Harvey’s Foundry Hayle, Cornwall Plantation And Pattern Stores

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Harvey’s FoundryHayle, CornwallPlantation and Pattern StoresHistoric Building RecordingforMiller Purcell Tritton LLPOn behalf ofHarvey’s Foundry TrustCA Project: 3876CA Report: 12201August 2012

Harvey’s FoundryHayle, CornwallPlantation and Pattern StoresHistoric Building RecordingCA Project: 3876CA Report: 12201prepared bydatechecked bydateapproved byPeter Davenport, Senior Historic Buildings OfficerAugust 2012Mark Collard, Head of ContractsAugust 2012Simon Cox, Head of FieldworksigneddateAugust 2012issue01This report is confidential to the client. Cotswold Archaeology accepts no responsibility or liability to any thirdparty to whom this report, or any part of it, is made known. Any such party relies upon this report entirelyat their own risk. No part of this report may be reproduced by any means without permission. Cotswold ArchaeologyBuilding 11, Kemble Enterprise Park, Kemble, Cirencester, Gloucestershire, GL7 6BQt. 01285 771022f. 01285 771033e. enquiries@cotswoldarch.org.uk

Cotswold ArchaeologyHarvey’s Foundry, Hayle, Cornwall: Historic Building RecordingCONTENTS1.INTRODUCTION .7The site (Fig. 2) .72.OBJECTIVES .8Methodology.83.BACKGROUND.94.DESCRIPTION.11The Pattern Store and Cart Shed .11The Plantation Store, exterior .14Plantation Store, interior .166REFERENCES .20APPENDIX A: OASIS REPORT FORM.22APPENDIX B: CONTEXT TABLE.23APPENDIX C: BRIEF FOR HISTORIC BUILDING RECORDING ANDARCHAEOLOGICAL INVESTIGATION .24APPENDIX D: WRITTEN SCHEME OF INVESTIGATION .29

Cotswold ArchaeologyHarvey’s Foundry, Hayle, Cornwall: Historic Building RecordingLIST OF ILLUSTRATIONSFig. 1Site location plan 1:25000Fig. 2Site plan (1:1,250?)Fig. 3Extract from the 1879 first edition 6” OS map of HayleFig. 4Extract from the 1908 second edition 6” OS map of HayleFig. 5Pattern Store and Plantation Store plan and the changes to the railwayviaduct (also showing viewpoint of Fig. 7)Fig. 6Pattern Store and Plantation Store ground plans, showing viewpoints offigures (1:200)Fig. 7Phased north-east elevation of the Pattern Store; i) based on the architect’smeasured, but schematic drawing; ii) PhotomontageFig. 8Interior of the north-east elevation showing the floor beam sockets (someblocked up),looking south-east. The stone jambs of the arch are alsovisible. Scale 2mFig. 9Detail of the foot-square cast-iron liner for the floor beam pockets in thePattern Store. Similar were used in the Plantation Stores.Fig. 10 The interior south-west wall of the Pattern Store, looking north-west. showingthe original beam positions, lower ones blocked, and, less clearly, theblocked pockets of the later floor level, between them. Scale 2mFig. 11 The south-west elevation of the Pattern Store: PhotomontageFig. 12 The interior of the north-west end wall of the Pattern Store showing floorlevels and joist pockets. Scale 2mFig. 13 The interior of the south-east end wall of the Pattern Store showing floorlevels, joist pockets, door and fireplace. Scale 2mFig. 14 The north-west exterior of the Pattern Store and the northern structure,looking west-south-west. Scale 2mFig. 15 The south-west wall of the northern structure and its relationship to therailway viaduct. Scale 2mFig. 16 Phased north-east elevation of the Plantation Stores: i) based on thearchitect’s measured, but schematic drawing; ii) photomontageFig. 17 The north-west end of the Plantation Store, looking south-west. Scale 2mFig. 18 The south-west, south-east and north-west elevations of the Plantation Store(1:100)Fig. 19 Blocked window/archway in the south-west face of the Plantation Storeopposite the tunnel. Scale 2m)Fig. 20 The brick-arched portal of the tunnel south-west of the Plantation Store.Scale 2m

Cotswold ArchaeologyHarvey’s Foundry, Hayle, Cornwall: Historic Building RecordingFig. 21 The blocked arch at the north-west end of the Plantation Store and Window17, looking east. Scale 2mFig. 22 First floor timbers in the central part of the Plantation Store, looking northeast. Beams 4a and 4Fig. 23 The joist mortises on Beam 4. Scale in 0.50m divisionsFig. 24 One of the iron hangers which supported the intermediate beams 1a-7a,minus its beamFig. 25 View along interior of the Plantation Store to the south-east. Scale 2mFig. 26 One of the buttresses along the south-western wall of the Plantation Store.Scale 2mFig. 27 The position of the demolished southern buttress on the south-western wallof the Plantation Store. Scale 2mFig. 28 The south-east end of the Plantation Store, W2 to top centre and Arch 1 andD3 to left and right. Beam 8 has fallen due to a rotted east end; 7 and 7a aremissing entirely. Scale 2m

Cotswold ArchaeologyHarvey’s Foundry, Hayle, Cornwall: Historic Building RecordingSUMMARYProject Name:Harvey’s FoundryLocation:Hayle, CornwallNGR:SW 5579 3710Type:Historic Building RecordingDate:June 9th and 10th 2012Planning Reference:not applicableLocation of Archive:To be deposited with Cornwall County MuseumAccession Number:Site Code:A programme of Archaeological Building Recording to English Heritage Level 2 to 3was undertaken by Cotswold Archaeology in June 2012 at the site of the formerHarvey’s Foundry in Hayle, Cornwall.The building recording was carried out to mitigate enabling works to and to inform anintended application for Planning Consent and Listed Building Consent for works tothe Plantation Store and the Pattern Store, two derelict parts of the historic buildingsof Harvey’s Foundry, dating from the mid 19th century. A photographic and drawnrecord was made and alterations to the fabric of both buildings over time noted. Bothbuildings suffered serious arson attacks in 2000. The Plantation Store still retainedelements of the interior pre-datingthe attack and had been given a new roofstructure. The Pattern Store is currently a roofless shell with no interior structures inplace.

Cotswold ArchaeologyHarvey’s Foundry, Hayle, Cornwall: Historic Building Recording1.INTRODUCTION1.1In June 2012 Cotswold Archaeology (CA) carried out a programme ofhistorical building recording for Miller Purcell Tritton LLP on behalf ofHarvey’s Foundry Trust on two Grade II Listed Buildings, the PlantationStore and the Pattern Store, at Harvey’s Foundry Hayle, Cornwall, (centredon NGR: SW 5579 3710; Fig. 1).1.2Harvey’s Foundry is a component of the Cornwall and West Devon MiningLandscape World Heritage Site (WHS A2, Port of Hayle - WHS 2006) and isthe subject of a regeneration programme. A draft Conservation Plan wasprepared in 2002 which identified the general and specific areas ofsignificance (Parkes Lees 2002). The potential for WHS status wasacknowledged at that time in assessing significance. Phase Three of thisregeneration programme is currently being developed in preparation forPlanning and Listed Building applications later this year and Enabling Worksare required; A Written Scheme of Investigation (WSI) was prepared to dealwith these Enabling Works (Appendix B), and this document reports on theworks carried out in mitigation following the WSI and the requirements of aBrief for historic building recording and archaeological investigation from theCornwall Council Historic Environment Planning Advice Officer (dated 24April 2012, Appendix C). Any further archaeological works required, forexample as part of Listed Building Consent, will the subject of a furtherseparate WSI and mitigation programme.1.3The archaeological work was guided in its composition by the Standard andGuidance for the archaeological investigation and recording of standingbuildings or structures (IfA 2008), the Management of ArchaeologicalProjects 2 (English Heritage 1991), The Management of Research Projectsin the Historic Environment (MORPHE): Project Manager’s Guide (EnglishHeritage 2006) and Understanding Historic Buildings: A guide to goodrecording practice (English Heritage 2006).The site (Fig. 2)1.4Harvey’s Foundry is a 2ha site on the western side of the linear town ofHayle in West Cornwall. It lies on level ground at the base of the low hill to

Cotswold ArchaeologyHarvey’s Foundry, Hayle, Cornwall: Historic Building Recordingthe west, adjacent to the dock and wharves at Carnsew Channel and PenpolRiver. Although many of the buildings that made up the Foundry have nowgone, the remaining imposing structures and buildings are a testament to theactivity and wealth generated in this part of Cornwall during the industrialrevolution. Much of the site has remained derelict for two decades and someof the important industrial buildings have been replaced by a cash and carrywarehouse and by social housing. Parts of the site have been re-used toprovide workspace for small businesses and further workspace is beingprepared from new and existing buildings. However, the majority of the sitewith most of the important remaining buildings remains unused. Two phasesof regeneration have been completed: Phase One saw the restoration of theDrawing Office on Foundry Square (Renamed John Harvey House) and anew building (Dowren House); and Phase Two converted the derelictFoundry Farm into workshops and live/work units.2.OBJECTIVES2.1The objective of the archaeological building recording was to produce arecord of the two buildings affected by the Phase Three regeneration: thePlantation Store and the Pattern Store (including the traces of the nowmostly demolished Cart Shed) This included the analysis and interpretationof the records, and formation of a site archive to secure the long-termstorage of records in appropriate conditions, along with appropriatedissemination of the findings.2.2Site-specific objectives were:oTo record the form and nature of the buildings, including any evidencefor changes in use over time, in their present state before anyalterations due to necessary partial demolitions arising from the needto make the buildings safe.Methodology2.3The building recording followed the methodology set out within the WSI (CA2012). The survey was undertaken to Level 2/3 (Levels as defined inUnderstanding Historic Buildings: A guide to good recording practice (EnglishHeritage 2006). A measured survey supplied by the client was used as thebasis for the drawn record, with some necessary corrections and additions.

Cotswold Archaeology2.4Harvey’s Foundry, Hayle, Cornwall: Historic Building RecordingThe archive and artefacts from the evaluation are currently held by CA at theiroffices in Kemble. A summary of information from this project, set out withinAppendix A, will be entered onto the OASIS online database ofarchaeological projects in Britain.3.BACKGROUND3.1The detailed history of the site development and an assessment of thebuildings of the site are contained in Parkes Lees 2002, which incorporatedthe results of Historic Buildings Survey and Archaeological Evaluation carriedout by Cornwall Archaeological Unit (CAU 1995; 2001). Reference shouldbe made to those reports and it is not considered necessary to reprise thecontents here. In summary, the Conservation Plan describes the history ofthe foundry:John Harvey (1720-1803) was a blacksmith at Gwinear who moved to Hayle in1779. He had the vision and commercial instinct to realise that the Cornishmining industry would welcome and benefit from a county-based foundry andengineering works capable of supplying their needs. Although his businessremained localised and small-scale for the first few years, by 1800 50 menwere employed by Harvey The early years of the 19th century werecharacterised by the establishment of many Cornish industrial enterprises setup to serve mining and quarrying, where previously such services had ofnecessity been sought outside the county. Gunpowder manufacture, fusemaking, brick-making, engineering and iron-rounding all flourished with thegreat expansion of hardrock mining as the century progressed.John Harvey's son, Henry Harvey (1775-1850), expanded the Foundrybusiness and made Harvey’s an international and greatly respected firm,largely due to the management and energy of the noted engineer and enginedesigner Arthur Woolf. Close family ties with Richard Trevithick and laterprofessional partnerships with great engineers such as William West gave thefirm a continued level of expertise unmatched by other engineering works inCornwall. By the 1870s the Foundry included a forge and smithy, two machineshops, a boring mill, two fitting shops, hammer mills, pattern shops and stores,and the foundry itself with five cupolas and two air furnaces (Fig. 3).Their reputation was built on the design and manufacture of Cornish beamengines, but these machines were merely the most spectacular and visible

Cotswold ArchaeologyHarvey’s Foundry, Hayle, Cornwall: Historic Building Recordingportion of a great range of mining machinery and equipment. The bedrock ofthe business was not the great engines, splendid though they were, but thewholly mundane though essential import and sale of coal, timber, and buildingmaterials through the now rapidly expanding port of Hayle.Harvey's influence and prosperity peaked from around 1820 to 1870, and 460were employed in the Foundry in 1841, with another 400 engaged in thewharves, building and coal trades. Engines were built for mines in Cornwall,many other metal and coal mines in Britain, Australia, South Africa, SouthAmerica and 6 Spain; engines were also supplied to waterworks in Britain andHolland (the Haarlem Mere engines). During this period (and especially in the1840s during the period of the Haarlem Meer contracts) the works in FoundrySquare adapted and expanded to cope with an ever-increasing volume ofwork.Two years after the death of Henry Harvey in 1850, the firm was dividedbetween his nephews, the Harveys retaining the foundry, shipping and generalmerchandising business, the Trevithicks taking the milling, baking, farm andgrocery business, this change has had a notable impact on the character andappearance of the surviving buildings on site.Harvey & Company's main competitors during this period were theCopperhouse Foundry of Hayle, and the Perran Foundry at Perran Wharfbetween Truro and Falmouth. By 1876-7 both of these had gone out ofbusiness, victims of the decline in Cornish mining, and Harvey's was alsoforced to diversify in order to survive. A new shipbuilding yard was constructedwith slipways and boilerworks, intended to compete on a national level withother yards producing vessels up to 4000 tons. The foundry was gradually rundown as the century ebbed, having been subsidised by the trading branch formany years; final closure came in 1903, and the firm concentrated on thetrading and shipping sides of business. The firm of Harvey & Co. continued toact as builder's merchants, and merged with UBM in1969.3.2The two buildings which are the subject of this report were built, according toParkes Lees 2002, 26, in 1840-45, the Plantation Store being more preciselydated to 1843-5, 22. The Pattern Store is first identified on a plan of 1853,(as Pattern Shed) but is there shown as a parallelogram (CAU 1995). ParkesLees 2002, 7 implies it was in existence by 1841. It first appearsunequivocally in its present plan in 1879 (CAU 1995, and see Fig. 3). By thistime it has the Cart Shed, called a linhay in the CAU report, attached to itswestern façade, and attested by 1864.

Cotswold Archaeology4.Harvey’s Foundry, Hayle, Cornwall: Historic Building RecordingDESCRIPTIONThe Pattern Store and Cart Shed4.1The Pattern Store is rubble-built in local sandstone with granite quoins,jambs, lintels and sills (Fig. 7). Brick is also used. It is three storeys high andrectangular in plan (Fig. 4). It is currently roofless, but had a low, hipped roofuntil this was destroyed in a fire in 2000. The interior timberwork wasdestroyed in the fire and removed. However, cast-iron beam pockets in theinterior walls indicate the spacing of the beams and the level of the originalfloors (Figs 6, 8 and 9) and that they were replaced by a two-storey layout ata later date (Fig. 10). The store is set into a slight slope to the west andsouth so that the ground floor of the west and south elevations is terracedinto the hillside. A retaining wall leading in an arc from the south-west corner,and another joining to the Pattern Shop/Boring mill, a major roof-lessstructure to the south-east mark the change in level on the south where awater reservoir once stood, at least by 1853 (CAU 1995 and Figs 4, 6 and11). This area is now occupied by car parking and a modern office block.4.2The east elevation is the only one with a significant “design”, the others beingessentially blank. It has six bays, mostly defined by the fenestration. Thesecond and fifth bays are different (Fig. 7). The second has a large doorwayreaching up into the second floor. This is obviously an insertion and has brickjambs and a timber lintel. The fifth bay has a wide, elliptical-arched doorwayin the ground floor (with brick voussoirs) and a loading door in the first floor.In fact, the traces of a similar door and arched opening can be seen in thesecond bay, largely removed by the inserted opening (Figs 7 and 8). Theoriginal design was, therefore, symmetrical. Concern for architectural effectis evident in the sharp finish of the corners of the granite elements,contrasting with the rough faces, producing a low-key rusticated effect.Wooden casement windows and plank doors seem likely to be original or atleast early. All the ground floor openings except the large one are nowblocked with concrete blockwork.4.3The internal layout can be glimpsed from traces in the present structure but ithas been thoroughly stripped out. The original floors were boarded and laidon joists supported between bridging beams and into pockets in the endwalls (Figs 8, 9, 10 and 12). The interior was lime-washed and there is themark of a contemporary internal partition in the middle of the south end wall

Cotswold ArchaeologyHarvey’s Foundry, Hayle, Cornwall: Historic Building Recording(Fig. 13). The blocked door in the south end of the west wall led into thispartitioned-off space. At the north end a doorway (still with its wooden doorand frame) opens at first floor level into what was a further room to the north(see below, 4.5). The room this leads from has the remains of a fireplace andis plastered (Fig. 12). The remains of the plaster presently extend as farsouth as the first floor beam and this may have been the original extent, i.e,just the northern bay of the first floor, this and the fireplace marking an office.4.4The large opening in the south end of the east elevation has already beenremarked upon. It cuts across the original first floor and indeed has removedone of the first floor beam sockets, indicating that, at least here, the first floormust have been heavily modified (Fig. 8). In fact, there is a complete set ofnew beam pockets in the west wa

Harvey’s Foundry Trust on two Grade II Listed Buildings, the Plantation Store and the Pattern Store, at Harvey’s Foundry Hayle, Cornwall, (centred on NGR: SW 5579 3710; Fig. 1). 1.2 Harvey’s Foundry is a component of the Cornwall and West Devon Mining Landscape World Heritage Site (WHS A2, Port of Hayle - WHS 2006) and is

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