Custom Metal Products of Distinction Since 1909

Blog - Products

What to Consider When Choosing Your Air Flow
Posted Fri, February 22, 2019

You’re evaluating the grille type and design you want to use from Coco Architectural Grilles & Metalcraft’s extensive line to fit the architectural style in your home or other building, but before you make the leap, you need to consider proper air flow for optimum comfort. How will your grille decision factor into the air flow equation?

What is air flow?

Air flow in the HVAC – heating, ventilation, air conditioning – world is the process of delivering conditioned air to rooms and then removing it from those rooms so it can be returned for re-conditioning. This process is accomplished through HVAC duct work. In a duct, air flows from a higher pressure to a lower pressure. A fan creates the higher pressure while the open end of the duct has a lower pressure, causing the air to flow out.

After conditioned air flows into a room, an equal amount of air must be removed. This return air is transported back to the central air system for reprocessing.  But, not all of the return air can be reused. Otherwise, the air would become stale. To avoid this, fresh air is ventilated into the system through an outside air intake.

The air flow percentage is the percent of air that the metal grille lets into (and out of) the room throughout the air flow cycle.

What you need to know when selecting air flow percentages

First, of course, you need to select the HVAC system itself. You need to make sure that the system is suited to the space to which it is supplying heating and cooling. Make sure the HVAC system ducts are free of leaks and that all the air is flowing into the proper spaces. To get the proper performance from the system, the air flow must be correct. Otherwise, the system performance and longevity will be adversely affected. When airflow is not good, it’s difficult to properly charge refrigerant or set up a gas furnace.

Comfort and safety are primary concerns of proper air flow. Air flow is what provides the proper heating or cooling to a room. When room air flow is low, it’s certain the room will be hot in the summer and cold in the winter. It also can affect the amount of humidity in a room, making it sticky in the summer and dry in the winter. The key safety concern addressed by proper air flow is the potential for carbon monoxide poisoning. Air flow imbalances can cause flue gases containing carbon monoxide to spill into rooms.

After ensuring the integrity of the HVAC system, you will want to consider positioning of your HVAC grilles. We create HVAC grilles for all heating and air conditioning systems, and we can customize to your specifications. You can rely on getting the utmost in quality, variety, aesthetics and functionality.  We provide the best priced options to engineers, woodworkers, contractors, HVAC companies and homeowners. Whether you need a curved wall matched, a mitered corner or a special finish, we can exceed your expectations while ensuring that the grille you select provides proper air flow.

As opposed to a shutter-style linear bar grille, a perforated grille is typically not adjustable. It is cut in a specific pattern and allows air to flow freely. To ensure proper air flow, you’ll want to take into account the free area not covered by the metal pattern. For perforated patterns with small vent holes, you will want more free area. This will allow more air to be pushed through the grille. The opposite applies for large vent holes. The perforation of our customized metal grilles are constructed to properly balance your HVAC system. Upon request, we can do cubic feet per minute (CFM) calculations in order to determine the best free-area percentage to use for the optimal grille size.

Are you ready to get the optimal metal grille to provide the best air flow and quality to your space? Be sure to check our product catalog for a full, detailed list of our products. For a consultation or to order your grilles, contact us at 631.482.9449 or

Posted in : Products |  No Comments >>
Tags : N/A

Why a Custom Metal Air Grille is Worth the Plunge
Posted Wed, January 30, 2019

custom l-bead linear bar grille installed above archway text above photo (Why a Custom Metal Air Grille is Worth the Plunge)

When designing your home or office, it’s important to pay attention to the details. Something as simple as a metal grille can be the difference between a polished interior design and a messy, haphazard one. But what is a metal grille and why does it matter? A metal grille is a permanent fixture that can function as either an air supply or return vent. They’re typically found in ceilings or walls but can be installed in the floor if necessary. It’s common to see multiple grilles installed throughout office spaces, as opposed to one large installation – which is why it’s crucial that you have a seamless and professional design for the grilles.

Coco Architectural has been in the metal crafting industry for more than a century. We have tried and true experience to create the right metal grille for your space. Our team of metalwork professionals pairs time-proven techniques with top-of-the-line technology to create almost any product a customer could need.

Don’t let your interior design seem low-quality by using generic metal air grilles. Custom grilles will elevate your space’s aesthetic and relieve the stress of self-installation. Don’t believe us? Here are our top reasons why a custom air grille is worth the plunge.


Selecting an air grille seems like an easy decision, but many people don’t realize the amount of planning that goes into the selection process. First of all, have you properly measured the installation space? Do you need a flangeless (flush-mounted) or flanged linear bar grille? Will your project require access doors, welded support bars, concealed fastening or other installation hardware? If so, does the general store have these pieces in matching materials? This is just the start of the questions you’ll need to ask before selecting a metal grille for your space.

Luckily, ordering a custom grille can alleviate most of these concerns. It can be frustrating to go back and forth to the store to get a new size or find new, matching hardware. Instead of dealing with that hassle, our team can take your order, making sure to help answer all the necessary questions to get the perfect finished product – like our popular L-bead linear bar grilles.

The Coco Architectural L-bead linear bar grille is created with a custom method to ensure the best quality wall and ceiling grilles available. This includes:

  • Grilles that are ready to install on delivery
  • No reworks, rivets, or joining of dissimilar metals
  • Ability to choose between a welded or removable core grille
  • Fully-welded aluminum L-bead for maximum durability
  • Pre-punched mounting holes
  • Curved or mitered corner grille options
  • Ability to choose an A-frame, band frame or core-only grille

Flush plaster or drywall finish

Our patent-pending L-Bead installation option creates a flush finish for plaster or drywall installations of linear or perforated grilles. Also known as “mud-in,” this option provides the highest level of plaster recess and a removable grille core while preventing plaster cracking. Essentially, the finished product looks like it is part of the wall, as opposed to grille installations with metal fasteners that sit on top of the wall’s surface.

Ability to easily create matching metal products

Why limit yourself to just metal air grilles? Our all-inclusive metal fabrication facility provides our team with the capability to create an almost unlimited scope of products – even if it’s outside of our specialties of custom laser and waterjet cutting services, stainless steel fabrication and custom metal corner guards. We have created a wide variety of products, including desks, consoles, wall panels, handles and pulls, ornamental trim, railings, cladding, louvers, precision sheet metal, signage, tree grates, column covers, retail displays, trench boxes, headers and jams, convector enclosures and more.

Instead of worrying if your generic metal grille will match the other metal hardware in your space, let our team create custom, coordinating products. We work with a variety of metals, including aluminum, brass, bronze, stainless steel and steel. In addition, we can create a beautiful finish on your product with options that include satin/brushed, mirror polished, anodized, duranodic, blackened, baked enamel colors, statuary/antiqued and oil rubbed.

If you’re ready to take the plunge and choose your custom metal air grille, our team is ready and willing to help! Peruse our product catalog for a full, detailed list of products. For a consultation or to order your custom grilles today, contact us at 631.482.9449 or

Posted in : Products |  No Comments >>
Tags : N/A

Antiqued Finish for Architectural Design
Posted Mon, November 12, 2018

Antiqued Finish for Architectural Design title photo with vintage spiral staircase

If you’re rehabilitating a historic property to keep its original charm, an antiqued finish is the ideal choice for your metal installations. Antique metal finishes have been a popular product among metal manufacturers for decades. Demand for the product soared in the 1970s and has continued its popularity to this day. Antiqued finishes are most popular on bronze and brass products, such as our perforated metal grilles. The treatment creates a classic look often desired in a lobby, bedroom, living room or ballroom.

How it works

The metal antiquing process begins with a thorough cleaning of the metal. It is important to remove all oils, buffing compounds, fingerprints, oxides and other materials to prepare for a high-quality finish.

Test the cleanliness of the metal grille with a water-break test. After completing the cleaning process, dip the grille into clean water. Remove the product and watch for where the water beads as it drips. The beaded areas are not completely clean, whereas the water will consistently flow off the clean areas without breaks.

Once the grille is clean, it is time to begin the finishing sequence. To achieve an antiqued finish, the underlying base metal is uncovered in certain areas to create a worn appearance. Essentially, the finish is removed from the highlights – keeping the lower areas as they are. This process can be completed by buffing, tumbling or vibrating.

A buffing machine is essentially a turntable with many buffing wheels (constructed of cotton discs approximately a half inch thick and three to four inches wide). As the grille is moved around the turntable, the buffing heads work on certain sections with abrasive or polishing compounds.

Tumbling machines create an antiqued finish by rolling the metals against each other in a rotating drum. A vibratory finisher operates similarly in a bowl instead of a drum. By using wet or dry metals – or ceramic or plastic additions – these machines can buff the grille in unique ways. While you would think this would create randomized results, the machines can be programmed to create identical products time after time.   

After the desired antiqued finish is completed, a topcoat is applied to protect the grille from tarnish or corrosion. Typically, this solution is a clear lacquer.

brass and bronze pipes

Why choose an antiqued finish

At Coco Architectural, we offer antiqued finishes on brass and bronze products. These metals are optimal base metals for antiqued results. Brass and bronze contain high levels of copper, which creates a beautiful result after the buffing, tumbling or vibratory techniques are applied.

Many designers aim to maintain the original aesthetic during a historic renovation project. Antiqued finishes create the perfect design. You can install high-quality, new metal grilles that look like they are original to the building. Our team can construct custom metal products to match the original design when replacing the corroded or broken originals.

Our linear bar grilles, perforated metal grilles and custom metal products are all manufactured with the same standard of excellence and commitment to customer satisfaction. We offer a wide variety of metal finishing options including satin/brushed, mirror polished, anodized, duranodic, baked enamel colors, blackened, statuary/antiqued and oil rubbed. If you’re considering adding a specific metal finish to your project, download our catalog for compatible products and request a free quote.

Posted in : Products |  No Comments >>
Tags : N/A

Anodized Aluminum Finishes for Architectural Design
Posted Mon, November 5, 2018

Anodized Aluminum for Architectural Design feature photo with a metal grille across crown molding

Anodized aluminum is the ideal choice for many projects. From highly durable building exteriors to staircases in skyscrapers, anodized aluminum has a wide versatility for architectural design. It’s even trusted to protect satellites in space.

The sleek appearance of anodized aluminum is coveted by architectural designers. We’ve broken down the basics of anodized aluminum to help you determine if it’s the best solution for your project.

What is Anodized Aluminum?

Anodized aluminum is the final product of a finishing process called anodizing. To create anodized aluminum, the aluminum is placed into an anodizing tank containing a mounted plate (an electrode where electrons enter a cell and cause reduction). The aluminum is then submersed into an acid electrolyte solution while an electric current is passed through the tank.

Once the aluminum is submerged, a positive electric charge is added to it, causing it to become an anode. A negative charge is then applied to the plate, making it the cathode. The positive ions gravitate to the plate while the negative ions rush to the aluminum. This process is essentially a highly controlled oxidation process which results in anodized aluminum.

Colorants can be added to the anodization process where the pigment fills the empty pores on the surface of the aluminum and is permanently sealed. Color anodized aluminum has a metallic appearance due to the rough surface left behind after the electro-chemical process and the reaction between the electrical current, colorant, and uncolored metal.

Benefits of Using Anodized Aluminum

There are a variety of benefits of using anodized aluminum which are evidenced by the wide use of anodized aluminum in commercial, industrial, and consumer projects. Not only is it significantly lighter than copper, gold, brass, bronze, and stainless steel, but it has a strong formability, allowing it to be reshaped into many different designs.

cylinders of aluminum

Aluminum’s ease of use is bolstered by its durability. Aluminum is naturally resistant to most forms of corrosion and the anodization process increases its weather resistance. Since the anodized finish becomes a part of the metal through the oxidation process, it will not peel, chip, or flake away. During anodization, the base aluminum is enhanced with a corrosion-resistant and very strong finish, creating an extended lifespan.

Aluminum is also considered to be environmentally friendly and recyclable, lessening the architectural design’s environmental footprint. According to the Aluminum Association, approximately 75 percent of all aluminum produced since its introduction to the United States in 1990 is still in use. In addition, anodized aluminum is a much greener finish than coatings like paint. Anodizing is “recycle-neutral” and does not use toxic organics or volatile organic compounds (VOCs) prohibited by the United States Environmental Protection Agency (EPA).

Anodized aluminum is a crowd favorite among the architectural community. At Coco Architectural, we offer a variety of anodized colors and finishes for a variety of projects. View our product catalog for a detailed list of our products. For a consultation or to order perforated grilles today, contact us at 631.482.9449 or

Posted in : Products |  No Comments >>
Tags : N/A

History of the Parquet Perforated Metal Grille Pattern
Posted Thu, November 1, 2018

History of the Parquet Perforated Grille Pattern featuring photo of the parquet perforated grille

The parquet perforated grille pattern (CA815) is a popular choice for historic renovations hearkening back to the 17th century, as well as contemporary spaces with geometric themes.

Parquet (pronounced pahr-kay) is French for “flooring”, a term derived from the French word parc, translated to “an enclosure”. Parquet encompasses a variety of patterns and ornamentations to create unique, fluid designs. Essentially, the parquet design is made of geometric patterns, typically angular with squares, diamonds or triangles.

The origin of parquet

In 17th-century France, marble was the preferred flooring for the elite population, compared to dirt and concrete floors among the lower class. The most famous example of parquet flooring is seen in the  Palace of Versailles. Louis XIII began construction on the palace in 1630, yet the project was not completed until 1963. At this point, Nicodème Tessin, a Swedish Baroque architect, wrote, “parquetry is quite like paneling. There’s one single room in Versailles which parquet is not by squares…the entire rest is diamond-shaped in the new style.”

The parquet de Versailles was widely popular in the 18th century and was kept in style through Louis XIV, Louis XV and Louis XVI. At the time, only a few professionals had the skill required to hand-cut and lay the wood in the proper patterns, so parquet flooring was considered a work of art and only available to the extremely wealthy. To construct parquet flooring, geometric shapes are cut out of wood and glued to a concrete sub-floor. The pattern was adopted by other well-to-do aristocrats and modified to fit their taste.

example of parquet flooring in the Palace of Versailles

[“Salon de Mars” by Jorge Láscar is licensed under CC BY 2.0.]

Another example of parquet flooring among the elite is found at The Château de Maisons-Lafitte, which features parquet flooring with floral ornamentations. Luckily, these architectural works of art are still viewable today. After Louis XVI was forced to leave the Palace of Versailles during the French Revolution, the building was still considered a work of art. In 1837, it became the Museum of History in France by King Louis-Phillippe.

Parquet patterns

There are a wide variety of parquet patterns, the most popular of which is herringbone. Other patterns include brick, hexagon weave, Bordeaux, Brentwood, Celtic, Chantilly, Versailles, chevron, basket weave and others. The key to parquet flooring is to begin in one section of the room (in Versailles, the flooring always began at the fireplace) and move to the other end. This keeps the pattern unidirectional and uniform.

parquet pattern created with rustic wood floor

CA815 Parquet Perforated Grille

The CA815 Parquet perforated grille is based on the square basket weave parquet pattern. The alternating directions of the squares create an entrancing design popular in both historic renovations and contemporary builds. This pattern provides 30 percent free air flow through the 1 3/16” squares.

Is the parquet perforated grill the perfect perforated metal grille for your space? Our team is happy to discuss installation options or assist you in selecting an alternative pattern. Make sure to view our product catalog for a full, detailed list of our products. For a consultation or to order your perforated grilles today, contact us at 631.482.9449 or


Posted in : Products |  No Comments >>
Tags : N/A

Satin Stainless Steel for Architectural Design
Posted Mon, October 29, 2018

Satin Stainless Steel for Architectural Design - satin stainless steel outdoor installation

A satin metal finish, also known as No. 4 in industry terms, is an all-purpose, polished finish that gives the metal a smooth, unidirectional appearance. Available for aluminum, brass, bronze and stainless steel, the satin finish is a trendy addition for most projects. Here at Coco Architectural Grilles & Metalcraft, we offer satin/brushed finishes where the smooth, frosted look of satin stainless steel is achieved through a brushing technique.

How it works

Satin finishes are created through a process called metal brushing. This can be achieved with a metal brush, sandpaper or another abrasive material. In many cases, a grit belt is used for speed and efficiency.

After the metal has been cut into the chosen grille pattern, it is polished with a fine bristled brush in a unidirectional motion. It is then softened with a greaseless grit compound or abrasive, nonwoven belt or pad to create a matte finish. The result is a frosted appearance with fine lines in the direction of the brushing.

satin stainless steel

Why satin stainless steel

Satin stainless steel not only protects the metal from rust and corrosion, it also creates a trendy, modern appearance. Satin finishes are popular in heavily trafficked areas such as kitchens, bathrooms and stairs, as it is not likely to smudge or show fingerprints.

This finish is also commonly used in rooms with natural lighting because the metal becomes less reflective after the satin finish is applied. This creates the satin sheen the finish is named after.

Our linear bar grilles, perforated metal grilles and custom metal products are all manufactured with the same standard of excellence and commitment to customer satisfaction. We offer a wide variety of metal finishing options including: satin/brushed, mirror polished, anodized colors, duranodic, baked enamel colors, blackened, statuary/antiqued, and oil rubbed.

If you’re considering adding a specific metal finish to your project, download our catalog for compatible products and request a free quote.

Posted in : Products |  No Comments >>
Tags : N/A

Go to > 1 2 3 4 5 Next >
Last >>
Blog Categories
RSS All Posts
RSS Products
RSS Projects
<< May 2019
Sun Mon Tue Wed Thu Fri Sat
Email Signup