How Cast Iron Bathtubs are Made: Kohler Factory - Did You Know?
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- Опубліковано 8 лют 2025
- It all began in 1873. It was then, in the middle of a depression that would last for five years, that John Michael Kohler purchased the Sheboygan Union Iron and Steel Foundry. The company produced cast iron and steel implements for farmers in the area around Sheboygan, Wisconsin. It also made castings for furniture factories, and ornamental iron pieces including hitching posts, cemetery crosses, urns and settees.
One of the company’s products was called a horse trough/hog scalder. In 1883, Kohler heated one of these to a temperature of 1700 degrees Fahrenheit and sprinkled on some enamel powder. A picture of the item in the company’s catalog indicated that the horse trough/hog scalder finished in such a fashion was suitable for use as a bathtub.
In 1911, there was yet another Kohler innovation. This time it was a one-piece built-in bathtub with an apron. In 1927, Kohler brought forth the coordinated bathroom suite with a line of products that featured identical colors on vitreous china and cast iron fixtures.
Today, the Kohler foundry in Kohler, Wisconsin is a modern facility capable of producing far more than its founder may have dreamed. The electric melt, for instance, has the capacity to melt more than 2 million pounds of iron a day. And much of what the company produces can be made through automated processes. The Herman foundry has the biggest automatic molding machine in the world. It can produce a bathtub every 26-27 seconds. The machine uses 700 tons of sand per hour. The two man crews pour 30-35 tons of iron per hours to fill the molds.
And it’s not just about plumbing fixtures anymore. Kohler has a Cabinetry and Tile division that includes Ann Sacks Tile & Stone, Robern and Canac. Ann Sacks is a maker and retailer of ceramic tile, marble and stone. It is particularly noted for its hand-made ceramic tile, customized colors and patterns. Robern makes mirrored cabinets, lighting fixtures and accessories. Canac makes wood cabinetry.
Kohler is also known for its power systems business. This part of the company dates back to the 1920’s, when Kohler made a 1500-watt generator powered by a Kohler cast iron diesel engine.
Admiral Richard E. Byrd took Kohler generators with him when he went on his expeditions to the Antarctic. During his year alone on the continent, a Kohler generator was Byrd’s only source of heat, light and communication with the rest of the world.
After World War II, Kohler developed lines of cast iron 4-cycle engines that also established a reputation for endurance in tough conditions. Today, Kohler continues to produce generators from 5kW to 2,000kW. The company’s engine division continues to make horizontal and vertical shaft 4-cycle engines. Models range from 4hp overhead valve single cylinder engines to 26hp overhead valve twin cylinder engines. You can find Kohler engines in power lawn and garden equipment.
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nothing can beat a cast iron tub!!! sooo beautiful
Kohler cast iron bathtubs are the Best. The building I live in still has the original tubs from 1949.
That tub in the last part is a DREAM!!! Beautifull!
The energy ,materials, the process is awesome
Thank you for sharing your process. Beautiful finished products! Stay safe.
I used to be a bathroom buyer and went to the jacob Delaphon cast iron bath foundry in Paris France and it was hell on earth
Kohler owns that as well
@@caseyisaretard they do
I was lucky enough to get an old cast iron tub and 2 sinks someone was throwing away
kohler warranty excellent have all through out house only Kohler
An Electric bill that high of $350,000++ monthly.
It's time to create Your own electric/power source.
There's quit a bit of quality in Kohler products but they stand behind them well. If you want the best get cast iron porcelain sinks tubs...Composite stuff forget it, if it was so good they'd make composite toilets.
Can old claw foot tubs be stripped and recoated with porcelian???
these products last a life time , only human error on application of the primer and paint can maybe chip after 50 years, but i prefer this over any bathtub they make these days.
I love large deep cast iron tubs, particularly the older ones, once I get in one I sleep like a baby. Newer tubs that are smaller thinner just don't do it for Me.
Damn shame most people think showers are great. They're good for 2 things: quick showers to cool down in the summer & rinsing off *_after a long hot bath._*
After seeing this 1,000$ seems cheap
?
Their is one catch. Metal will rust. One speck of rust will spread and the tub will eventually fall apart.
and nothing will last longer
Your options are :
Acrylic tubs reinforced with fibreglass which last less then 20years. ( 10 - 15 )
Fibreglass tubs which last 10 -15 years.
Steel Bathtubs are supposedly good for 15 - 25 years
Cast Iron Enamel coated Bathtubs ( like in this video ) which last an easy 70years.
There are of course other options like Copper, or PURE ARTISANAL BOUTIQUE “I GOT MONEY” BathTubs, etc !
I grew up all My 50+ years of owning & living in places that have cast iron tubs & sinks. I've never seen rust to where it makes a cast iron sink/bathtub fall apart.
I also cook on cast iron cookware. I have found a few that people throw away completely rusted, never seen any falling apart.
I soak in 30% vinegar for 2-7 days, rinse off the gross rusted _"slag" (if You will),_ scrub vigorously with coarse steel wool, then SOS/Brillo pads, rinse/repeat several times until all rust is gone. Grease it with shortening, olive, or corn oil, soybean _(no Canola oil)_ bake it for 2+ hours 500 degrees until turning black.
Lots of work, of course, but it won't be if You *_like/love_* restoring cast iron, simple cleaning & maintenance after restore. Many people have other methods to restore Iron.
*_Each time its cooked in oil/grease between each use & cleaning, the better it gets at being naturally non-stick._*
Unlike that toxSICK garbage called Teflon/nonstick ceramic/Etc.
wait, so the glass goes on first or the primer, and the enamel?
⚫️ *Your options are* :
▪️ *Acrylic tubs reinforced with fibreglass which last less then 20years. ( 10 - 15 )*
▪️ *Fibreglass tubs which last 10 -15 years.*
▪️ *Steel Bathtubs are supposedly good for 15 - 25 years.*
🖤 *Cast Iron Enamel coated Bathtubs ( like in this video ) which last an easy 70years.*
▪️ *There are of course other options like Geoengineered Polymer Tubs Copper & Finally* :
🖤❤️🖤 *PURE ARTISANAL BOUTIQUE “I GOT MONEY BÎTÇH !¡!” BathTubs.* 🖤❤️🖤