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Sole surviving John Nash church given Welsh slate roof

2024-03-27

All Souls Church in Marylebone, London has celebrated its bicentenary with a new roof from Welsh Slate as part of a large scale refurbishment of the John Nash designed Grade I listed church.

This is known to be the only surviving church by Georgian and Regency era architect John Nash and sits in the Harley Street Conservation Area and was built in 1824. In 1940, it was damaged by bombing and the roof was renewed during the post-war rebuild. As a result, it is estimated that Welsh slates that were most recently replaced were likely to be about 75 years old.

It has been reroofed with Penrhyn Heather Blue slates and these were installed over 240m2 of the main nave roof, which has a pitch of 28°, using thick copper nails, and the flat roofs of the aisles, half of which had been covered in copper after the Second World War, were laid with 16 tonnes of lead by roofing contractors Lead Roof Solutions for the main contractor, Quinn London. 

The roof, which is hipped at the south-west end and incorporates a timber louvred structure for ventilation, is also fitted with several conservation rooflights which sit flush with the slates. To improve ventilation, the Welsh slates were counter-battened to raise the roof level, and to incorporate this, secret gutters were used at the abutments and around the rooflights. A slate and a half were employed on all abutments, and ridges and hips were finished with a lead roll and wing detail.

The first phase, to the external fabric, required a temporary roof and full scaffolding reaching to the top of the spire which now has ability to light up in any colour to suit the seasons and festivities. The scaffolding had to be engineered in great detail as the church occupies 100% of its ownership footprint.

Specifiers Matthew Lloyd Architects, who specialise in historic and heritage buildings and are a conservation-accredited practice, have specified Welsh Slate on numerous occasions for a variety of church and secular buildings.

Director Alex Sherratt explained that during All Souls’ quinquennial inspection in 2019 it was identified that the slate roof and remaining areas of copper roof had numerous defects and were near the end of their serviceable lives. In addition, there were a number of stonework and other issues which required attention. The client, the parochial church council, therefore decided to carry out a single conservation project on the entire external building fabric, to leave it in the best condition possible for its bicentenary in 2024.

Alex said: “Welsh Slate was the natural choice, as the church would always have been roofed in Welsh Slate from its original construction in 1824. Re-roofing the nave in Welsh Slate was possibly the most significant element of the project, as it prevents problems with ongoing water ingress, and contributes greatly to the longevity of the roof, and the church as a whole.  

"The church is an iconic building, occupying a key position on Regent Street, and is highly visible from the surrounding streets, therefore the aesthetic qualities of Welsh Slate were a major consideration. The roof at All Souls is overlooked from BBC Broadcasting House and is often used as the backdrop for filming current affairs programmes from the studios and rooftop terraces.

“One of the driving factors behind the project was the need to extend the lifespan of the building as far as possible by using appropriately durable materials. The 100+ years of useful life offered by Welsh Slate was an important factor in the selection of Welsh Slate for a roofing material at All Souls. The fact that the material is 100% natural and has a low carbon footprint were also important considerations in the specification of Welsh Slate.”

Phase Two of the refurbishment of the church will focus on the building's interior.

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University of Sheffield select HIMACS wall cladding

2024-03-27

Sheffield University's Faculty of Social Sciences has undergone a large scale transformation with the introduction of a mini campus called The Wave – uniting facilities that were previous spread across 18 separate buildings. Designed by HLM Architects with a budget of £65m, the nucleus of the project is The Drum – a circular lecture block comprising three levels with lecture theatres inside, surrounded by mezzanines with tables and chairs for study or socialising and topped with a glass roof to let the light flood in.

The Drum is fully clad in 500 sheets of LX Hausys' HIMACS solid surfacing in Alpine White S028, which was sourced from Latham Timber. More than 1,300 individual pieces were then thermoformed  by fabricators 3G Joinery & Shopfitting in Leeds to complete the design.

Amy Hipwell, Interior Designer at HLM Architects, explains why they selected HIMACS for the project: “There were a number of key considerations when choosing the material that would clad the Drum within the atrium of The Wave building. The material needed to be durable and low maintenance with the ability to be curved and appear seamless. The Drum is a central feature of the atrium and is not only visible from every area within the building but it’s also accessible from every level.

“The concept for the interior focused on well-being and the use of natural materials. The chosen material for the Drum needed to contrast against these softer finishes. Due to the amount of daylight through the atrium roof, it was important that the colour wouldn’t be affected over time. It became clear that solid surfacing was the right material, as it would stand the test of time and still look impressive in years to come.”

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Deadline to enter SkillBuild approaching

2024-03-22

There's just a couple of weeks left to enter the largest multi-trade skills competition in the UK for construction trainees and apprentices. SkillBuild is delivered by CITB and is open to apprentices and full-time learners in the UK – and tutors and employers can enter on behalf of apprentices and students, too. The completion includes trade sponsors including Albion Stone and is supported by organisations such as the Natural Stone Industry Training Group (NSITG).

Regional Qualifiers will take place in 19 locations across the UK and during these one-day events apprentices and trainees will complete a set task relevant to their trade. On completion of the task,  marks are collated and the eight highest-scoring competitors in each specialist skill go through to the next round – the SkillBuild National Final.

The deadline for applications is 1 April 2024. Register now by following this link.

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Stone of Destiny arrives at its new home in Perth Museum

2024-03-19

The Stone of Destiny, also known as the Stone of Scone, has left Edinburgh Castle during a ceremony attended by First Minister Humza Yousaf and arrived at its new home, Perth Museum, which is due to open at the end of this month.

This marks the first time in more than 700 years that the Stone has returned to Perthshire and it will be a central attraction of the new museum housed in the former Perth City Hall. This Edwardian building was saved from demolition by Historic England in 2012 and in 2019, work began on a £27 million redevelopment project to transform the building into a museum.

It is expected that demand to see the Stone will be high and free tickets to view it on the Museum's opening weekend, (30-31 March) will be released online at 10am on 22 March. Visitors will be taken on a 10-minute immersive, journey through the Stone’s long and mysterious history, before seeing the Stone. 

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Cumbrian quarry trials new live air monitoring equipment

2024-03-18

Burlington Stone in Kirkby-in-Furness has recently become the first quarry in the UK to trial new live air monitoring equipment as part of an initiative by the Minerals Product Association (MPA) in conjunction with Trolex Engineering.

The quarry's broad range of minerals, products and applications made it an ideal choice for the trial. These wearable monitors continuously assesses the quantity of fine particles in the air, providing live as-it-happens data to managers in the factory.
 
While dust and RCS (respirable crystalline silica) monitoring is a legislative requirement, samples are currently sent away for analysis however these monitors can deliver results instantly and identify any spikes throughout the day. However, these monitors are not designed to replace the regulatory requirement of sampling, but to help managers know in real-time the air quality, meaning action can quickly be taken to address any problems.
 
Pete Walker, HSEQ manager at Burlington, which is part of the Holker group, explained:  “We create everything here, from roofing slates to gravestones, kitchen worktops to aggregate for roads and driveways, so we are cutting and breaking stone in every which way possible, and the stone we quarry has around 40% silica.”

“I can identify the hotspots immediately,” Pete continued. “There is a safety level and the regulatory sample might show that the activity produced a sample that was under that over the eight-hour period. However, under those current tests we wouldn’t know if one particular aspect of that activity is more risky during a different stage of the process or different time of the day.”
 
“The data was absolutely invaluable to us,” he said. “It certainly opened my eyes: it helped us to see, for example, that in part of the factory we have 10 employees all doing the same activity, using the same tools, at the same time, but because of their different techniques we found a substantial difference in total dust particles from one end of the factory to the other.

“We are able to use these monitors to better and more quickly understand a new machine or new process, so we could monitor that in live time and get a real understanding without having to wait for the laboratory analysis.

“We are the first to kickstart the trial because, although we are not one of the major national quarrying companies, we do every element of quarrying and a wide variety of downstream added-value processes here which is extremely rare. We also got involved because we want to be part of what the industry is leading on.”

As a result of the three-week trial that took place in January, Burlington has already identified some improvements and their findings will now be analysed and shared with the MPA and Trolex and the rest of the industry.

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Neolith launch two new products

2024-03-14

Neolith has today announced the launch of two new products inspired by natural landscapes and materials including marble and volcanic rock. Calacatta Roma is representative of Italian Carrara marble with ochre and grey veining on a white background, while Cappadocia Sunset is inspired by Turkish rock formations caused by volcanic eruptions.

Both Calacatta Roma and Cappadocia Sunset will form part of Neolith's The New Classtone and Fusion collections which interpret marble and natural stone, respectively, and offer NeolEAT technology to hamper bacteria growth on countertops. The products, created from natural, raw materials contain no added quartz to their formulation and can also be recycled at the end of their usable life.

Calacatta Roma and Cappadocia Sunset are now available through Neolith's own international distribution centres, as well as its global network of distributors. The new models will be available to all channels within the UK & Ireland including A&D, kitchen and bathroom showrooms, and housebuilders.
 

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Worktop supplier sentenced after death of worker

2024-03-14

The director of a worktop supplier in the West Midlands has been sentenced following the death of a worker who was crushed by two granite slabs each weighing 250kg in 2020.

Robert Czachracz, a 46-year-old from Poland, had been unpacking and moving the slabs onto storage racks, using an overhead crane, at Graniteland's Lyde Green site in Halesowen.

An investigation by the Health and Safety Executive (HSE)  found Graniteland Limited and its director, Mr Shu Lai Li, "failed to implement staff training or develop safe systems of work for the unloading, loading and handling of granite slabs. There was no evidence that employees had received training in the safe operation of machinery, including the overhead crane. The overhead crane and forklift truck had also not been thoroughly examined, as required by law, and that webbing slings, that could have been used during the unpacking process, were damaged."

Graniteland Limited, of Lyde Green, Halesowen, pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc. Act 1974. The company was fined £18,000 and ordered to pay £4,196.03 in costs at Dudley Magistrates’ Court on 6 March 2024.

Mr Shu Lai Li, of Lyde Green, Halesowen, pleaded guilty to breaching Section 37(1) of the Health and Safety at Work etc. Act 1974. He was ordered to complete 120 hours of unpaid work and pay £4,043.42 in costs at Dudley Magistrates’ Court on 6 March 2024.

Mahesh Mahey, inspector at HSE said: “This was an entirely preventable accident. The risks of lifting and moving granite slabs were obvious, yet could have been controlled by relatively simple and inexpensive measures. The company and director failed to adequately control lifting operations which resulted in an employee needlessly and tragically losing his life.”

HSE guidance states employers must manage and control the risks to avoid any injury or damage during lifting operations. Information on Lifting Operations and Lifting Equipment Regulations (LOLER) can be found on the HSE website.

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Will Davies - My story so far

2024-03-12
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How did I get here? It’s a question many of us ask ourselves but here’s how sculptor and mason Will Davies found his own way
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It was a sunny morning in May 2001, I was 20 and sitting on Bournemouth beach trying to think of an excuse to get out of my 10am interview at what is now Arts University London.

I had already had interviews at most of the London art schools and a few others around the country, but none felt right.  I called the receptionist at the university and apologised that my train from London had been cancelled and I was stuck at Waterloo Station. The receptionist had enough time to say “but I can hear waves and seagulls in the background, are you on the beach?” before the line went dead. It must have been something about the sea air that stirred a gut feeling that this wasn’t the right path for me, although I didn’t know what the right path would be.

That evening, I went home and told my parents what I’d done. During the following conversation Mum suggested stonemasonry.  She had grown up in Winchester and had been friends with the masons that worked at the cathedral. My great grandfather sang in the cathedral choir and had taken her in as a child to sit in the choir stalls while he sang.  Her father had a building firm, The Webb Bros in Winchester and had worked on many of the local churches. Me and my sister used to love climbing in his dusty blue pick-up truck while he drove around proudly showing us the work that he’d done around the town and neighbouring villages. My paternal grandfather in Yorkshire had a garage full of wood and tools and would set simple carpentry projects to keep us busy when we went up there to visit them. It was at this point in the early 2000s I set my sights on working as a stonemason at Winchester Cathedral, a building that my family have grown up with and love.

Stonemasonry offered a vocational option for somebody practically and creatively-minded and I found the Architectural Stonemasonry Course at Weymouth College in the UCAS book and enrolled. Over the two-year course we learnt how to work architectural details in stone – ball finials, tracery and mouldings as well as geometry and geology, and the importance of working to 1mm tolerances.

Following the course, I was offered a job with the Cathedral Works Organisation (CWO), a restoration company based in Chichester and London which is sadly no more. In my interview, their only prerequisite seemed to be that I didn’t have a criminal record. I told them that I had a caution for ‘fishing without a licence’ and they laughed.

At 22, I moved to London and worked on their sites there. A day on a masonry site is like a team building exercise. How will we move that stone that weighs half a ton from here to there, and then get it up onto there? Just doing that involves problem-solving, using simple mechanical aids (levers, pulleys, fulcrums, made up from bits of wood and scaffold tube found lying around), communication, co-ordination of movements, physical exertion, and paramount, an awareness of your teammates’ safety. You have their safety in your hands most of the day, and yours in theirs. This environment builds bonds and trust quickly. The banter that goes along with it teaches you how to laugh at yourself and how to not take life too seriously. There is a book called Stone Mad written by an Irish stonemason, Seamus Murphy, which describes this environment perfectly and far better than I can.

Countless people have helped me along the way but the four that stand out are Adam Stone, Jack O’Brian, Matt Pullen and Glen Daley.  Adam was the director of CWO (now director of Chichester Stoneworks) and has continued to act as a mentor for me to this day. Jack and Matt are both masons who I worked with as a mason’s mate. They taught me the importance of having pride in your work, your workplace, and most importantly your tools and other people’s tools. Glen was a site foreman, and one of the best managers I have had, striking the balance perfectly between authority and friendship.

When we  were working on the restoration of St Georges Chapel, Windsor Castle, where I met students from The City & Guilds of London Art School (CGLAS).  They had been carving grotesques and were on site fixing their creations into the building. This was the art school I had been looking for some eight years previously.  The three years I spent at CGLAS were the best three years of my life. Diane Magee taught an incredible and pivotal life-drawing course that ran alongside the Historical Stone Carving Diploma for the full three years. Kim Amis taught portraiture in clay, and mould making. There were a number of practicing professionals who each taught a day a week in their discipline, letter carving and design, and architectural stone carving and it was led by the course leader, an incredible mason and sculptor, Nina Bilbey. After my graduation, CGLAS took me on as a part-time technician for a year, and then as a part-time tutor, which I did alongside freelancing in London.

 

Bronze busts for the Battle of Britain Memorial Trust

Bronze busts for the Battle of Britain Memorial Trust

I left CGLAS with a huge amount of debt but it was worth it. Through the CGLAS course and a scholarship from The Queen Elizabeth Scholarship Trust, I was introduced to many contacts and opportunities which were invaluable. I was fortunate to be involved in the fabrication of the prow sculpture for the Queen’s Jubilee barge, and was asked to produce two bronze busts of WWII heroes for The Battle of Britain Memorial Trust among other projects.

I eventually got fed up with the expense of London, paying off debts, but still not being able to afford to live and save, I left and spent a year in the South of France.

I returned to England having been offered the opportunity to help carve four 5-metre long lions with Chichester Stoneworks. As that job finished, a masonry job came up at Winchester Cathedral in 2013. I applied and was thrilled to be offered a position. When I started, there was an Heritage Lottery-funded project which provided mountains of work for a small team of three masons and two apprentices.  We worked well as a team under the direction of another great manager, Ian Bartlett, who has since moved on to become the clerk of works at Westminster Abbey. Ian’s strength – a Viking of a man – came from the trust and respect that he had in his team to do the work they specialised in. In return he earnt our respect. Like Glen and Nina, Ian is able to navigate the line between authority and friendship with an instinctual dexterity.  The defining attribute of all the good managers that I’ve had the privilege to work under, Adam, Glen, Nina and Ian, seems to be that they ensured that the happiness of their team was as important as the work they were doing.

After six years at the cathedral, I was offered the promotion to head mason. With my family history in Winchester, I took this role with a great sense of pride. It was also a welcome challenge. For the five years following the completion of the HLF project we had not worked on conserving the cathedral in the capacity that we, as a team were able. I took the opportunity to create projects that suited our abilities and continued the restoration of the beautiful building where it needed it most. The projects chosen would also enable us to employ an apprentice, and a chance to pass on the valuable skills required for protecting the country’s built heritage to the next generation. There are only nine cathedrals with working masonry departments left in the country, and they are one of the few places where traditional techniques of masonry can still be taught.  These nine workshops are tied together by The Cathedral Workshop Fellowship (CWF) through their brilliant career development diploma course in conservation.

It was in my final year as head mason that I was approached by The James Caird Society who wanted to commission a memorial stone for the heroic achievements of Sir Ernest Shackleton, to be installed in the Cloister of Westminster Abbey.  This was a career defining opportunity but involved sacrifices. To remain in my post as head mason, or to return to self-employment and accept the offer. I decided it was an opportunity too good to pass up and eventually took the plunge to go it alone again. I am enormously proud of the mark that I have left on Winchester Cathedral.

At the outset of the commission, The James Caird Society members gave me the inscription and two items that must be included in the design. One was the use of a beautiful olive-green marble from Connemara to reflect Shackleton’s Irish heritage. The second was that a triangle should feature somewhere in the design. When composing photographs, Shackleton would create a triangle within the composition. When designing any piece of work, I find that an image is quickly formed in my head of what the final piece will look like.

The design I had in mind would take influence from the shape of The James Caird — the modified lifeboat in which Shackleton and his team navigated 800 miles of treacherous Antarctic waters. This would be made in Carrara marble and, with its grey marbled streaks and beautifully translucency with an icy quality would form the cartouche, or main body of the memorial. Fixed into the upper half of the memorial would be a subtly convex globe, showing Antarctica centrally and the surrounding landmasses around the outside. The globe would be formed from Kilkenny limestone that when polished is a deep black, punctuated by silvery-grey shells, and resembling a clear night sky. The two stones together would contrast well and create the imagery of an Antarctic landscape at night. Antarctica itself would be inlaid into the globe with Carrara marble, and the continents of Africa, India and Australia would be inlaid with the Connemara marble, all worked back to be flush with the Kilkenny mother stone, to a fine polish that would highlight the lovely features of all the stone together. The inscription would in part run around the chamfered edge of the cartouche. On the face of the cartouche, the inscription would fit inside a triangle, completing the wishes of the commissioners.

 

Will with HRH The Princess Royal at the special dedication ceremony for the Sir Ernest Shackleton memorial at Westminster Abbey
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Will with HRH The Princess Royal at the special dedication ceremony for the Sir Ernest Shackleton memorial at Westminster Abbey

As I write this, I’m still on a high as the memorial has just been unveiled by HRH The Princess Royal at a special dedication ceremony at Westminster Abbey. It was wonderful to meet her and she was very complimentary about my work – it all feels very surreal.

 

Will received a Duke of Gloucester Award for Excellence in the Craft of Stonemasonry

Will received a Duke of Gloucester Award for Excellence in the Craft of Stonemasonry

And in December, I was awarded a Duke of Gloucester award from the Duke himself – another career highlight.

I am writing this for the benefit of the people who are leaving school or college, sitting on a beach not knowing what direction they want their life to go, not knowing what careers are available to them. I was lucky that my mother suggested masonry to me as a career, and that we had a ‘craftiness’ in our family already. When I started working it was rare to meet a female stonemason, but over the years that has changed. On most of the CWF cohorts there is nearly an equal split of male and female students, and many more women are entering the trade. The industry is in desperate need of experienced and passionate workers to continue the conservation and care of our heritage, and it all starts at apprenticeship level.  I have made a career out of working with a material that I love, and not a day of it has felt like work.

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Smile Plastics turn waste to wonder

2024-03-12
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As a zero-waste restaurant, it was only natural that owner Douglas McMaster of Silo in London wanted furniture and fittings that fit in with this ethos. They are so committed to sustainability that butter is churned on site, wheat is ground into flour and oats are rolled – even the drinks are fermented from live cultures on the premises. Produce delivered to the restaurant arrives in reusable vessels, and the natural waste is turned into compost.

Nina Woodcroft at Nina + Co led the interior design and specified that only recycled materials were to be considered. This led to a collaboration with Smile Plastics. Based in Swansea, Smile Plastics has been in business for more than 30 years and takes pre- and post-consumer waste including discarded packaging and chopping boards – even white goods – and turns them into architectural panels and aesthetic surface products in its own factory.

For this project, a bar top next to the open kitchen was to be the focal point and was created with Smile Plastics’ ‘Grey Mist’ while a private dining table features multicoloured ‘Kaleido’. Other tabletops are monochromatic in design and showcase ‘Charcoal’ with white flecks.

Smile Plastics also created chopping boards, splashbacks, a host stand, mirror frame and coat hooks for the restaurant. This blend of textures and tones creates a relaxing ambience and showcases the versatility of recycled materials.

On completion of the project, Smile Plastics co founder, Rosalie McMillan, said: “Working with Silo restaurant was a dream come true for us. When we meet likeminded brands that share so deeply in our vision, it fills us with excitement for the future. What the team at Silo have achieved is truly amazing – a fantastic example of how the circular economy can be fully adopted with no impact to commerciality. We’re extremely proud to have our materials in the space.”

 

Smile Plastics' Earth Collection
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Smile Plastics' Earth Collection

Inspired by nature

Smile Plastics recently launched a new range called Earth Collection inspired by the intricate patterning found in the fine detail of solid natural matter and the landscape close to its factory in the Welsh countryside.

“Like our belief in celebrating imperfections, each recycled plastic surface tells a story of transformation. These stories are woven into the hues of Mawn, the calm balance of Brecon, the nod to our heritage in Slate, Quarry, Limestone, and the poetic mysticism of Grey Mist; all showcasing the nuanced charm of the Welsh landscape. By incorporating these surfaces, you not only bring nature indoors but also contribute to a healthier, circular manufacturing process – a crucial step for our built environment's sustainability,” says Rosalie.

The six colours are:

  • Mawn – with earthy hues reminiscent of the peatlands of the Welsh countryside.
  • Brecon – has a speckled base palette of golden yellow, light greys and white, giving off a calming, natural aesthetic, which subtly evokes the outdoors and casts the mind to the soft reeds that line the Severn’s riverbank.
  • Slate – reminiscent of slate quarries and caverns rooted in Smile’s Welsh heritage, the new Slate material comprises a palette of deep mossy green with glimmers of white.
  • Quarry – with a visual appearance somewhere between lava and volcanic sediment, this material is reminiscent of the sea-soaked beach at Black Rock Sands. It also has fire-like elements and the lighter specks glinting through hint at the materials’ former life
  • Limestone – the Limestone material offers a pared back beauty – slightly rugged and weather-beaten – just like the boulders you might expect to find atop the remote peaks of the Brecon Beacons or The Black Mountain range.
  • Grey Mist – previously in the Smile Plastics’ Classic range, Grey Mist has moved into the Earth Collection as it was inspired by walks in the Welsh hills.

Materials are available in 3000mm x 12000mm and 1500mm x 1200mm sheets, in 5, 12 and 20mm thicknesses.

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