Historical Context of Lead as a Building Material

Lead has been a cornerstone of construction for millennia. The Romans were among the first to use it extensively, crafting plumbing systems, roofing, and even ornate architectural features. Its longevity and malleability made it ideal for these purposes. During the Middle Ages, lead adorned the roofs of grand cathedrals and public buildings, including iconic structures like St. Paul’s Cathedral and the Tower of London.

What makes lead so enduring is its resistance to corrosion. Even in the harshest weather conditions, lead roofs and fittings have withstood the test of time, often outlasting the buildings they were designed to protect. This durability has cemented lead’s role in architectural heritage, ensuring its continued use even in the modern age. Today, both heritage and commercial building contractors rely on this remarkable material to maintain architectural integrity while meeting modern standards.

The Challenges and Artistry of Leadwork

Working with lead is both physically demanding and intellectually challenging. The material’s weight alone makes handling it a significant effort. As Quinn explains, “Historic buildings are frequently specified with the heaviest codes of lead. Code 8 lead weighs over 40 kg per square meter, and individual pieces for large gutters can weigh upwards of 169 kg.”

The timing of the Woodside Library’s project added another layer of complexity. Originally planned as a summer job, delays meant the work took place in the middle of winter. Quinn recalls, “We endured some of the coldest weather of the year, even a spell of snow. The cold impacts the elasticity of the lead, making it harder to work with. Often, heat is applied to raise the temperature of the lead, making it more pliable and easier to manipulate.”

Beyond shaping, welding the lead requires absolute precision, especially for tight shapes or where joints need to be made. “Welding is crucial in these areas to ensure both durability and a seamless finish,” Quinn adds. The process demands steady hands and careful attention to detail to avoid thinning the material or creating weak spots.

The artistry lies in shaping the lead to fit complex architectural designs. From domes and spires to intricate finials, leadworkers must precisely manipulate the metal. Quinn describes the process of bossing, which involves carefully moving the molecules of the metal to create seamless joints and detailed features without thinning the sheet. Bossing is a process that moves the molecules of the metal by repeatedly striking the lead sheet with hand tools. This technique allows excess material to be manipulated into areas requiring additional lead while avoiding thinning or creasing the sheet. The skill lies in understanding the movement of the metal to ensure seamless joints and complex details are achieved without forming fractures, making the process both efficient and precise. This ensures a smooth, professional finish that aligns perfectly with the architectural design.

Advantages and Disadvantages of Lead as a Material

Advantages:

• Longevity: Lead can last centuries with minimal maintenance, making it an excellent investment for heritage projects.
• Resistance to Corrosion: Its natural ability to withstand weathering ensures durability in various climates.
• Malleability: Lead’s flexibility allows it to be shaped into intricate designs, meeting both functional and aesthetic needs.
• Environmental Considerations: Lead is the most commonly recycled metal in the world, with higher recycling rates than newspapers or glass. Its low melting point requires far less energy to reprocess than most other metals, making it highly sustainable. In Europe, 95% of the lead used in the construction industry is recycled, and it can be recycled indefinitely without any degradation in quality. This high value and recyclability mean that lead is rarely, if ever, disposed of.

Disadvantages:

• Health Concerns: Lead is toxic, but in sheet form, it is very safe to handle as long as basic precautions are employed. Lead cannot be absorbed through the skin as its molecules are too large, but it can enter the body via cuts and abrasions. The most significant risk occurs when stripping old roofs, as lead carbonate (a white powder found beneath corroded lead) can pose a contamination or inhalation hazard if not handled carefully. Welding in confined spaces for long periods can also pose risks, although welding in open, well-ventilated areas is generally safe. Maintaining thorough personal hygiene, including washing hands and under fingernails before eating and washing work clothing separately, is essential. Smoking poses additional risks as lead can be transferred to cigarettes by hand, leading to vaporised inhalation.
• Expense: The cost of lead, coupled with the skilled labour required to work it, can make it a significant investment.

Insights from the Craftsman: A Q&A with Quinn

Quinn, the master craftsman behind the cupola’s leadwork, shared his extensive knowledge and experiences with us. Below are highlights from our conversation, showcasing the intricacies of his craft:

Q: You mentioned that math plays a big role in leadwork. Could you share a bit more about the calculations involved?
A: Often, drawings show virtually no detailed specification for setting out leadwork; they may depict the roof structure and insulation but leave the leadwork as a single line. I start by making drawings to comply with BS6915 and Codes of Practice in Rolled Lead Sheet. From there, I calculate sizes, the amount of lead required, and allowances for trimming and wastage. This involves basic trigonometry and geometry for most details, but ornate features like domes or spires require more in-depth calculations.

Q: The cupola had curved surfaces, ledges, and a dome finish. What were the biggest challenges in creating a seamless design?
A: Designing the leadwork to meet codes of practice while achieving the desired aesthetic was challenging. Each piece required careful measurement, cutting, and shaping to ensure it fit perfectly. Heat was often used to make the lead pliable. Welding was used for some of the most complex elements, such as forming flashings beneath the cladding and at the finial of the cupola roof. These welds created secure and close-fitting weatherings, especially in vulnerable ridge areas. While these details could have been bossed, welding was employed to avoid thinning the lead, which I find is faster and more effective for such intricate work.

Q: For people who might not know much about leadwork, what do you think are the most misunderstood aspects of the craft?
A: Many people don’t realize how demanding the work is, especially in extreme weather conditions. The craft involves moving the molecules of the metal through a technique called bossing, which allows me to shape the lead without it thinning. Understanding expansion joints, suitable fixings, and the limitations of the material is critical to ensuring the leadwork performs its primary function of keeping the weather out while looking visually appealing.

Q: Is it physically demanding work?
A: Absolutely. The work is extremely physical, especially when carrying heavy lead sheets or working at height. For this project, we were climbing up and down ladders all day, often 60 feet up, which is a workout in itself. Add to that the intensity of working in freezing temperatures during the winter months, and you start to rediscover muscles you’d forgotten you had!

Q: What advice would you give to someone just starting out in leadworking?
A: Be prepared for physically demanding work and challenging conditions. Patience is key; rushing the process will only lead to mistakes. Understanding the project as a whole and planning each step before starting on-site is essential. Skills like bossing and welding can be taught, but practice and experience are the only ways to truly perfect them.

Q: How does it feel to know your work will be part of a museum’s legacy?
A: It’s incredibly satisfying. This project will be there long after I’m gone, and I hope it inspires appreciation for traditional craftsmanship. There are easier professions out there, but few are as rewarding as this.

Why Leadwork Matters Today

Leadworking is a craft steeped in history, yet it remains relevant in modern construction. Its role in preserving architectural heritage cannot be overstated. As Quinn notes, “The skills involved are virtually unchanged from hundreds of years ago. As long as we have historic buildings to maintain, these skills will always be required.”

Projects like the Woodside Library demonstrate the importance of keeping traditional skills alive. They also inspire the next generation of craftsmen to take up the mantle, ensuring these techniques endure for future restorations. For both heritage and commercial building contractors, preserving traditional methods while incorporating modern innovations ensures that historic buildings remain functional and beautiful for generations.

Conclusion

The restored cupola at the Black Country Living Museum is more than just a structural feature—it symbolises the enduring art of leadworking. Quinn’s expertise and dedication have ensured that this historic element will stand the test of time, blending tradition with modern precision. Visitors to the museum are encouraged to see the cupola for themselves, marvel at its craftsmanship, and appreciate the legacy it represents. To follow the rebirth of Woodside Library in all its glory, visit our gallery page, where we document the build’s progress. You’ll also find drone footage capturing the building’s transformation from above, showcasing its journey from restoration to revival.

As a commercial building contractor, Gravitas Build is proud to be part of Woodside Library’s rebirth. Visit our news feature to learn more about our involvement in this remarkable restoration project.

Are you interested in carrying out a heritage or listed building project? If you have a project you’d like to discuss with us, feel free to contact us; we’d love to help.

Call us on 0121 403 3693 for more information.