mounted faucet with an applied rust patina,

here's Kohler's answer to that patina, oil-rubbed bronze. Again, what they're describing is the color.

The two faucets pictured up there are separated by production methods, a slight variance in color and about 1500 dollars. The real bronze fixture will continue to change over time and the bronze-colored fixture is guaranteed never to change. Confused? Don't be. Let the price tags be your guide. If a lavatory faucet costs over a thousand dollars, chances are good that it's made from copper, bronze or brass and will have a living finish. If faucet costs under $500, it will not have a living finish and it will look factory fresh for life.

So Monday I'll delve into the exciting world of nickel, chrome and steel. I'm already giddy with anticipation.

Thanksgiving re-runs: No really, what's a living finish?

This is the second post in a series that started yesterday. I wrote them originally in February '09.



OK, so yesterday I ran through three basic, reactive metals that come into play when it comes to faucets: copper, bronze and brass. When it's the actual metal we're talking about, manufacturers use terms like "living finish" and "organic finish" to indicate that their fixtures will continue to age and change with time. I'll get into nickel, chrome and stainless (the non-reactives) later, for now I want to stick with copper, brass and bronze.

Now, these living finishes are pretty much the exclusive province of the higher end of the market. For a lot of people, the changeable nature of brass, copper and bronze is a selling point. And that changeable nature comes at a premium.

Here's a $1500 kitchen faucet from Herbeau. It has a living finish of weathered copper and weathered brass.

And here's a $1900 tub faucet in weathered brass, also from Herbeau.

These fixtures are truly made from brass and copper and then they have a patina applied to them in the factory. These patinas are pigments and chemicals that react with the base metal to speed up the aging process. These patinas allow the base metals to look like they're already aged upon arrival. On a living finish, the metal is left unsealed. That is, without a clear top coat to prevent corrosion. Without that clear topcoat, these faucets will also continue to age and their colors will continue to evolve as the base metal reacts with the environment. No two of these faucets will age at the same rate or go through the same color phases. Their continued evolution is completely dependant on the environment where they're placed. Hence the term living finish.

It's important to remember that the world of plumbing fixtures doesn't use the conventions of science to categorize these finishes. Fixture manufacturers across the market use these metallurgical terms to describe a fixture's appearance, and not necessarily its composition. However, when there's a desirable base metal involved, that fact is made amply clear.

Here's a deck-mounted faucet from Rocky Mountain Hardware. It's made from bronze and has had a rust patina applied to it. Rust is iron oxide, a common reddish pigment. So this faucet is made from bronze with a reddish brown patina applied to it. With time it will continue to to turn more brown. It also has a suggested retail price of $1900.

Here's a wall-mounted faucet, also from Rocky Mountain Hardware. This faucet has been cast in bronze and has a medium patina applied to it. It carries a suggested retail price of $1600 and it's mind bendingly beautiful. Bronze has a warmth to it that no other metal comes near. Bronze has been a desirable metal for thousands of years for a very good reason --it's beautiful, strong and lasts forever.

This medium finish also looks suspiciously like something that started showing up in the consumer market around ten years ago, oil-rubbed bronze.

Now oil-rubbed bronze is where my conversation with the Kohler finish developer comes in. Since these living finishes and desirable base metals are the province of the high end of the market, how does this stuff trickle down to the consumer end? Well, come back tomorrow when I tackle the inter-market grudge match between true bronze and  the oil-rubbed bronze gang.

Thanksgiving re-runs: So what the devil's a living finish anyway?

I'm taking a few days off to celebrate Thanksgiving and in lieu of writing a post a day over the holiday, I'm going to run a series on faucet finishes I wrote in February '09. Happy Thanksgiving one and all!

I had a similarly phrased question from a reader the other day and it's sent me on a quest to find out. As luck would have it, I'd already set up an interview with a finish developer from Kohler prior to being asked that living finish question, so I asked the source directly and I learned a thing or two.

That Kohler conversation gave me a ton of information to write about by the way, so look for a series on plumbing fixture finishes over the course of the next week or so. But in the meantime, here's a little something I learned about metals and patinas.

This is copper.

This is what happens to copper when it's exposed to the elements. Copper reacts to acids and alkalis in the environment to form a variety of chlorides, sulphides and carbonates known collectively as verdigris. That's French for green gray. Verdigris is composed of  copper carbonate or copper chloride primarily and those chemicals make up the green patina most people associate with copper. 

Copper is a highly reactive metal that's almost never used in its pure form. Generally, copper's combined with another metal to make it stronger and a little less reactive. When copper's combined with tin the result is bronze. These are bronze ingots.

When copper's combined with zinc the result is brass. And here's what raw brass looks like.

Due to their copper content, both metals retain a lot of the reactivity inherent in copper, though it's a bit less pronounced.

So here's what happens when bronze is left to its own devices. It turns a warm brown with yellow tones. These are the doors to the Pantheon in Rome and they're about 1800 years old. They're also the color of dark chocolate.

Brass on the other hand goes golden brown with a slight greenish tone to it.

These naturally occurring patinas are what's meant by a living finish. These patinas take time to develop and really, they never stop developing. After all, they're an ongoing chemical reaction.

When it comes to faucets; copper, bronze and brass are never left in their natural states to be allowed to age into their natural patinas on their own. It can get confusing because most manufactured faucets and fixtures have a patina applied to them. Let's back up for a sec though.

If you remember your basic chemistry, an alloy is the mixture of two or more metals. Alloys like brass and bronze aren't categorized scientifically, and there aren't any standard recipes for these metals. On top of that, copper never shows up in its pure state --it too is usually an alloy that's made mostly of copper. Add to that that the natural process of oxidation is called a patina, but so is virtually any color applied to a base metal. Argh.

I'll dig into this a little further tomorrow, but for now just remember that a living finish is a finish that will age and change color with time. On purpose.

Thanksgiving break time

As every good blogger knows, web traffic plummets on holidays. On major holidays it falls precipitously. So I'm joining the exodus and am going into re-runs until Monday. So I want to wish everybody out there a great Thanksgiving. To everybody outside of the US, happy week of 22 through 26 November.

But back to everybody in the US for a sec.

Rather than joining in on the March to Armageddon on Friday, why not try something a little more civilized and a little more meaningful? Why not spend some quality time talking to someone or some ones you love? Why not stay home and make something with your family or friends? Why not buy nothing?