12 Materials Commonly Used in Older Buildings

Historical construction was fundamentally an exercise in local resourcefulness, utilizing the geology and biology of the immediate landscape to create enduring shelters. Unlike modern “sealed” buildings that rely on chemical barriers and mechanical ventilation, older structures were designed to be “breathable,” using porous materials that managed moisture through natural evaporation. This era of building was dominated by substances like lime, heartwood, and hand-fired clay, each chosen for its specific thermal properties and structural longevity. From the intricate joinery of heavy timber frames to the protective qualities of exterior lime render, these materials were the products of centuries of artisanal refinement. This listicle examines 12 essential materials that provided the physical foundation for the historic built environment, reflecting a time when durability was measured in centuries rather than decades.

1. Old-Growth Heartwood Timber

Older buildings frequently utilized “old-growth” timber, which refers to wood harvested from forests that had grown slowly over centuries, resulting in a much higher density of growth rings. The heartwood, or the non-living inner core of these trees, was particularly prized for its extreme durability and natural resistance to rot and wood-boring insects. These massive beams formed the structural “bones” of homes, often connected with complex mortise-and-tenon joints rather than metal nails. Because the wood was so dense, it had structural capacities far exceeding those of modern “dimensional lumber” grown on rapid-cycle plantations. This material allowed for the creation of expansive roof spans and soaring vertical frames that have remained straight and true for hundreds of years. The presence of old-growth timber in a structure is a hallmark of historical quality, representing a lost age of forestry where the raw materials were as robust as the craftsmen who shaped them.

2. Hand-Pressed and Kiln-Fired Brick

Before the 20th century, bricks were often produced locally using native clay, hand-pressed into wooden molds, and fired in small kilns, resulting in a unique variety of colors and textures. These “common bricks” were significantly softer and more porous than their modern, factory-made counterparts, which allowed them to absorb and release moisture in harmony with the local climate. Because they were not uniform in shape, masons used thick beds of lime mortar to compensate for irregularities, creating a wall that was both structurally sound and visually rich. These bricks were often used in multiple layers to create solid walls that were sometimes two or three feet thick, providing incredible thermal mass that kept interiors cool in summer and warm in winter. The weathered, “crumbly” appearance of historic brickwork is not necessarily a sign of failure but a characteristic of a material that was designed to age gracefully alongside the house.

3. Natural Lime Mortar and Plaster

Until the widespread adoption of Portland cement in the late 19th century, lime was the universal bonding agent used for nearly all masonry and interior finishing. Produced by burning limestone in a kiln to create “quicklime,” which was then “slaked” with water, lime mortar remained flexible and breathable throughout its long life. This flexibility was crucial; it allowed the mortar to “self-heal” small cracks caused by the building’s natural settling, preventing the catastrophic structural failures often seen when rigid modern cements are applied to old walls. Inside the home, lime plaster was applied over wooden laths to create smooth, durable wall surfaces that naturally regulated humidity. Unlike modern gypsum drywall, lime plaster is resistant to mold and acts as a natural carbon sink, slowly reabsorbing carbon dioxide from the air over decades as it cures into a rock-hard, limestone-like finish.

4. Wrought and Cast Iron Detailing

The 19th century saw a revolution in the use of iron, which moved from a structural necessity to a highly decorative architectural element found on porches, balconies, and rooftops. Wrought iron, which is “worked” by hand while hot, was used for structural ties, nails, and intricate railings, valued for its high tensile strength and relative resistance to corrosion. In contrast, cast iron was poured into molds, allowing for the mass production of ornate columns, window lintels, and even entire building facades. These metal components provided fire resistance and structural support, enabling buildings to grow taller and feature larger windows. The juxtaposition of heavy, dark iron against soft brick or wood became a defining aesthetic of the Victorian and Edwardian eras. Maintaining these elements required regular painting and “pointing” to prevent rust, making the upkeep of ironwork a continuous part of the building’s maintenance cycle.

5. Natural Slate and Stone Roofing

For those who could afford it, natural slate was the premier roofing material of the past, valued for its incredible longevity and fireproof nature. Extracted from quarries and hand-cleaved into thin shingles, slate could last for over a century with minimal maintenance, developing a beautiful “patina” as it weathered. Because slate is a heavy material, it required a massive roof structure of thick timbers to support its weight, often resulting in the steep roof pitches seen in Gothic and Queen Anne architecture. In regions where slate was unavailable, “stone slates” or flat slabs of limestone and sandstone were used, providing a rugged, textured appearance that integrated perfectly with the local geology. These roofs were not just functional covers but statements of permanence; while a thatched or wood-shingle roof might need replacement every twenty years, a well-laid slate roof was intended to protect a home for multiple generations.

6. Lath and Plaster Wall Systems

The standard method for finishing interior walls before the invention of drywall involved a labor-intensive system of wooden “laths”—thin, horizontal strips of wood—covered by several layers of lime or gypsum plaster. The laths were nailed to the wall studs with a small gap between them; when the wet plaster was pressed against the wood, it oozed through the gaps and curled over, creating a mechanical bond known as a “key.” This system produced walls that were exceptionally thick and provided excellent soundproofing and fire resistance compared to modern hollow walls. Because the plaster was applied by hand, it could easily follow the curves of a room or the irregularities of a ceiling, creating elegant coved corners and ornate moldings. The weight of a lath-and-plaster ceiling is immense, and its survival depends on the integrity of the “keys,” making the preservation of these systems a primary concern for restorers.

7. Hand-Blown and Plate Glass

Historic windows are characterized by the subtle distortions and “imperfections” of early glass-making techniques, such as “crown glass” or “cylinder glass.” Before the advent of modern float glass, panes were created by blowing a large glass bubble, spinning it into a flat disc, or blowing a cylinder that was then cut and flattened. This resulted in glass that featured “seeds” (tiny air bubbles) and “reams” (wavy lines), which give older buildings their distinctive, shimmering reflection when viewed from the street. Because large sheets of glass were difficult and expensive to produce, windows were typically made of multiple small panes held together by lead cames or wooden “muntins.” This “divided lite” design was a structural necessity that became a beloved architectural feature. The thickness of this glass varies across the pane, and its unique optical qualities are nearly impossible to replicate with modern manufacturing, making original window glass an irreplaceable asset.

8. Terracotta and Glazed Ceramic

Terracotta, which literally means “baked earth,” became a popular material for architectural ornamentation in the late 19th century due to its durability and ease of molding into complex shapes. Often glazed to look like stone or finished with vibrant colors, terracotta was used for cornices, friezes, and window surrounds, particularly on the early skyscrapers of Chicago and New York. It provided a lightweight alternative to carved stone, which was expensive and difficult to transport. Because it was fired at high temperatures, terracotta was highly resistant to the acidic soot and pollution of industrial cities. Inside the home, glazed ceramic tiles were used in kitchens, bathrooms, and around fireplaces, valued for their hygienic, waterproof surfaces and decorative potential. These ceramic elements were often the only “splash of color” in an otherwise muted palette of brick and stone, representing a marriage of industrial production and artistic craftsmanship.

9. Lead and Copper Flashings

In the era before synthetic sealants and rubber membranes, the “watertightness” of a building’s joints was ensured by the skilled use of malleable metals such as lead and copper. These metals were used for “flashings”—the protective strips placed where a roof meets a chimney or a wall—and for gutters and downspouts. Lead was particularly valued for its “dead-soft” quality, which allowed it to be beaten and shaped by hand to fit the complex curves of a roof without cracking. Copper, while more expensive, was prized for its longevity and the protective green “verdigris” it developed over time, which sealed the metal against further corrosion. These metal components were the primary defense against water infiltration, the greatest enemy of any building. The craftsmanship involved in soldering and “bossing” these metals was a specialized trade, and the presence of original copper or lead detailing is a sign that the building was constructed with no expense spared for its long-term survival.

10. Sandstone and Limestone Ashlar

The most prestigious buildings of the past were constructed using “ashlar” masonry—precisely cut and dressed blocks of natural stone that were laid with very thin mortar joints. Sandstone and limestone were the most common choices because they were relatively easy to carve when first quarried. Unlike “rubble masonry,” which uses uncut fieldstones, ashlar provided a smooth, formal facade that signaled wealth and institutional power. The stone was often “face-bedded,” meaning it was laid with its natural geological layers parallel to the ground to prevent moisture from causing the stone to flake or “spall.” Over time, these stones would weather and change color, absorbing the history of the environment. Because stone is an excellent conductor of heat, these buildings required thick walls to maintain a stable internal temperature. Today, the art of hand-carving ashlar is a rare skill, making the massive stone blocks of older courthouses and mansions a testament to the physical labor of the past.

11. Linoleum and Encaustic Tile

Flooring in historical interiors often featured durable, highly decorative materials, such as “true” linoleum or encaustic cement tiles. Linoleum, invented in the mid-19th century, was a natural product made from solidified linseed oil, wood flour, and cork dust on a burlap backing. Unlike modern vinyl, it was biodegradable and anti-bacterial, with patterns that went all the way through the material, meaning they didn’t wear off with heavy foot traffic. Encaustic tiles, popular in the Victorian era, were made by layering different colors of clay together before firing, creating a pattern that was an integral part of the tile’s body. These floors were designed to withstand the muddy boots and heavy cast-iron stoves of a busy household while providing a level of geometric beauty. Both materials represented the early industrial era’s ability to mass-produce high-quality, long-lasting finishes that were accessible to the growing middle class.

12. Horsehair and Natural Fiber Reinforcement

A hidden but essential material in older buildings was animal hair—usually from horses, cows, or goats—which was mixed into lime plaster to provide “tensile strength.” The long, coarse fibers acted like a primitive version of rebar, binding the wet plaster together and preventing it from cracking as it dried and settled. This simple addition allowed plasterers to apply thick layers of material to ceilings and walls that could withstand the vibrations and movements of a living house. In addition to hair, other natural fibers like straw, flax, and even “cobs” (a mixture of clay and straw) were used in rural construction to create walls that were both insulating and structural. These biological additives are a reminder that historical construction was a chemical-free process that relied on the byproduct of the local farm to enhance the performance of mineral-based materials. Finding horsehair in a piece of fallen plaster is a direct link to the animals and workers of the past.

• Tags:
• Historic Construction
• Traditional Masonry
• old buildings
• common materials