Following our specification of sand cast lead for the total re-roofing of a Grade II* country home, PBA & the client visited the workshop to see this historic process in action.

Firstly the sand bed is prepared and levelled to the required depth, a smooth bed is critical so the surface is worked with hand-held copper planes.

Then the molten lead (all lead from the existing roof was reused) is poured over the sand bed, the lead is worked by the casters with a timber strickle to ensure an even thickness. The lead soon cools and solidifies, it is then cut and rolled ready to head back to the site.

The sand bed is then completely re-made and dampened for the next casting.

A fascinating process and well worth viewing!