This is always the first stage; you need to physically remove the rock from the face.

Generally, this is where we bring in the big boys! The largest machines in the quarry with a large pick on the front of them. The hammer comes down on the top of the rock face to break off the best piece that it can.

Once removed, it is then gathered up and transported ready for the next stage.

We have different products that we can produce so it is important that we channel the right stone to the right place.

The biggest chunks are sent to the biggest saw to be cut into more manageable pieces ready for splitting and trimming into roof tiles.

Remaining is a mixture of small and medium pieces. These will be picked out from the pile and sorted for walling, hedging or aggregates.

At the biggest saw each large slab is assessed for the best way to cut it and then marked up with pencil. These lines are then scored before the blade goes in for cutting, this helps to prevent the slate from breaking of losing shape. Here they are cut into manageable pieces ready for their next step.

This isn’t the only cutting that we do!

We select slate out for facing stone and cut it to 100 mm or 150 mm bed depth (distance from the front to back of the stone), as well as single or double Quoin’s (corners).

We try not to waste anything so the pieces that are trimmed off are recycled. Crushing and screening allows us to give a wider selection of products as well as reducing waste.

This is where the pieces from the big saw have their next step having been cut and washed. It is important to keep the stone damp as if it dries out too quickly then it can separate where you don’t want it to.

Splitting is carried out by hand as it has always been done using basically the same tools. The Bettle (hammer) and Chisel have also given their name to one of the local pubs in Delabole.

The pieces are skilfully split into different sizes, shapes and thicknesses. Any excess or loose extras being scraped and trimmed away leaving the perfect roofing slate.

Not all pieces are suitable for splitting but are ideal for slate flooring which can be trimmed on all four sides or more along the lines of crazy paving being truly random.

They don’t all make the grade!

Some split and break up as the layers separate others can have faults of cracks in them. Any waste can be crushed and recycled into another product line.

Trimming is a vital step now to make sure that the pieces are the correct measurements.
The roofing slates are also dressed at this point.
Dressing involves trimming the top two corners at an angle forming the traditional shape that we have come to expect.

There is always an element of grading at each step along the way as the stone is divided up into its resident lines, but it is particularly essential when dealing with roofing slates.

Once trimmed, cleaned and measured, it’s now time to divide them into different categories based on colour and thickness.

Grades are an indication of thickness and texture, each with specific attributes.

Once graded the roof slates are carefully crated up ready for delivery to the right customer.

Some customers request the same size of slate whist other are looking for different sizes in order to create diminishing courses (large at the bottom gradually getting smaller towards the top of the roof).

Walling stone usually measures 3-9”, whist hedging stone could be small or medium/large in size.

You may be looking for rough or screened hardcore or something more refined and crushed.

Each has to be separated out and be ready for delivery.

The method of shipping and delivery can be dependent on the product you are having.

Roofing slates are lined up in crates to keep them secure.

Facing stone is palleted and wrapped to 1 ton or 11/2 ton.

Walling and hedging slate is usually delivered loose, but we can discuss bagging small amounts.

Different size aggregates are predominantly loose.

We are very proud of what we produce and aim to find you the best product for your needs.

Slate in our opinion is one of the best materials available whether you are using it internally or externally. Centuries have proved this to be true so if it’s not broken, don’t fix it!

Keep using slate wherever you can! It’s time to get creative.