St Pancras International
Client: Union Railways (North)
Architect: Rail Link Engineering
Historic buildings consultant: Roderick Shelton
Brickwork Contractor: Irvine Whitlock
Brick procurement consultant: Philip Mason
Main contractor: Costain O’Rourke Bachy Emcor Rail (Corber) Consortium
Bricks: Bulmer Brick & Tile Soft Reds/ Charnwood Forest Non-standard Imperial Facing Brick
Specialist brick craftsmanship is alive and well, as proved by the transformed CTRL terminus.
If you think there aren’t enough specialist brick craftsmen around, then take a look at the work going on at St Pancras International Station in London. There you will see the sort of stunning, intricate brickwork craftsmanship that you might be forgiven for thinking had died with the Victorians.
Threatened with demolition in the 1960s, the grade I-listed St Pancras station is now being given new life by the planned high speed Channel Tunnel Rail Link. CTRL operator London & Continental Railways is behind the station’s metamorphosis into the new international terminus for Eurostar from Autumn 2007.
However, this has meant drastic changes to Gilbert Scott’s 1876 Gothic Revival masterpiece. A new underground section of Thameslink has necessitated the demolition and reconstruction of a whole section of elevation opposite the eastern side of the British Library.
Up to two storeys high and complete with brick and stone arches, the new red brick facade has been termed 21st century Gothic by lead architect Alastair Lansley. Historic buildings consultant Roderick Shelton, who detailed the new facade, explains: ‘It’s primarily a replica of what was there originally and occupies the same footprint but has been tweaked to account for subtle changes arising out of the station’s new functions.’
Structurally self-supporting, the 152m long facade is tied to the station’s steel structure for transference of wind loads. Up to 14.5m above pavement level at its highest point, the facade is strengthened by brick/stone piers that vary in thickness from 690mm to 1370mm. Although some are hollow to accommodate rainwater pipes, the masonry is generally solid to resist the steel arch thrusts.
Trying to match the existing brickwork proved tricky as the original bricks were no longer available. But despite some inevitable compromises, the finished result is extraordinary in terms of architectural continuity and quality. Clearly, both the bricks and the craftsmen were found.
All bricks on the project were handmade. In keeping with the Victorian originals, half a million facing bricks were ‘thrown’ sideways to give a frog on both sides. This helps laying the bricks, particularly given the relatively thin 5mm joints that were used. In addition, a double frog can provide extra key for the mortar. Other than where the new facade abuts the existing building, the use of hydraulic lime mortar has removed the need for movement joints in the facade.
Creating the Gothic arches required 20,000 ‘red rubber’ bricks in 45 different shapes, each numbered individually to ensure correct assembly. These were laid with fine 2mm joints using a pure, sand-free lime putty.
Many of those who have seen the finished project have been impressed by the excellent workmanship. This is a credit to the skill of the 30 bricklayers and eight stonemasons who carried out the work.
Geoff Irvine of brickwork contractor Irvine Whitlock says: ‘Many architects seem reluctant to design detailed brickwork because of their perception of a shortage of skilled bricklayers. I do not believe such a shortage exists in the UK – and the proof is in the quality of workmanship at St Pancras.’