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New introduction to the 2007 edition of

Plastering

J. T. Sawyer

First published in 1951 by Edward Arnold Ltd of London, Plastering was re-printed by them in 1957. In 1966 George Hurding, the honourable secretary, and other members of The Plasterers’ Craft Guild, persuaded Joe to republish the book as a revised second edition. This he did, paying for the publishing costs out of his own pocket. He added an extra chapter, entitled ‘New Trends’, and had 1,500 copies printed. The thirteenth chapter covered developments in materials that had occurred in the intervening fifteen years, including p.v.c. and polyester resins for mould making, which can still be considered fairly modern today.

This reprint is of the first edition, as this covers the materials and topics most relevant and applicable to the repair of historic buildings, on a like for like basis. However, the index, which appeared in the second edition, has also been included in this reprint as we feel it was a very useful addition.

J.T. Sawyer’s seminal book on plastering was first published in 1951. It was designed to present information up to the Craft (Intermediate) Level of the City and Guilds syllabus, and the simple and accessible format still makes it an ideal book for both beginners and more experienced plasterers involved in historic building repairs who want to develop traditional skills.

Mr J.T. Sawyer, Joe to his friends and colleagues, was a founder member of The Plasterers’ Craft Guild, which was formed in the early 1950s. He was also a Certificated and Registered Plasterer (C.R.P.); a scheme that ran from 1928 to the 1970s, as a collaboration between The National Association of Operative Plasterers and the Worshipful Company of Plaisterers, to encourage competent craftsmen to attain certain standards in plastering. Joe was awarded a silver medal, in the City and Guilds of London Institute final examination in plastering (later called The Advanced Craft Certificate). The Plasterers’ Craft Guild is still in existence, unlike the C.R.P. Scheme and the City and Guilds exams, which hopefully one day can be resurrected in some form.

The period when this book was written, in the middle of the twentieth century, was a significant point in time when traditional building trades began to be replaced by modern construction methods. The Second World War had a major impact on the building trades, not only because so many people with skills and the knowledge were killed, but also because the following two decades were driven by a belief in a brave new world, where modern methods and materials would supersede the old. The consequent decline in traditional skills is still in evidence today.

Joe Sawyer came from a family of plasterers, and taught the subject at East Ham Technical College and School of Building, London. His knowledge was based on the craft the way it was before the Second World War. Consequently, his book deals mainly with traditional wood lath work and lime plastering, whilst also referring to Portland cement, plasterboard and gypsum plastering. It acknowledges newer methods and materials, but it is written from the perspective of someone with a real understanding of the tried and tested methods of plastering. It is clear that he was a great communicator and so was ideally suited to producing this book. The illustrations, all of which he drew himself, are excellent, and are so descriptive that sometimes there is no need to read the accompanying text!

The terminology used in the book is based on terms that had been agreed as nationally accepted standards. Although this was primarily for the purpose of the City and Guild Examinations (plus British Standard specifications, etc.), it clearly establishes the level of understanding required from a plasterer in the 1950s. We personally believe that the standards it sets, and the terminology used, are as important to our generation as they were to the students who read this book first time around.

The following introduction to the chapters just gives an overview of the subjects covered, with our views on the relevance, or otherwise, of some of the tools and materials described.

Chapter 1 Tools

This chapter gives an excellent description of the basic tools for lime plastering etc., a kit of tools that in many cases had not really changed for centuries. It is interesting to note that Joe mentions the twitcher (a tool invented by Mr R. Millar, William Millar’s brother, in the mid-nineteenth century) but not the external angle trowel, which came into use with sand/cement backing coats and gypsum finishes, during the 1950s and 60s.

The tools described were usually made in this country and were generally well made. The primary companies were: Tyzack for trowels; Brades for lath hammers; and Emir for wooden hawks and wooden floats (although many craftsmen would make these themselves). One tool described in the book that we have never come across is an 18-inch gauging trowel; 9 inches being the largest surviving size. 

Chapter 2 Plant and Equipment

Most of the items described in this chapter are in general use today, the main exception being ‘split heads’ that have been banned for many years on health and safety grounds.

All the ‘rules’ described were made of wood. These are the best for lime plastering, as opposed to the aluminium ones of today, which have been developed for use on gypsum and cement based plasters.

Chapter 3 Materials

This is an excellent chapter describing materials in use during the first half of the twentieth century. The entry on gypsum plasters is very interesting, showing the vast variety and grades that were available at that time. It is also interesting to note that there are only three paragraphs on plasterboard. Although this was written during a period of transition, Joe Sawyer still spends considerable time talking about lime plastering. But we need to be clear that it could be ‘gauged’ with gypsum or Portland cement.

The word ‘gauge’, in plastering parlance, can mean to measure (e.g. gauge box, plinth gauge) or to mix (e.g. gauging trowel, gauging stick). So the term ‘gauged stuff’ usually describes lime putty or plaster to which gypsum (or Portland cement) has been added.

Chapter 4 Templates and appliances  

The items described in this chapter are, in a sense, specialist tools. They were often made by the craftsman himself, or were sometimes specially manufactured for a particular purpose. Their use requires experience, plus a natural intuition on how to overcome problems, which is what craftsmanship is all about.

Chapter 5 Running Moulds

This is another excellent chapter and is an example of how good illustrations can explain the principles so well that one hardly needs to read the text. Joe Sawyer’s drawings demonstrate the different architectural features that can be formed in plaster.

The only aspect we can add is to mention that these days three-quarter inch marine ply is best for making the majority of the wooden parts as it does not warp when wet.

Chapter 6 Plain Interior Plastering

This really is text book stuff on plain plastering, from describing that “a forward push from the shoulder” when pricking-up a wood lath ceiling, to the methods used in high class work with Keenes cement, through finishing an external angle (in the days before metal angles and plastic beads) to floor laying. Rarely has the subject been put over so well.

Chapter 7 Plain Exterior Plastering

This chapter reminds us that this book was written at a time when it was widely believed that Portland cement was the answer to everything. It was a decade, or more, later before most people realized that hard dense cement renders could cause problems. Despite this, the description of methods is very good and is as equally relevant to hydraulic limes as to Ordinary Portland Cement (O.P.C.), so is well worth studying.

Chapter 8 Interior Mouldings

The description of running mouldings in situ is very good indeed. Sadly the decline in the use of these methods started about the same time as the publication of this book. Even though they have almost become a thing of the past, traditional in-situ methods like this are still the correct way to repair historic plasterwork (as it was fabricated using these methods in the first place). A great deal can be learned from this chapter.

Chapter 9 Exterior Mouldings

The comments on chapter 8 also apply to this one, but with the reminder to avoid the strong sand and cement mixes (as in chapter 7).

Chapter 10 Benchwork

This chapter is very interesting and useful on mould making, and the casting of various items. Although it is titled ‘benchwork’, it could equally be entitled ‘fibrous plaster’. This is a fairly modern development, in the history of plastering, dating from the 1850s. Virtually all decorative plasterwork these days is made using 'fibrous plaster' methods, with excellent results, but it is worth understanding the differences between this and traditional in situ work. Although 'fibrous plaster' can be used to repair old plaster, it often involves replacing original work with mouldings made on a bench, whereas traditional in situ methods are usually less intrusive. Unfortunately financial constraints and the lack of sufficient skilled labour to carry out work in a traditional manner mean that some historic buildings are repaired or restored using fibrous plaster.

Chapter 11 Measuring and Estimating

This brief chapter is helpful for anyone who wishes to price plastering work, although it would clearly need to be brought up to date by including the change to metric measurement.

Chapter 12 Geometry and Drawing

We think Joe Sawyer really had a particular love for this side of the craft. Although this chapter is brief, it is very informative on setting out and designing features. All the mouldings are classical (as they are throughout the book) so anyone faced with Gothic moulds will have to research elsewhere.

This is a wonderful technical handbook that has been written by someone with a real practical knowledge and love of plastering. Colleges and training centres dealing with the traditional crafts will find this book an invaluable tool. We hope that it will help and inspire many newcomers to traditional plastering, but we believe it will also be useful to older and more experienced craftsmen and craftswomen as well. The author’s daughters, Pamela Purdy and Joanna Philipps, have written an interesting short biography to accompany this Introduction.

Biography

by Pamela L. Purdy and Joanna H. Philipps

J.T. Sawyer (1908-2001) left school aged fourteen and was apprenticed as a plasterer to his father, W. H. Sawyer C.R.P. (1873-1959), who had been apprenticed to his father, R. W. Sawyer (1830-1892).

Working as a journeyman from the age of nineteen, the author gained valuable experience in all types of work, including antique restoration. He and his father frequently worked as a team, both in London and countrywide.

After World War II there was a serious shortage of skilled craftsmen due to the suspension of training schemes as men were conscripted into the armed forces. In 1945 he took a post at The East Ham School of Building, where he stayed for 28 years. At the school, boys from the age of 13 received a general education in addition to practical skills. The first edition of Plastering was intended to provide the basic technology for students. The author drew all the diagrams that accompanied the text.

J.T. Sawyer worked tirelessly to raise the standards of students entering the craft, expecting them to achieve City & Guilds of London Institute qualifications. The most talented were also encouraged to enter the International Apprenticeship Competition where they always attained good results. He was an Examiner for these organizations, travelling extensively in the UK and abroad and to accompany his students.

In the late 1950s, amongst other techniques, he pioneered the use of the new plastic moulding materials. He also wrote a regular column in an American trade journal based in Seattle and contributed articles for popular British DIY magazines.

The author was a Founder Member of the Plasterers’ Graft Guild and proud to have held the office of Chairman.