The Flag’s Beginnings
The Star-Spangled Banner’s history starts not with Francis Scott Key, but a year earlier with Maj. George Armistead, the commander of Fort McHenry. Knowing that his fort was a likely British target, Armistead told the commander of Baltimore defenses in July 1813 that he needed a flag—a big one. “We, sir, are ready at Fort McHenry to defend Baltimore against invading by the enemy…except that we have no suitable ensign to display over the Star Fort, and it is my desire to have a flag so large that the British will have no difficulty in seeing it from a distance.”
Armistead soon hired a 29-year-old widow and professional flagmaker, Mary Young Pickersgill of Baltimore, Maryland, to make a garrison flag measuring 30 by 42 feet with 15 stars and 15 stripes (each star and stripe representing a state). A large flag, but one not unusual for the time. Over the next six weeks, Mary, her daughter, three of Mary’s nieces, a 13-year-old indentured servant and possibly Mary’s mother Rebecca Young worked 10-hour days sewing the flag, using 300 yards of English wool bunting. They made the stars, each measuring two feet in diameter, from cotton—a luxury item at the time. Initially they worked from Mary’s home (now a private museum known as the Flag House), but as their work progressed they needed more room and had to move to Claggett’s brewery across the street. On August 19, 1813, the flag was delivered to Fort McHenry.
For making the Star-Spangled Banner, Mary was paid $405.90. She received another $168.54 for sewing a smaller (17 by 25 feet) storm flag, likely using the same design. It was this storm flag—not the garrison flag now known as the Star-Spangled Banner—which actually flew during the battle. The garrison flag, according to eyewitness accounts, wasn’t raised until the morning.
http://www.smithsonianmag.com/history/the-story-behind-the-star-spangled-banner-149220970/