Our projects cover a wide range of craft operations. As we are required to work on buildings from a variety of periods – from medieval to modern – we have pursued training to deepen our knowledge and understanding of traditional craft techniques.

Sourcing and matching of materials.

We work closely with our suppliers to try to find the best materials for repair work. This involves on-site analysis of mortars, sourcing correct aggregates and binders, taking brick samples for matching, and often ordering purpose-made bricks to achieve accuracy in size, colour and texture. We provide samples for client approval before commencing with our work.

Range of aggregates ready to mix Mortar sample biscuit,
Cobham Hall, Kent		 Taking original bricks as
samples for matching at
Bulmer Brick and Tile Co. Ltd

Re-pointing

We examine the make-up of the original mortar and the profile of the joint in order to produce samples for approval. Cutting out is carried out carefully with a range of tools, depending on the hardness of the mortar to be removed and the size of the joint.

Brick replacement

Often all that is needed to extend the life of a wall is sensitive replacement of damaged bricks and patch re-pointing.

Before After

Plastic repairs

Sometimes it is appropriate to face up a damaged brick with a protective mortar. These kinds of repairs are purely sacrificial and will not be as durable as a brick replacement. However, they can be useful when used at the right time and when mortars are prepared carefully to match the host brick as closely as possible. We use a range of aggregates, lime, and natural earth pigments and we produce samples, allowing them to weather before final decisions are made

This picture shows a detail of a gauged brick pier. A queen closer has been replaced and the bricks either side have had plastic repairs.

Recording, dismantling and re-building

For some of our work, it is necessary to record the location of every brick with great care, whilst at other times, such detail is not appropriate. However, we always carry out some form of recording before dismantling any structure. We use sketches, photographs, gauge rods and full-size tracings on plastic sheeting, depending on the accuracy required. Records are essential aids for sensitive re-building, as well as providing useful information for the Building Manual, adding to the on-going picture of the building’s history.

Wherever possible, we re-use sound material, carefully cleaning up bricks for re-use and sometimes numbering for replacement in their original locations

Recording, dismantling and re-building of a pier nib at Hampton Court Palace.
4, Mill Lane, Cambridge

Dry-laying a panel of gauged brickwork, following dismantling. New bricks are being cut to replace damaged areas.

 Recording the Great Fireplace walls in the Tudor Kitchen at Hampton Court Palace, prior to repairs

Gauged brickwork

We are able to repair, re-build or replace gauged brickwork, carrying out the entire operation. This includes making templates to match original shapes, setting out arches, manufacture of cutting boxes and turning pieces for arches, cutting finished shapes from red rubber blanks, and fixing gauged work in situ.

Cutting shapes for a decorative gable at Mill Lane, Cambridge.
The cutting boxes have been made using templates taken from sound original bricks.
Fixing pre-cut units for a new arch at St Pancras Station, London
Piecing in repairs to a gauged pier, Twickenham, Middlesex

Cutting special shapes

As well as employing traditional gauged work techniques and producing shapes by using cutting boxes and bow saws, we also cut shapes by hand using a variety of tools: saws, rasps, files, hammer and chisel. This allows us to produce any shape as a one-off for replacement, without the necessity for production of cutting boxes. We also sometimes use these methods when the original work pre-dates the use of the wire bow saw and hand shaping will generally produce a more authentic feel.

Shaping replacement bricks for a pier nib at Hampton Court Palace
Cut and rubbed details for the base of a pier at Waterlow Park, Highgate.