Fibrous Plaster Panels and Coffer Services
Using HPCS products to stabilize and strengthen fibrous plaster panels.
Expert Fibrous Plaster Panel & Coffer Restoration
Fibrous plaster panels and coffers are defining architectural features in many historic buildings, valued for their intricate designs and lightweight construction. However, age, environmental exposure, and structural shifts can weaken the natural fibers and adhesives holding these decorative elements in place, posing a risk of detachment or collapse.
At John Canning & Co., we specialize in stabilizing, reinforcing, and restoring fibrous plaster ceiling panels and coffers. Combining deep expertise with advanced restoration techniques, including the HPCS (Historic Plaster Conservation Services) method, we ensure that these plaster features retain their beauty, strength, and historical integrity for years to come.
Our team of plaster restoration experts uses RE Aramid Gel™, an innovative HPCS product specifically designed to strengthen fibrous plaster panels without causing surface damage. This advanced material forms strong, flexible support that resists cracking and adapts to the natural micro-movements of historic buildings. Through independent testing, RE Aramid Gel™ has proven its ability to deliver long-term stability and tensile strength, making it an ideal solution for complex plaster conservation projects.
Here is a short video showing the HPCS process of the treatment of fibrous plaster.
Testimonials
"Architects know that Canning will only do the finest work possible. "
-DUNCAN G. STROIK,AIA, PRINCIPAL DUNCAN G. STROIK ARCHITECT, SOUTH BEND, INDIANA-
"Canning has brought an outstanding common sense attitude of accomplishment to their work when many others are lost within myriad complex issues."
-RUTHANN HUBBARD-KEMPER, EXECUTIVE DIRECTOR, PENNSYLVANIA CAPITOL PRESERVATION COMMITTEE, HARRISBURG, PENNSYLVANIA
Our Process
Often, a plaster survey/assessment of the fibrous panels/coffers is required to determine the extent of the problems.
Step 1: Structural Integrity Assessment
We assess the structural integrity of the plaster system. This involves comparing its current condition to its original "as-built" state to determine where the plaster is in its "service life" and identify areas requiring reinforcement.
Step 2: Inspection of Plaster & Fiber Wads
Our team carefully dissects one or more plaster and natural fiber (jute) wads that connect the panels to the supporting armature. This inspection reveals whether the natural fibers have become desiccated (dry-rotted), reducing their ability to hold the panels securely in place.
Step 3: Determining Necessary Reinforcements
- If fibers are desiccated (dry rotted), the panel connections need to be reinforced.
- If panels are cracking and natural fibers are desiccated, then panels also need to be reinforced.
Typical Treatment Process of Fibrous Plaster Panels/Coffers:
- Apply a diluted formulation of acrylic resin to the back of the panel/coffer. The resin will fill cracks and strengthen the matrix of the panels.
- If only a relatively small area requires treatment, hand-brush apply an acrylic gel mixed with polyester fibres (i.e. Kevlar) to the back of each panel.
- If a larger area requires treatment, spray apply the acrylic gel mixed with polyester fibers to the back of each panel.
This treatment program will strengthen the fibrous plaster panels and reinforce each panel’s connection to the metal or wood armature.
Cost Factors
The exact cost of stabilization & reinforcement of fibrous plaster panels/coffers naturally depends on a number of factors. These include, but are not limited to:
- Whether or not the process begins with a plaster conditions survey/assessment
- The size of the work
- The complexity of the work
- The location of the work, and required access (for example, whether or not scaffolding will be required to access the space)
- Special materials cost, such as consolidants, adhesives, etc.
For this reason, it is difficult to say what the “typical” cost for stabilization & reinforcement of fibrous plaster panels/coffers may be. The best way to get an accurate idea of what costs your project may entail is to contact us directly.
Our Specialties
In addition to the stabilization & reinforcement of fibrous plaster, we specialize in a number of other complementary services, including:
FAQs About Fibrous Plaster Panels
How Are Fibrous Plaster Panels Made?
Fibrous plaster panels are crafted by creating a mold from a custom pattern. Plaster is brushed into the mold and reinforced with plant fibers to increase strength. Additional plaster layers are applied until the panel reaches the desired thickness. The fibrous plaster panels can be as thin as ½ inch. Once cured, the panels are transported to the site for installation.
How Are Fibrous Plaster Panels Installed?
Panels are typically hung on-site through a combination of various attachment methods. Plaster wads reinforced with natural fibers like jute are often applied in this process to secure the panels while allowing for minor building movements.
What Are Common Problems with Fibrous Plaster Panels?
The main issue is the breakdown of natural fibers due to age, humidity changes, and environmental exposure. Over time, these fibers rot or dry out, causing the panels to weaken, crack, or detach from the frame, creating potential safety hazards.