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a Close Up Photo of a Large Iron Chandelier Dark Stained Wood Ceiling Beams and the Top of a Plaster Door Surround of a Spanish Bedroom Remodel in Santa Barbara Ca

Plaster Registers: Quality Details Built into Spanish Homes

Jeff Doubet shares before, during and after photos showing how quality plaster registers are built into a Spanish home interior in Santa Barbara, California. Today I share how custom plaster register grilles were incorporated into a Spanish-style bedroom design to enhance the room with additional layers of detail.

a  Inch Thick Plaster Register is Installed Above a Plaster Door Surround in a Spanish Style Bedroom Remodel in Santa Barbara Ca
Decorative Plaster Hvac Register on Spanish Wall

Thick cement grills and plaster registers have been incorporated into Santa Barbara Spanish homes and businesses for well over 100 years. My first introduction to the genre was back in the early 1980’s. I lived in a 1920’s Montecito home that had beautiful window grilles.

a Pair of  Inch Thick Plaster Registers Are Installed Above a Plaster Door Surround and a Pocket Door to a Closet in a Spanish Style Bedroom Remodel in Santa Barbara Ca
Iron Chandelier Hanging from Dark Wood Beam Ceiling

I was so impressed with the artistic nature of these functional items, that I began to incorporate them into my own design projects in 2003. Scroll to learn more about decorative window grille and plaster vent grille upgrades you can make.

Plaster Registers Before and After

In a collection of articles I have written on the subject, I wanted to focus on the before, during and after process of incorporating plaster registers and vents into any project.

a Before Photo of the Framing of a Spanish Style Bedroom Being Remodeled in a High End Spanish Home in Santa Barbara California
Spanish House Remodel in Santa Barbara Ca

BEFORE PHOTOS: For this particular Santa Barbara home, we were redesigning and remodeling interior spaces. This article focuses on the plaster registers we incorporated into the primary suite. The interior walls were stripped to the studs making way for a large walk-in closet and new luxurious bath.

Spanish Style Remodel in Santa Barbara with Mahogany Interior Doors Being Installed in Newly Framed Room
Mahogany Interior Door Installation

You can see the heating and air conditioning flexible duct work In the upper right corner of the photo ABOVE. An extra thick wall was framed for the aesthetic upgrade of the opening, as well as housing a sliding pocket door.

a Large Iron Chandelier Hangs in a Recently Completed Spanish Style Bedroom Remodel in Santa Barbara California
Spanish style Bedroom with Large Chandelier

AFTER PHOTO: The completed Spanish bedroom entrance remodel. Please scroll the dozens of photos below, to learn more about how you can accomplish a similar, stunning result.

What Are Plaster Registers, and Where Can They Be Installed?

Plaster registers are custom fabricated, decorative HVAC vent covers. They are an upscale alternative to standard duct air vent covers you can purchase on Amazon. They are fabricated by first casting a special formulated plaster as a “block”. The perforated design that creates the vent is cut into the block panel using a CNC waterjet.

Almost any design can be cut into a panel of plaster, provided they are first approved by the manufacturer, who will analyze the structural viability of your design.

Three Decorative Plaster Register Panels Are Being Removed from a Shipping Crate
Plaster Hvac Register Panels in Shipping Crate

ABOVE: Three custom plaster register vents were well packed in foam when I opened the shipping crate. Plaster vents can be installed throughout the interior of a home. I have even specified them in areas of a house just for their aesthetic value on a wall (not associated with a heating or other functional use).

a Close Up of a Custom Decorative Plaster Register Panel with Edge Detail Designed for Receiving Metal Installation Clips
Close Up of a Pair of 2 Thick Plaster Hvac Panels

For this project, I wanted to create a vent with extra depth in it’s perforated detail. To accomplish this, I specified the plaster registers in a non-standard 2″ inch thickness.

Jeff Doubet recommended product(s) for designing and building a quality Spanish-style home and landscape.

Preliminary Construction Steps for Incorporating Plaster Registers

There are some basic preliminary steps you will need to take to build custom plaster registers into your own project. As I wrote in a previous article, it is important to work closely with the manufacturer to understand the technical aspects you will need to know and incorporate, before you get too far into your project.

a Close Up Photo of the Galvanized Steel Duct Work Needed for Installing a Custom  Thick Plaster Register Panel to the Surrounding Wood Framing of the Hvac Opening
Galvanized Steel Hvac Vent Duct Work in Santa Barbara Ca

The design you choose for your plaster registers will need to coordinate with the custom design of your galvanized ductwork. This is standard type ductwork, but the geometry will need to be compatible with the specific air flow supplied through the decorative grille design.

a Spanish Style Bedroom Under Construction in Santa Barbara Ca is in the Drywall Stage a Plaster Door Surround Receives Metal Bullnose Corners
Spanish Bedroom Remodel in Santa Barbara Drywall

ABOVE CONSTRUCTION PHOTO: Our heat and AC ductwork were sized and engineered to our specific register design. The HVAC system installed in the house is an important calculation. ABOVE: The rough-in of the duct work is complete, and 5/8″ drywall has been installed.

Galvanized Steel Ductwork Has Been Painted Flat Black in Preparation for the Installation of a Two Inch Thick Plaster Register Grille
Flat Black Painted out Galvanized Steel Duct Work

Here is a close up photo of the galvanized box and duct. Notice how deep this box is? Again, it is designed for the volume of air flow, and function of our specific plaster register cover design.

How To Install Plaster Registers With Custom Clips

A lot of my clients are intrigued with incorporating custom plaster register vent grilles into their projects. But they don’t understand how they are installed, and there is often trepidation. I took these photos on the job site to help you visualize how they are installed.

a Close Up Photo of the Clip System for Installing the Custom  Thick Plaster Register Panel for a Spanish Home Remodel in Santa Barbara California
Plaster Hvac Vent with Mounting Clips Installed

Here, one of our custom 2″ inch thick plaster registers has been secured in place with the manufacturer supplied metal clips.

a Close Up Photo of a  Inch Plaster Grille Register Cover Showing a Routed Edge for Metal Clip Installation Technique
Jeff Doubét Holding Up 2 Hvac Decorative Vent Panel

ABOVE: This photo shows how the plaster register manufacturer fabricates the 2″ thick panel with a routed and stepped edge of 5/8″ thick.

a Close Up of the Edge of a Plaster Register Panel Designed for Metal Installation Clips That Will Secure the Panel to Wood Framing in the Wall
Closeup of Plaster Hvac Register Edge Detail

ABOVE: Another close up photo of the front edge of the panel. See how it has a thin frame routed all around? This allows you to install the metal “Z” clips along the edge. It gives you many options for how best to secure the panel to the adjacent wood framing.

Installation Details for Plaster Registers

This photo below shows how you will need to cut back the 5/8″ drywall by approximately 3/4″ – 1″ (from the opening of the ductwork box).

a Close Up Photo of the Clip System Being Installed to Secure a Custom  Thick Plaster Register Panel to the Surrounding Wood Framing of the Hvac Opening
Factory Mounting Clips Installed on Plaster Register

The process exposes the wood framing, allowing a flush mount of the thick panel (to be even with the surface of the wall). You can also see here how the panel is secured with manufacturer supplied “Z” clips.

a Close Up of a Custom Decorative Plaster Register Panel Showing the Edge Detail Designed for Receiving Metal Installation Clips
Decorative Design of a Spanish style Plaster Grille

This 2″ thick grille was supplied with a “ledge” edge detail. It allows the panel to rest on the wood framing it is being installed onto. Further, the front edge groove is needed for the installation of the “Z” clips. Scroll to see more images of this procedure in action.

a Close Up Photo of a Metal Clip for Installing Custom  Thick Plaster Register Panels in a Spanish Bedroom Remodel in Santa Barbara California
Metal Clips for Mounting Plaster Panel

ABOVE: A zoomed in view of the metal clips holding the plaster register in place. Our General Contractor also ran a bead of construction adhesive along the backside of the panel “ledge edge” for extra strength in holding the panel in place within the wood framing.

A direct link to Spanish-style products on Amazon and project overviews where installed.

More Installation Tips and Tricks for Decorative Grilles

Your General Contractor should be detail oriented in their plaster register installations. The ones I have worked with build in “tolerance” in their framing. This allows them to move the panel around a bit to level the design on the wall.

a Spanish Home Remodel in Santa Barbara California Includes Installing Custom  Thick Plaster Register Panels Above the Entry Door As Well As the Pocket Door Leading to the Walk in Closet
Spanish Hvac Plaster Registers Being Installed on Wall

Shims can be used to adjust the grille panels vertically and horizontally, as well as to be “plumb” with the wall itself.

a Close Up Photo of Two Custom  Thick Plaster Register Panels Being Installed Above Door Openings in a Santa Barbara Ca Spanish Home Remodel
Plaster Hvac Register Grilles Being Installed in Spanish Bedroom

Now that the panels are secured with construction adhesive and metal clips, the drywall gaps will need to be patched.

a Custom  Inch Plaster Grille is Installed Above an Interior Door Being Outfitted with a Plaster Door Surround Details Being Developed for a Spanish Home Remodel in Santa Barbara Ca
Thick Plaster Walls and Door Surround in Spanish Bedroom

The way we fill the bulk of these gaps is with 20 min. joint compound mixed with general all purpose drywall mud. The 20 min. sets up fast. Once dry, fiberglass mesh tape can be applied over the patched areas to help prevent cracks.

Refining The Installation Of Decorative Plaster Vents

Once the plaster register has been completely integrated into the wall, the drywall team will follow up with the final details.

a Topping Coat of Drywall Mud Has Been Applied to the Surrounding Patch Areas of Two Decorative and Functional Plaster Register Grilles in a Spanish Style Remodel Taking Place in Santa Barbara Ca
Final Drywall Mud Layer Being Applied to Plaster Door Surround and Wall

They will match and blend the vent grille panel into the surrounding wall. To see a photo of me personally doing this, CLICK HERE.

an Installed Custom Plaster Register Receives a Final Coat of Drywall Mud to Blend in the Installation to the Surrounding Walls
Spanish style Heat Register Made of Plaster

ABOVE: A close up photo of the plaster register after a final topping coat of joint compound has been sanded. This is what a completed installation of a plaster register looks like. It is now ready for wall paint.

a Spanish Style Bedroom Remodel in Santa Barbara Ca Includes Decorative Plaster Door Surrounds Dark Stained Wood Ceiling Beams and Installed  Inch Thick Plaster Hvac Registers
Spanish style Primary Suite with Plaster Door Surrounds and Clay Tile Floors

MORE COMPLETED PROJECT PHOTOS

the Completion of a Spanish Style Bedroom Remodel in Santa Barbara Ca Includes a Spanish Colonial Revival Bed Artwork paintings and Large Iron Chandelier
Spanish Bedroom with Carved Bed and Vintage Paintings
a Spanish Style Bedroom in Santa Barbara Ca Includes a Spanish Colonial Revival Bed Artwork paintings and Large Iron Chandelier
Large Iron Chandelier Above Spanish Bed in Santa Barbara
a Close Up Photo of a Plaster Hvac Register Grille Installed Above a Decorative Spanish Style Door Surround
Interior Plaster Door Surround with Decorative Register

Would you like access to a plethora of other Jeff Doubet photos, designs and pro tips for cement and plaster grilles? Click direct link above.

Future Episodes for Building Spanish Style Interiors

I invite you to continue visiting my Creating Spanish Style Homes Photo Blog, as I add more intriguing projects, site visits and teaching moments of how high-end Spanish style interiors are designed and built.

a Spanish Style Bedroom Being Remodeled in Santa Barbara Ca Showing Custom Door Surrounds Under Construction
Spanish style Bedroom Remodel in Process in Santa Barbara Ca

For example: Beyond the door (on the left) is a gorgeous Spanish style master bath. At some point I will be sharing that portion of this remodel in a future episode.

a Finished Spanish Style Bedroom Remodel Features Decorative Plaster Door Surrounds Dark Stained Wood Beams and Terra Cotta Clay Floor Tiles
Completed Spanish Bedroom with Carved Wood and Leather Chair

Well friend, this wraps another site visit episode in beautiful Santa Barbara, California. I hope you enjoyed learning how to infuse more Santa Barbara Style into your own Spanish interior design project. Scroll to explore more helpful links and resources for designing and building your own Spanish-style home and landscape.

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I’ve organized my snapshot posts and full-length articles into 4 main categories: Interiors , Exteriors , Landscapes and Store + More. For popular sub-categories like Spanish sheds, fireplaces, garage doors, tiles, etc. see my Portfolios. With well over 1,250+ photos and countless design tips shared… peruse at your own pace, or do a QUICK SEARCH for your specific needs!