Barrels and Buckets
52
barrel, and, as the smoke poured out the top hole, they hammered wooden
and iron hoops onto the staves, forcing the barrel to curve around the tapers
of its staves. The staves heated and dried as they hammered, but if they had
been made well, they bent and did not split. When all the hoops were in
place, the barrel’s curved shape was fi nished.
The cooper then shaved the barrel smooth inside and out; a rough inner
surface collected bacteria and made ale spoil unless its alcohol content was
high. He made the fl at end covers (heads) by pegging staves together with
wooden dowels into two small solid boards. He cut them into the proper-
sized circles to fi t into the ends of the barrel and shaved them to have the
correct angles. The curved staves were now dry and would not change their
shape if the iron hoops were removed, so the end hoops (called chimes)
were loosened to let the round heads into their places. One by one, they
fi tted into the notches cut in the staves’ ends. A fi nished barrel had all
of its iron hoops hammered tightly into place. A well-made wine or beer
cask could be used for 50 years.
The last step was branding the barrel, no matter what size or purpose
it was meant to serve: bucket, churn, wine tun, ale fi rkin, or beer barrel.
Every cooper in the guild had his own branding iron to mark his bar-
rels. When a cooper died, his iron was immediately taken to the guildhall
so nobody could forge his mark on substandard barrels. It was illegal to
use unmarked barrels—since no cooper had certifi ed their legal size, they
were usually too small.
Barrels came in all sizes, and they had different names. Hogsheads, kegs,
butts, barrels, fi rkins, pipes, casks, tuns, and kilderkins were specifi c sizes
that were used in certain industries. Sweet wine was sold in butts, small bar-
rels holding only 18½ gallons, or in pipes, which were larger. Ale came in
30-gallon barrels and beer in 36-gallon barrels, the size that is most com-
mon today. Most wine came in casks, if not the larger wholesale tuns.
Since the industries that used these containers could not independently
measure the amount of liquid they poured in, they trusted the coopers to
make them correctly so customers would not be cheated. When coopers
used green wood, over time the barrels shrank and became illegal measure-
ments. By the middle of the 15th century, offi cials outlawed the use of un-
seasoned oak. Coopers were permitted to recycle old barrel staves as long as
they had not contained anything noxious like tar, soap, or oil. When barrels
wore out, coopers were able to fi x them.
Beginning in the 13th century, German coopers along the Rhine River
began competing to make the largest cask. It became a tradition, and the fi -
nal record was not set until the 18th century with the Heidelberg Tun,
which used more than 100 oak trees.
See also: Beverages, Hygiene, Kitchen Utensils, Weights and Measures.