Traditional Sandcast Lead Production

Sand Casting is the traditional method of casting lead sheet and has been so since the Roman era, its uses being for both roofing and decorative pieces. Sand Cast lead sheet is now primarily used on Ecclesiastical and Heritage buildings for its authenticity.

Composition and Manufacture

Manufacture is by the traditional method of running molten lead over a bed of smooth prepared sand on a casting bed. This method produces lead with a characteristic rough underside finish with a microstructure of large columnar grains. 

The lead is prepared by the careful mixing of virgin and salvaged lead with metal additives in a fully digitised oil fired furnace that ensures no chemicals are burnt off through overheating.

The casting bed is prepared by the compacting and turning of mixed sands, laid within a timber framed, metal edged box known as the "table". The "strike", a traditional tool comprising a wood plank with protruding handles for easy operation, is then dragged over the bed to remove excess sand and provide an initial smoothing. The bed is then planed totally smooth by the skilled use of copper plates. The molten lead is then allowed to flow over the casting bed to form a sheet. When still in its molten state the "strike" is used again to skim off the surplus lead and produce the exact code of lead required. This is to a tolerance of +- 5% of theoretical weight - half of the existing specification!

But thou, thou meagre lead which rather threatenest than dost promise aught.

They paleness move me more than eloquence

And here chose I

(The Merchant of Venice)