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Posts Tagged ‘plantation shutters’

Kirtz Shutter Craftsmanship; what a quality finish adds to your custom shutter

Thursday, August 20th, 2009
Without a quality finish on  a custom shutter, the value created by using a high quality wood, and rigorous construction standards would be minimized.   Let’s take a look at how Kirtz Shutters achieves a  quality finish on our custom shutters. 

Linear Priming (painted shutters only)

Components of our painted maple shutter are primed in lineal form.  By priming in lineal form we can ensure an even coating of primer, up to two mill thickness on each part of the shutter.  A high quality prime helps the shutter take finish coats well.

Wood Grading (painted and stained shutters)

Not all components make the final cut for a Kirtz Shutter.  All of our components are inspected before they reach the production line and undesirable sections of wood with flaws are marked as not suitable for a Kirtz Shutter.

Prep Work~ Where the Magic Happens

Even the best quality wood has some imperfections.   To get a smooth finish involves a high level of attention to detail during prep work.   Imperfections are fixed during 2 different stages of manufacturing.  

The Production Line — Filler is applied to the any noticeable flaws in the wood and sanded out smooth.  

Brown and Sand — Shutters enter this area after they are built, and before they enter the finish room.  High intensity spotlights shine down upon the shutters, highlighting any slight flaw that might show up in the final product.  These minor flaws are fixed with putty and sanding, and then the finish sanding begins. 

Finish sanding is done by hand, with very fine sandpaper.  Every inch of the Kirtz Shutter is finish sanded, including the top of the tilt rod, an area that few manufactures take the time to address.  After final inspection, they are ready for finish.

shutters are inspected for flaws under hign intensity lights

shutters are inspected for flaws under hign intensity lights

 

any small flaws are fixed before finish is applied

any small flaws are fixed before finish is applied

During finish Kirtz Shutters are hung from a track system on cars that allow the shutter to rotate completely.  This makes sure, whether painted or stained, each shutter receives an even amount of paint/stain on all parts of the shutters resulting in a smooth, even finish from any angle.

plantation shutters in the paint finish room

plantation shutters in the paint finish room

Painted Shutters receive  two coats of  lacquer paint finish on top of the primer.  In between coats, shutters are quality inspected.  All our paint has UV inhibitors in it to help keep your custom shutters looking great, even in the most intense sun.

Stained Shutters are sprayed with your stain color, typically a custom mix done just for you.  Each shutter receives two coats of stain.  In between coats, the shutters are taken down off the track, hand wiped and lightly sanded    This step is the differential between standard finish and a truly furniture quality finish.    Without it the shutter color would appear a bit opaque, what some people call “muddy” .  To finish up, we put two coats of clear finish on the shutters to protect the wood and bring up the beauty of the grain.   We use a 20 sheen, which gives a nice luster to the wood and provides the finish with depth.  

After finishing is complete, Kirtz Shutters sit overnight to let the finish have time to cure.  Depending on the time of the year, painted finishes are given extra curing time in a cool room.

While each area of our factory plays a key role in making the Kirtz Shutter a bench quality product,  the finish department plays a critical role in making the work of all the other departments really shine.

Kirtz Shutter Craftmanship; assembling a quality custom shutter

Monday, August 17th, 2009
The assembly department is responsible for turning lengths of components into a plantation shutter.

First, all parts are cut to length according to the exact specifications for your custom shutter.  After parts are cut, they are placed onto a cart with job sheets that details each opening in the order.

At Kirtz we take a few extra steps during assembly before the panel comes together to make sure that your shutter is built to the highest of quality standards.

Each tilt rod is given personal attention.  We shape the top of the tilt rod in a machine we designed to give the rounded top that is unique to a Kirtz Shutter.  Then, the top of each rod is sanded smooth so it has the same quality finished look as other parts of our shutters.

tilt-rod-shaping

After shaping it is sanded smooth

After shaping it is sanded smooth

Before the shutter is put together, each louver end is burnished with a sander.  Again, this extra step allows the ends of the louvers to accept the painted finish better, and eliminates the rough ends you would typically find with louvers that are cut, but not sanded.

Burnishing louver ends

Burnishing louver ends

Next, the louvers and tilt rod are fed through a machine that attaches them together with staples and puts pins in the end of each louver, and your shutter panel is ready to be put together.

Joinery of a Kirtz Shutter

At Kirtz we use dowels to join the stiles and rails of each shutter together.   Wood glue is put into each hole that will be receiving a dowel.  Then we use dowels that are slightly larger than the hole they are inserted into.   This requires the use of a hydraulic clamp to put the stiles and rails together.  After the shutter has been clamped together, small pin nails are applied to the backside of the shutter through the dowels, giving it an extra dose of reinforcement.

This method has been used by Kirtz for many years, and we confidently stand behind the joinery of a Kirtz Shutter for a lifetime.

The shutter comes together on the clamp table and is pin nailed for extra strength

The shutter comes together on the clamp table and is pin nailed for extra strength

Framing

Just like a door hangs in a frame, many times your  hardwood shutter will be in a frame.  We have several framing options at Kirtz to accommodate a variety of decors and types of windows.    After your shutters have been assembled, the frames that surround them are built.

At Kirtz we customize many of our frames so that they fit around window cranks and lever locks.  By doing these notches in the factory when possible, the notch receives a finish coat of paint instead of touch up in the field.

For more information on notches, see my post about plantation shutters in casement windows.

This completes your shutter assembly, next stop finish department!

Kirtz Shutter Craftmanship; Making the parts makes the difference for your custom shutters

Thursday, August 13th, 2009
Most shutter manufacturers buy their shutter components from large milling companies that deliver ready to assemble pieces to the manufacturers.    These components can be from the US, Mexico, and even China.   At Kirtz Shutters, we have rigorous quality control standards, and we use a variety of hardwoods, so components are made in-house in our milling department.

Hardwood shutters by Kirtz start at our factory as raw lumber.  We typically buy direct from the best lumber mills across the country, with a great deal of our lumber coming from the Northern US. 

A load of lumber for Kirtz Shutter, before sorting

A load of lumber for Kirtz Shutter, before sorting

 Lumber goes through the following process to become parts for your plantation shutters.

All lumber is tested upon arrival for proper dryness.  Using lumber that has been wet, or is not properly kiln dried could result in warping.  Obviously, this would be bad news for a shutter, so each load is tested immediately upon arrival to be sure that it meets the criteria for furniture quality use.

After unloading, lumber is sorted and it is determined what component part each board will be used to make.   Next, the lumber is fed through our Weinig molder and shaped into the different parts needed to make your shutter order.  As lumber is shaped into parts, each part is quality checked to see that it does not vary from our standard, which are +/- 5000 of an inch, a more exacting measure than industry standard, which is +/- 10,000 of an inch.

lumber being milled into components for plantation shutters

lumber being milled into components for plantation shutters

Verifying the milled parts meet quality standards for Kirtz Shutters

Verifying the milled parts meet quality standards for Kirtz Shutters

Since we use so many different types of woods in our shutters, the milling department must constantly calibrate the machine to handle the varying density of each wood.  Although this is a time consuming process it is the only we can maintain the rigid quality standards of a Kirtz Shutter.

After the louvers are molded they are run through a specially designed sander.  The belt of the sander is contoured so that it follows the shape of our elliptical louvers.  As the louver passes through the oscillating belt provides a random orbital sanding, the industries highest standard.  The louvers are now ready for the assembly line. 

Sander designed for elliptical shaped louvers for custom shutters

Sander designed for elliptical shaped louvers for custom shutters

The milling department is also responsible for laminating our stiles, which glues together two opposing pieces, resulting in a longer, straighter stile than industry standards.  
Once shutter parts finish the above processes, production is notified and your shutters are ready for the assembly department!

Painted Custom Shutters… Why Use Maple?

Friday, July 31st, 2009

At Kirtz we like to do things different, not just simply for the sake of being different, but because we want to bring something above average and a little special to our customers.  In our painted plantation shutter, that something special is the wood we use.

The founder of our company was a woodworker, in fact he got his start in the industry as a trim carpenter until the economy and life took him a new direction (I’m sure a few of you can relate given the world’s present state).  So when he decided to make shutter, he picked the wood that from his experience, would the best wood for a plantation shutter– MAPLE.

Why Maple?   In one word, STRENGTH.

 Maple is about twice as dense as shutter industry standard woods such as basswood and poplar.   What does that mean for the you, the buyer?  An awful lot in the long run.  Your shutter is put together with fasteners, staples that hold the louvers into the tilt rod.  Time and use of the product stresses these fasteners.  In softer woods, such as basswood and poplar, they often come loose over time.  The result is that the shutter does not function as it was originally intended.   A Kirtz Shutter is guaranteed never to have this problem, and if it did, it would be covered by our warranty.

Have you ever had a piece of pine furniture?  Did you notice how easy it was to dent the wood if something accidently bumped or banged into it?  The same is true of a poplar or basswood shutter, they can easily dent and ding at the slightest impact, thus increasing the look of wear and tear on the shutter.

The strength of maple also gives us ultimate FLEXABILITY IN DESIGN. 

In Height:  The Kirtz Shutter does not need a midrail (also called a divider rail) until after 96″ in height.  Industry standard is 72″.  That means you can have two more feet of unobstructed louver space by using a custom shutter by Kirtz out of maple.

In Width:  With shutters warrantied up to 38″ in width, customer’s have the ultimate flexibility in designing their shutters for the best fit to their space without the constraints of industry standard shutters.

Often I meet with customers who are confused with the variety of materials that a plantation shutter can be made from and the variety of pricing that goes along with them. 

My advice to them, and to you, is this – 

Plantation Shutters are one of the largest financial investments in window treatments that you can make.    They will provide beauty and protection for many, many years.  All shutters are NOT created equal.   In an economy where every dollar counts,  we all want to make sure we spend our money wisely.  

Choose the plantation shutter that will provide you the best product experience over the life of your shutter, not just in the beginning.  And just as important, choose a company that you can trust to provide you great customer service, both before the sale and years after your shutters are installed.  That, in my life experience, is true value that pays dividends long after the check has cleared the bank. 

I’ll end this (and step off my soap box) after I share my favorite quote.  I try to live it every day, in the products I represent to the products I purchase for myself and my home.

“The bitterness of poor quality, lingers long after the sweetness of low price is forgotten.”

A Case Study in Customization of Kirtz Plantation Shutters

Friday, July 24th, 2009

Yesterday we finished a plantation shutter installation at a new branch of SNB, a local bank, with national presence.     Just like many of our jobs, this was a “one off” of Kirtz custom shutters.   Let me explain, with some photos to help.

Designer Request:

Make each window opening appear as one seamless unit, and provide a finished casing around the opening. Build the custom shutters out of oak and custom stain them to match the flooring.

Sounds simple, right?

The Challenge

When the windows arrived from the manufacturer the transom portion that seamed to the lower window did not line up uniformly.  This is because both outside and inside jambs of the upper unit were different widths than the jambs of the lower unit.

The Solution

Kirtz mounted the oak shutter and frame inside the window jamb with custom width framing around each unit.  This allowed us to align the stiles (vertical part of the shutter) so that each shutter panel is the same width and provides a continuitous vertical line.

One issue solved, one to go…….

The Challenge

Standard work of applying casing onto a frame at the factory would not provide a cased look to the opening since this opening had to be installed as four separate shutter units due to the window jamb issues mentioned above.

The Solution

Custom width casing was milled to be applied in the field around the entire window unit.  These trim pieces not only surround the outside of the opening, but run along all vertical and horizontal window mullions to provide a uniform cased appearance, eliminating any hint of the window’s irregularity.

The windows before hardwood shutters

The windows before hardwood shutters

This illustrates the different jamb widths of the window pre-shutter installation

This illustrates the different jamb widths of the window pre-shutter installation

This close up illustrates how we unified the upper and lower units to look cohesive

This close up illustrates how we unified the upper and lower units to look cohesive

Thefinished unit

Thefinished unit

Triangle Windows (aka rake windows) and Plantation Shutters

Monday, July 20th, 2009

Architectural Shaped windows such as triangles, arch tops, ovals, circles and hexagons all present many challenges when choosing a window covering.

This blog is focusing on triangle shaped, or Rake Top window openings.

Plantation Shutters are a great choice for Rake Windows for several reasons

  1. You can treat the entire opening, not just the rectangle portion, thus allowing greater privacy and light control
  2. They are one of the only window treatments that once installed into the shape that are functional instead of fixed, allowing you to control the light that enters the room.
  3. Every type of triangle is possible.  Unlike other window coverings, shutters have no restrictions  on width, height or degree of angle, making even the most challenging of window possible.

Just as your window is an architectural statement for your home, the window treatment you choose should complement and enhance it.  If you choose shutters (which I hope you will) be sure that the company you choose makes all the louvers movable in rake tops with horizontal louvers.  See my earlier post about arch top windows for more info on that subject and why it matters.  If you order a burst shape, be certain that the center hub is in proportion to the size of your window so that your finished product looks like a custom piece of millwork that belongs in your beautiful window.

Custom Shutters from Kirtz Shutters do just that.  The photos below are  a couple examples of homes that used Kirtz Shutters to compliment their triangle shaped windows.
rake shaped windows before plantation shutters

rake shaped windows before plantation shutterspartially open rake top shutters

Knotty Pine Shutters by Kirtz Shutters, Triangle (rake) shaped shuttters

Knotty Pine Shutters by Kirtz Shutters, Triangle (rake) shaped shuttters

A gothic arch show the burst concept for triangle shaped windows

A gothic arch show the burst concept for triangle shaped windows

Walnut Plantation Shutters in Commercial Spaces

Friday, July 10th, 2009

This post is about a very special project for Kirtz Shutters.    We just completed installation of walnut shutters for Coach Gundy’s office, the head football coach of Oklahoma State University. Go Pokes!

Our company is composed of many individuals who “bleed orange”, no one more so than our owner, Chris.  So needless to say, we felt privileged to have the opportunity to work on this project.

But lets talk about the shutters, there are a few unique charecteristics to note about this project.

1)  These are WALNUT hardwood shutters. Walnut is beautiful, but challenging to finish due to the large amount of sapwood in the lumber.  The sapwood produces a great deal of color variation throughout the wood.  On this job we used “premium” walnut, which contains less sapwood than normal and our finish department spent many hours tweaking the custom finish between coats to give a nice even look to the wood while maintaining the beauty of the wood grain.

2)   The Wall Curves: This office is located in the end zone of the stadium and we had to account for the curvature of the half wall on which the shutters sit.  We did this during installation by cutting down trim on site to fit the curve of the wall, thus giving it a nice even reveal down the length of the wall.

3) Plantation Shutters Sliding on a Track: These are a great option for sliding doors.  We build a frame around the shutters that allows for the installation of two tracks in the header of the frame.  The shutters have cars attached to the top of them and can then by-pass each other to allow access to the doors, or be moved over the doors and the louver’s open.

4) 4 1/2″ Louvers with Hidden Tilt: This is truly becoming one of our most popular product features.  Check out the photo below to see just how wonderful the visibility can be with this feature!

Walnut Shutters, Hidden Tilt, Louvers Closed

Walnut Shutters, Hidden Tilt, Louvers Closed

Walnut Planation Shutters, Sliding custom shutters run to the floor

Walnut Planation Shutters, Sliding custom shutters run to the floor

4 1/2" Louvers, View Outside

4 1/2" Louvers, View Outside

gundyoffice

Plantation Shutters for Sunrooms

Thursday, June 25th, 2009

Sunrooms are great, but in many parts of the country they are down right unbearable during the intense summer and winter months.

Have you ever thought about Plantation Shutters for your sunroom?

Plantation Shutters will:

  • Add greater energy efficency, saving you money
  • Allow greater control of intense sunlight that can fade furnishings
  • Add beauty and charm to your sunroom

In order to maximize the original purpose of the room (openness to the outside) there are a few design tips to keep in mind.

  • Order a large louver size (the larger the better)
  • Consider adding hidden tilt, to keep the least amount of obstruction to your view
  • Order your shutter panels as large as is reasonable with your window configuration.  This will minize the presence of too many stiles (vertical piece of the shutter) taking up more space than necessary.  Kirtz will build custom shutters with warranty up to 38″ wide.  We’ve often successfully built larger than 38″ wide panels, consult a sales rep for more details if you are interested.

Customization for Your Needs

The standard plantation shutter in a sunroom is typically set in a frame, and the shutter panel is hinged to the frame.

Another option is to place your shutters on a sliding track.  The benefit of this configuration is that one shutter panel will slide over another, fully opening up 1/2 of the window without swinging into the room.   This makes furniture placement much easier.  However, determining if this application will work for your sunroom is important, as a slider shutter frame is typically 5 1/2″ deep, compared to a standard shutter frame that is only 2- 2 1/2″ deep.

sunroom before shutters

sunroom before shutters

plantation shutter panels closed, louver open

plantation shutter panels closed, louver open

shutter panels slid open, louvers closed

shutter panels slid open, louvers closed

Kirtz Plantation Shutters with VERTICAL LOUVERS

Thursday, June 11th, 2009

This job was running through our finish department and I just had to share!  We’ve never done ANYTHING like it before.  It is two plantation shutter panels meant to install with the 5 1/2″ louvers running vertically (two firsts for us!).  These panels are massive with 2 panels 62″ high x 84″ .   They will sit side by side in a wood opening and will be doweled together on-site during installation.   Did I mention they are a custom stained red oak?

These go in a funeral home, and the idea is to offer privacy for the family, but still allow them to see out into the chapel where the service is held.    We used a hidden tilt bar so that there are no interruptions in the sight line for the family.  Notice the two bottom pics.  The louvers are set partially open. Notice how one side offers visibility while the other angle privacy?

More photos showing how these look in the room setting will be added once they are installed.

But really ~  have a unique project?  Call us!  I’m about convinced we can do any type of custom shutter, and make it look good.

View when the 5 1/2" vertical louvers are closed

View when the 5 1/2" vertical louvers are closed

vertical louvers, family view out to chapel

vertical louvers, family view out to chapel

5 1/2" vertical louvers, chapel side

5 1/2" vertical louvers, chapel side

I promised an update when I had installation pictures, and here they are!
opening before installation

opening before installation

5 1/2" louvers (aka california shutters) run vertical, hidden tilt ~ open

5 1/2" louvers (aka california shutters) run vertical, hidden tilt ~ open 5 1/2" red oak vertical louvers, closed

5 1/2" red oak vertical louvers, closed

5 1/2" red oak vertical louvers, closed

Exterior Shutters, plantation shutter style by Kirtz

Friday, June 5th, 2009

Exterior Shutters are a small segment of what we do, but occasionally someone will want a plantation style exterior shutter and turn to Kirtz for help with their project.

There seems to be some confusion about what makes a plantation shutter exterior or interior grade, so here is a brief explanation of what to look for in an exterior shutter.

Wood Species- exterior shutters that stand the test of time are made of western red cedar, cypress (pecky or clear), or mahogany.  These woods naturally repel water and insects, making them the longest lasting most durable choice. not to mention the beauty of handcrafted mahogany shutters!

Fasteners and Glue- Make sure your manufacturer is using exterior grade glue and stainless steel staples (found on moveable louvers).  Otherwise, the joints of the shutter will fail and the fasteners will quickly rust.  This is especially true if your home is near ocean air, as salt can be very corrosive.

Finish:  A marine quality finish is recommended.  A good finish will protect your purchase, so don’t skimp in this area.  Shutters used for exterior projects made by Kirtz can be ordered with a marine finish, or raw and you can source the finish work yourself.

Even with a great finish, maintenance will be required.  Your shutters should have a new protective coat added to them every few years.  It varies depending on your climate and their exposure to the elements how often this needs to be done.  It is a good idea to look them over ever year for signs of damage.

Below are some picture of exterior shutters we built for a home in Florida.

These louvers are fixed at an unusual angle to allow visability looking out of the home, but obstructing the view of those looking inside

These louvers are fixed at an unusual angle to allow visability looking out of the home, but obstructing the view of those looking inside

This gorgeous indoor/outdoor space is complemented by these shutters used as doors

This gorgeous indoor/outdoor space is complemented by these shutters used as doors

fixed louvered shutters by Kirtz, bahama style

fixed louvered shutters by Kirtz, bahama style