The quarry block
A tonne and a half of honey stone.
Every job starts here: a rough block of Lincolnshire limestone, split from the bed and left to season for over a year. Our masons read the bedding before they touch it, because stone cut against its grain will fail in the first hard frost.
Seasoned fourteen months
The template and the first cut
Mark once. Cut once.
A zinc template, cut to the drawing, is pressed to the face and the outline scribed in. Then the first cut: mallet and chisel take the block back to true, square and sharp at every arris.
Tolerance: half a millimetre
Carving
The face was always in there.
Point, then claw, then flat chisel. A gargoyle, a foliate boss or a worn corbel copied from the original: every stroke by hand, and the stone shows pale wherever it has just been cut.
Eleven days for this head
The arch is raised
Stone by stone, from both sides.
A timber centering holds the shape while our treadwheel crane lifts each voussoir. The masons bed them in lime mortar, working up from both springers at once so the load stays even.
Fifteen stones, three tonnes
The keystone
And then the last one drops in.
The keystone locks the ring. Strike the wedges, lower the frame and the arch carries itself: the moment we wait for on every job. Then the glass goes in, and the light comes through.
Built to stand for centuries