RESTORATION PROJECT…
The restoration of beautiful buildings such as the Natural History Museum and the Royal Albert Hall, is big business for one local company that is also working on numerous overseas projects
The list of prestigious restoration projects that Ribble Valley-based Jon Wilson has worked upon is like a Who’s Who in the world of historic architecture.
Among them is the Royal Albert Hall and the Natural History Museum in London, he has been involved in restorations in Europe, New York and Canada as well as working with Victoria Beckham in Paris.
But it’s not all been plain sailing for Jon and his business partner Steve Allen, who set up Darwen Terracotta after being made redundant in 2015.
Jon, who lives in Whalley, had worked for his previous employers for 35 years as commercial director, and during that time he developed the restoration and new build part of the business, manufacturing architectural terracotta and faience (glazed terracotta) for a variety of projects.
“I had made a lot of good contacts,” he recalls. “I didn’t want to just give it all up so I rang Steve and said, ‘Put the kettle on I’m coming round for a chat.’ We agreed that we should have a go and set up on our own.”
With a business plan in place, Jon and Steve raised £1m through private investment and their own money, and just four months later, set up Darwen Terracotta.
Moving into an empty 38,000 sq ft building in Whitebirk and installing a £100,000 kiln and driers, they initially worked as a small experienced team with the intention of gradually taking on more of the 36 former workers who had been made redundant.
Fast forward to 2018 and they now have 40 employees – they even managed to persuade lab consultant Mike Walsh, 75, out of retirement. Mike now works with Darwen Terracotta’s technical manager, who deals with the various colours and glazes in the faience side of the company, which has since invested in a second £180,000 kiln.
“We did not want to lose a workforce that had so much skill. These were master craftsmen, some of whom had worked in the trade for many decades”
“It was quite scary when we first set up. We had to hit the ground running but everyone was very supportive. We had sculptors, moulders, modellers and designers all with great skillsets,” recalls Jon.
Within a matter of weeks the company began to secure various projects including the renovation of Wigan Town Hall, which saw them restoring the red terracotta façade.
They also began work on a prestigious new-build project – the Alexander McQueen headquarters in Clerkenwell, London.
Just over two years down the line and the company is thriving and working on many historic buildings all over the world.
“Our work is probably split 50/50 split between extremely high value new build and historic restorations,” explains Jon.
In Britain, it was the Victorians who popularised the use of terracotta – especially in civic and prestigious commercial buildings. While terracotta and faience are long-life and low-maintenance materials, pollution and weather takes its toll, which has led to huge potential in the restoration business, as modern firing methods are more consistent giving pieces greater strength and endurance.
Current projects undertaken by Jon and the team include working on the interior and exterior of the Natural History Museum: “We have been restoring the original façade, it’s an ongoing project, a bit like painting the Forth Bridge.”
The company is measuring every leaf detail for work on the Royal Albert Hall and restoring the facades of the Russell Hotel in London and the Victoria Palace Theatre.
In what is a huge, complex development, Darwen Terracotta is manufacturing the exterior façade of the new Leicester Square Hotel for the Edwardian Group. This involves 16,000 pieces of cobalt blue stealth-shaped pieces.
Another project about to be completed is a 9m tall ceramic sculpture for the Eden Project and the company has also started work on cladding the new bars at the All England Lawn Tennis Club ahead of this year’s Wimbledon Championships.
Being able to create different coloured glazes on terracotta for the faience work has resulted in some really unique prospective projects, including the matching up of art deco tiles for renovation work on the turbine halls at Battersea Power Station. The £9billion restoration will see Apple relocate its European HQ to the Grade II listed building.
“In all our restoration work we have to match what’s already there. We go to see what’s needed. We take all the measurements and profiles and come back and draw it – it’s all very detailed.”
Further afield the company has completed the restoration of the Imperial Theatre, St John in Canada and is about to embark on restoring the façade of a theatre in Toronto.
“Restoration of this kind is very niche – there are a very limited number of companies who do this. We are now by far the largest company who do this kind of work,” explains Jon, who with Steve and their team of designers and craftsmen, are keen to build on their work abroad.
“Even taking into account sales and shipping costs, we can be competitive in overseas markets. We have even seen interest from Australia where terracotta and faience were popular in the early 20th century. They have no in-country producers of these materials so there is great potential for restoration and new build applications.”
“We also have a lot of work in New York and Chicago – we have a worldwide reputation so sometimes this involves flying out to a city to view what’s required.”
Having previously worked with Victoria Beckham’s architect, Jon has also been asked to supply ceramic plinths for her shop in Paris to display fashion accessories.
“We are also hoping to do some work for her new shop in Mayfair,” adds Jon, who is also working on a project for local Lancashire sculptor Charles Hadcock, whose work is displayed in many prestigious London locations.
Working closely with Blackburn and Burnley Colleges, Darwen Terracotta now has five apprentices, who are learning from the very best craftsmen.
“We work closely with schools and colleges and get involved in careers events. It is great to showcase what we do and show youngsters that they have something unique right on their doorstep.”
Looking to the future Jon and Steve are expanding the business, with the launch of the Whitebirk Sink Company, manufacturing traditional and contemporary fireclay sinks featuring bright colours and innovative effects: “We have already had huge interest from the UK, USA and Australia. This new range of products will increase our workforce and next month we are expanding into further premises.
“We are building a successful company with the highest quality of product and service, and we are investing in the huge talent of our artisans and our apprentices will be the next generation of craftspeople.”
