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St Pancras Hotel, London

In June we took a tour of the fabulous St Pancras Renaissance Hotel in London and also the impressive station of St Pancras to explore the wonderful architecture and look for inspiration in search of new designs and ideas for products. Our guide, Mike, took us on the hotel tour, which is open to non residence of the hotel for about an hour and gave us a grand tour.

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He explained the architect responsible for the building of the St Pancras was George Gilbert Scott. During the tour it became clear Scott would very much appreciate the castings we make at the Cast Iron Air Brick company as he too was a keen promoter of employing British foundries to make his goods. He loved to show off the products his  midlands workers could make to property owners in London, again, something we’re proud to do ourselves today!

Scott was a keen industrialist and revelled in promoting the skills of the craftsmen from the midlands in the materials used for his London designs. He incorporated not just the Quatrefoil design that we use in our “four clover” Quatrefoil channel gratings   but also Trefoil and even a “five clover” design rarely seen known as the Pentafoil . The quatrefoil can been seen at the top of the arches in the booking hall (below)

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St Pancras was used as a show piece to show the gentry in the capital the splendid brick work, stone carvings and above all cast iron castings that his Birmingham and Derbyshire foundries could make.  What is particularly impressive is that Scott used ground breaking design to elevate the entire St Pancras platform. This ensured the hotel entrance aligned perfectly for passengers arriving by carriage yet allowed the train to depart on a slight fall to ensure the departing trains did so without making too much noise or generating too much smoke in the station.

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The stunning main staircase featured flamboyant designs so Scott could show off all the skills of his workers and in particular the castings that the midland foundries could produce. In the example above, however, he tricked the guests into believing that the support, underslung along the stairs, was made of cast iron and was used to help support the structure. This support,  however, served no structural purpose as the stairs were self supporting and was made of a much lighter material, namely wood.  One reason, it is thought that the wood was painted to resemble iron was to help promote the skills of the foundries  rather than the skills of the carpenters!

pipe

Another ground breaking design that Scott incorporated into the structure was a fire main system to help fire brigades by ensuring the hotel had a huge reservoir of water. The water was collected by channelling water along intricate cast iron gullies and pipes and storing it underneath the building. (above) Cast iron pipes can be seen in the booking office  directing the rainwater into hoppers to storage tanks below.

aco with 5"

Upgrading Old & New Channel Gratings

Channel gratings, “Aco” drains, pavement drains, trench drains and French drains, whatever you know them as they’re the sort of long narrow drains you often see along the pavement or below door thresholds on footpaths or household patios.

Aco drain overhaul and new installations with cast iron grilles can be fraught with difficulty because matching the channel with the grating can be troublesome.

It is tiresome but if a cast iron grille is required to fit into an existing channel then it’s often more simpler to replace the channel as well to get a matching pair..

You see we use the 108mm wide Manthorpe Channel…

manthorpe

and then combine it with our 108mm Quatrefoil grille

manthorpe with quatrefoil

for a perfect fit !

However if you’re leaving an Aco drainage channel in place and fitting a new cast iron grille – then you have a problem…

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The problem is the Aco system is 117mm (above) so it certainly won’t accept a 100mm wide grille (4″) and it looks even worse with a 5″ (125mm grille)…

aco with 5"

… and it won’t even accept our Quatrefoil gratings below

quatrefoil with aco

There are a few other channel systems available but again, if they’re not 108mm wide then they’re not going to be suitable for our Quatrefoil grilles and hardly any are exactly imperial widths so even a 4″ 100mm grille will be too small …

aco with 4"

So the solution is to install a new channel complete with new cast iron so the two match like our stunning Quatrefoil complete with Manthorpe system below

Quatrefoil Channel Grating

Quatrefoil Channel Grating

There is one other method were cast iron bearers  are used and a channel is formed out of cement and or concrete. Find out how we installed this here to create a walkway and bridge.

Using a conservation vent as a drain outlet on a period cottage, North Devon Wall

Improving Exteriors in Conservation Areas

Rainwater from down pipes used to emit from an open drainpipe on this old wall. It looked a real mess but what other alternative was there? Now, the pipe is finished off with a cast iron conservation 4 or 5 inch cowl, it looks neat, tidy and in keeping with this period cottage, North Devon wall

More details of the Conservation vent (item CON4 and CON5) can be found here

blocked slit grilles

Efficient Drainage ?

You would think that drain grilles would be capable of draining water away, wouldn’t you? Well unfortunately no, as these modern narrow slit grilles show. This is an all to common problem with modern channel gratings and one of the reasons we developed the cast iron Quatrefoil channel grille system.

The modern grilles shown in the photograph are excellent for not allowing stiletto heels to pass through but they’re not very good at draining away water. It is impossible to achieve effective drainage with narrow slits unless the water is clean and the grilles are removed regularly for cleaning. If that’s not the case and the water contains any soil or silt then the grille will quickly block rendering it useless.

Whilst our Quatrefoil grilles  won’t prevent stiletto heels falling through,  they will do what they’re designed to do and that’s drain water away – and they are perfectly appropriate for the grounds of listed buildings and period properties , unlike their modern counterparts !

quatrefoil part one

Installing Quatrefoil Channel Grating Part 1

Channel Gratings are ideal for collecting surface water along the lengths of pavements, drives and at the base of doorways and conservatories. Here we are installing a Quatrefoil channel grating at the base of a 2.4 metre wide garden step in the grounds of a listed building. Our system uses the Manthorpe plastic channel with our own cast iron grating that screws into the channel and can be used in conjunction with a junction box to allow L T and X shaped channels to divert water in almost any situation.

First*, clear the ground and sink a new drain pipe to take away the excess water. Here you can see we have used a fixed drain that will connect up to the rainwater drain for the house and take away the water. You can install a drain pipe that leads to a soak away or if you don’t want to dig down then you can leave one end of the plastic channel open so the water can be diverted along the surface . This can be done forming cement channels to divert the water down hill to a soakaway or to another drain pipe elsewhere on the property.

Connect up the plastic channels and lay the full lengths were they will be installed. Using a level, check the fall and ensure they are square. Cut the hole at the base of one of the channels were the water will drain into the drain pipe and fit the end stop (from the accessory pack) to prevent the water escaping out of the of the plastic channel. Lay a base of concrete along the whole area for the channels to sit in and then fit all the channels ensuring the other end cap is fitted at the end of the run.

see part two for finishing off

* our products are especially designed for listed buildings but please ensure you obtain  permission from the conservation department of your local authority if you are listed before starting the works

Installation of channel gratings

Installing Quatrefoil Channel Grating Part 2

Once the channel gratings are all in place, carefully mortar/concrete the pathway ensuring the fall is towards the channel and the channel falls gently towards the drain hole. It may be worthwhile placing the cast iron Quatrefoil grilles in position to ensure the concrete doesn’t distort the plastic channel.

Allow to set and then clean along the plastic channel rebates were the cast iron grille will sit. Ensure the leaf trap is in position over the outlet drain hole and then screw the Quatrefoil grilles onto the channel. If there are several grilles to fit, lay all the grilles loosely in position before screwing them all in place. There are very small differences in the dimension on all castings so it may be necessary to swap Quatrefoils around to get the best fit and get an even gap between each grille.

The finish of the bare metal grilles will quickly rust to leave a natural rusty iron finish. If a black finish is preferred then choose a painted finish. These grilles will last many years regardless of the finish because the iron rust forms a barrier towards corrosion with or without the paint. It is likely the cast iron Quatrefoil grille will be strong enough to support pedestrian traffic even 100 years after installation.

More details on the Quatrefoil Channel Grating

Further information on installing the channels

Junction box for creating T L and X junctions

 

Quatrefoil Square

Quatrefoil Junction Box

We’re pleased to announce the introduction of an essential grille that will really expand the opportunities for different layouts using our Quatrefoil channel grating system. The Quatrefoil square is an essential grille to have when using our Quatrefoil channel grates in an L, T or X shape. The junction box beneath the grille clips into the channel grating to allow for smooth drain water flow around corners. Examples and installation guides are available via the Quatrefoil square webpage

Offsetting carbon emissions caused by manufacture of cast iron products with the planting of 350 trees

Tree Planting – Carbon Offsetting

Melting iron to create our products uses energy either electricity or gas in large quantities. We keep the amount of energy used by commissioning only British foundries who, use energy as frugally as possible and meet EU emission standards with regards to pollution (unlike their Chinese counterparts).

But there’s no escaping it, manufacturing our products creates carbon and that’s a fact so to offset this carbon we’ve just bought 350 native British broadleaved trees to plant along 5 acres of scrub land around our workshops here in North Devon.

We’ll bring you updates on the planting and the trees as soon as we have them delivered in from local tree nursery Bowhayes Trees in Devon

Channel Grating

New Channel Grating

After years of research and hundreds of requests from architects and period property developers, we’re delighted to introduce our latest innovation – an elegant and simply stunning cast iron channel grille combined with a modern interlocking channel system.

The Quatrefoil linear drainage channel, also known as channel gratings or French drainage channels are specifically suitable for removing surface water in domestic period properties and pedestrian areas in conservation areas. The system can be installed for light vehicular use on driveways, patios and paths with block and flag stone paving or tarmac or concrete.

The Quatrefoil grilles are 108mm wide and 10mm thick and are available in a variety of lengths up to 1000mm long with a choice of bare metal or painted black finish. For those wishing to create their own channel or use an existing channel or indeed use the Quatrefoil grille as a vent or internal floor grille they are available with or without the plastic channel.

Quatrefoil grilles purchased with the channel will be supplied fully assembled with screws.

It is no accident that we chose the Quatrefoil design for our grille. We wanted our grille to appeal to conservationists and period property restorers alike and to enhance walkways and driveways in the simplest home or grandest mansion. For such a grille, we needed a design with class, history and elegance and the Quatrefoil has all three in abundance. The design can still be seen today in windows of Norman churches in England and throughout many Gothic London properties. Although used predominantly in churches, it’s earliest use can be traced back 1000 years to an English penny from the London mint. The design is used extensively throughout Europe featuring most notably in Notre Dame, cathedral in Paris and also in Renaissance buildings in Venice, Milan and Florence and is sure to look good in the grounds and along the paving of homes in the 21st century.

A standard length is 1 metre long (1000mm) although it is possible to have shorter lengths to allow the channel to fit almost any situation. Shorter lengths available are 155mm, 300mm, 440mm, 580mm, 720mm and 855mm. Whilst the 1 metre long version has four screw holes ( a pair at each end as per photo), all shortened versions of the Quatrefoil grille are supplied with only two holes at one end.

More details on the Quatrefoil Channel Grating

Please Note:-

Estimated delivery time 2-3 weeks bare metal, 3-4 weeks painted

titanic deck vents

Cellar, Fresh Air Inlets and Sewer Vents

It sounds as if we’re describing three different types of vent here but the cellar vent, fresh air inlet and sewer vent are all the same vent. I’m sure you’ll want to know what on earth a picture of the Titanic has to do with all this but please read on…

These rather splendid looking angled vents have two uses, to ventilate cellars and below ground rooms or to allow fresh air into the sewer pipes to prevent loss of the water trap in WCs. If used as the former they are normally fitted with mesh, whilst for sewers the mesh is replaced with a flap non return valve that prevents any smells escaping.  Because many WCs were outside period properties, these vents, used as fresh air inlets were more commonly used towards the rear of the property some distance from the building – generally around knee high ( to save on expensive cast iron pipework)

You would be pressed to notice a sewer vent nowadays installed in a modern sewer system. Unsurprisingly, they’re tucked away, with the cost of plastic sewer pipes being relatively inexpensive they’re placed at a significant distance from windows and more commonly above the rainwater gutters around the roof eaves.

Another use, with a mesh front is to ventilate below pavements. There angled profile allows air to be piped below the floor level without rain water and puddles being drained into the basement – an ingenious and most attractive method of subterranean ventilation.

I’m sure that mariners, seafarers and filmgoers alike will suggest that this very same principle is very similar to the structure on the deck of steam ships that gathered fresh air from the upper deck to divert it below to cool the machinery and men working below. Our cellar vent although diminutive in size has very much the same purpose as the deck vents of ocean liners (also known as Dorade vents), but more to the point…

which came first ?