How Australian Roofs Went from Timber to Iron!
Long before corrugated iron became a familiar sight across Australia, early buildings relied on whatever roofing materials were locally available.
During the early years of European settlement, roofs were commonly covered with sheets of tree bark or timber shingles (also known as shakes). Large sheets of bark, particularly from stringybark and box trees, could be removed and prepared for roofing. Timber shingles were split from suitable trees, including ironbark and forest oak, and laid in overlapping rows across timber battens to shed rain.
Thatch, made from grasses and other plant materials, was another traditional roofing option in some settlements.
These materials served their purpose, but had disadvantages. Timber shingles required regular maintenance and could split or become dislodged in strong winds. Bark roofing was difficult to gutter effectively, while thatch and timber presented significant fire risks.
As settlements expanded, builders increasingly looked for roofing materials that were more durable, easier to transport and less vulnerable to the elements.
IT STARTED IN BRITAIN
The idea of corrugating thin metal sheets to make them stronger and more rigid was developed for building applications in Britain. English civil engineer Henry Robinson Palmer (1795–1844) patented his corrugated iron building system in 1829.
Palmer was no ordinary inventor. He had worked under celebrated engineer Thomas Telford and was one of the eight founding members of the Institution of Civil Engineers, established in London in 1818. His engineering interests extended to railways, roads, canals and dock construction.
However, the commercial production of consistently corrugated sheets took further development. According to the NSW Heritage Office, successful corrugating techniques emerged in the early 1840s, with grooved rolling machinery in use by 1845.
Another important figure was Richard Walker, who acquired Palmer's patent and helped develop the commercial use of corrugated iron. He also pioneered the concept of portable corrugated-iron buildings for export to Australia, an idea that became particularly attractive during the gold rushes.
THE ADVENT OF GALVANISED IRON
There was another problem to overcome: rust.
Iron exposed to rain and moisture corrodes, making it unsuitable for long-term roofing unless protected. The development of galvanising, a process that coats iron with zinc, provided the solution.
In 1837, Henry Crawford patented a method of coating metals with zinc, helping establish the foundations of commercially successful galvanised iron production.
By combining the strength of corrugation with the corrosion protection of galvanising, manufacturers had a product that was relatively lightweight, durable and practical for buildings.
CORRUGATED IRON ARRIVES IN AUSTRALIA
By around 1850, corrugated galvanised iron was appearing in Australian markets. An advertisement in the Sydney Morning Herald on 14 February 1850 promoted the material as a durable and economical building product.
The material offered considerable advantages over traditional bark and timber-shingle roofing. Its sheets could span between timber battens, reducing the amount of supporting framework required. They were also relatively easy to stack, transport by ship and move inland by horse and cart.
The gold rushes of the 1850s created enormous demand for quickly constructed accommodation, shops, workshops and commercial buildings. Prefabricated iron buildings could be manufactured in Britain, dismantled, shipped to the colonies and assembled on arrival.
Gradually, corrugated iron became a defining feature of Australian towns, country homesteads, railway buildings and rural industries.
ENTER JOHN LYSAGHT
One name that would become almost synonymous with corrugated iron was John Lysaght (1832–1895), an Irish-born engineer and industrialist.
In 1857, Lysaght established a galvanising business in Bristol, England, manufacturing iron products for an expanding industrial market. His business developed into a major manufacturer and exporter of galvanised iron.
Around 1860, his famous ORB brand of galvanised corrugated iron began attracting attention in the trade. The brand became internationally recognised and particularly familiar in Australia.
But Lysaght's business was about much more than roofing. His manufacturing interests included structural components for railway stations, warehouses, docks and churches, as well as wire netting and other metal products.
Recognising Australia's growing demand, the company established the Victoria Galvanised Iron and Wire Company in Melbourne in 1880, creating a stronger commercial presence in the Australian market.
MADE IN AUSTRALIA
For many years, Australian supplies depended heavily on imported British products. That changed in April 1921, when John Lysaght (Australia) commenced large-scale corrugated sheet manufacturing at Newcastle, New South Wales.
It was an important milestone in the development of Australia's domestic steel and building-products industry.
A LASTING LEGACY
From the early timber-shingle roofs of colonial cottages to the galvanised iron shearing sheds and country homesteads that became icons of the Australian landscape, roofing materials have come a long way.
And here's one interesting detail: when old corrugated iron roofs are removed from heritage buildings, original timber shingles can sometimes still be found underneath. They are valuable physical evidence of the building's earlier construction history.
Also, although we still commonly call it corrugated iron, much of the material used today is actually galvanised steel. The transition from wrought iron to mild steel took place as steel manufacturing improved between approximately 1890 and 1910.
So, the next time you see an old corrugated iron shed, spare a thought for Palmer, Walker and Lysaght. Their contributions helped transform the way buildings were constructed, not just in Australia, but around the world.
Not bad for a few ridges and grooves!
SOURCES & FURTHER READING
For those interested in exploring the history of corrugated iron, early Australian roofing materials and the people behind the industry, we've put together the following selection of historical, academic, government and archival references.
1. EARLY AUSTRALIAN ROOFING – BARK, TIMBER SHINGLES & THATCH
• University of Melbourne – Miles Lewis: Roofing https://acahuch.msd.unimelb.edu.au/miles-lewis-heritage-building-collection/roofing2
• Byron Shire Council – Roofing and Guttering Heritage Fact Sheet https://www.byron.nsw.gov.au/files/assets/public/v/3/hptrim/information-management-publications-forms-application-templates-current/heritage-fact-sheet-roofing-and-guttering.pdf
• History SA – Building Materials https://sahistoryhub.history.sa.gov.au/subjects/building-materials/
2. HENRY ROBINSON PALMER, RICHARD WALKER & THE DEVELOPMENT OF CORRUGATED IRON
• University of Edinburgh – Corrugated Iron Buildings in Britain: Cultural Significance and Conservation Challenges (Elizabeth Induni, 2020) https://era.ed.ac.uk/items/b81b1ca0-34de-4c10-803c-923d6f84c6fa
• State Library of NSW – Architectural Plans of Iron Buildings and Prefabricated Houses, 1850–1859 https://archival.sl.nsw.gov.au/Details/archive/110090514
• NSW Heritage Office – Corrugated Roofing, Information Sheet 4.1 https://www.environment.nsw.gov.au/sites/default/files/heritage-maintenance-corrugated-roofing-information-sheet.pdf
3. JOHN LYSAGHT, THE ORB BRAND & THE AUSTRALIAN INDUSTRY
• Lysaght – The Metal Trades' Referee and Storekeepers' Guide (1897) https://cdn.dcs.bluescope.com.au/download/lysaght-the-metal-trades-referee-and-storekeepers-guide
• Bristol Museums – Lysaght's Catalogue (1908) https://museums.bristol.gov.uk/narratives.php?irn=2894
• Lysaght – 100 Years of Local Manufacturing https://lysaght.steelselect.com.au/articles/lysaght-celebrates-100-years-local-manufacturing
• NSW State Records – John Lysaght (Australia) Limited https://www.nswera.net.au/biogs/UNW0075b.htm
A NOTE ABOUT OUR RESEARCH
At the Dave & Malou Channel, we believe historical storytelling should be supported by reliable research. These references provide further reading and allow interested readers to explore the original historical records, academic research and heritage documentation behind this story.
We encourage readers to consult the original publications and archival material for additional context.
Happy researching!
