The Art of Terracotta Manufacture

The name terracotta is derived from the Italian, Burnt Earth. Its colour varying from the natural clay colours of light buffs, oranges, browns and reds.

Faience is a term used in the UK for Glazed Terracotta, with a limitless choice of colour in matt to high gloss finishes.

Terracotta and Faience was one of the prominent building materials used in construction of major buildings in Britain. Its origins can be traced back to the Roman Empire and was used intermittently throughout Europe until the mid 19th Century when it became very popular in Britain and North America.

Used extensively up until the outbreak of the second world war, it rapidly declined in favour of new materials and radical stylistic changes. However in the late 20th Century a renewed interest has emerged in the form of construction and restoration and by the enthusiasm of Architects to once again explore the huge potential this material can offer in colour and shapes.

Composition
Architectural Terracotta is the body of material used in the manufacture, combining different clays, processed and blended to achieve durability, frost resilience, compressive strength, colour and finish.

Site Survey/CAD Design
Our specialist team visit site to undertake extensive measurements of size and profile of blocks to be replaced, prior to producing workshop drawings of each unit type to a pre determined clay shrinkage. For new build projects layout and elevation drawings are completed in conjunction with architect/engineer/contractor.

Laboratory Colour Match
We pride ourselves on unrivalled analysis and colour match development, using blended clays and glazes to replicate exciting colours for new projects.

Sculpture
We employ craftsmen who have the skills to create life size sculpture from actual pieces, drawings or photographs.

Modelling and Moulding
Still made in the traditional way, a plaster model is formed to the required shape, from which a reverse plaster mould is later taken.

Hand Pressing / Casting/Finishing
Once dry, the mould is filled with pre prepared and tested clay by hand or slip to a thickness of about 30mm. After a few hours or overnight, the piece is turned out of the mould where each seen face is then carefully hand finished using wooden tools, leathers and knives, bringing the finer particals to the surface, improving appearance and weathering properties.

Glazing
For blocks that require glazing (faience) a specially prepared engobe or glaze is applied to a specific thickness.

Kiln Fired/Packing
Shaws of Darwen have eight production kilns with the latest designed technology to ensure the very best quality of product. Finished blocks are quality control inspected for size, shape and colour prior to careful package and delivery to site.