The Great Staircase at Sudbury Hall

Step one

A plan is created

We’d known for years about the structural integrity of the stairs due to the poorly fixed treads, the resulting vibrations and the undersized carriage beams.

With the help of Structural Engineers, Frank W. Haywood & Associates, Building Surveyors, Kirby Surveying Ltd and conservation and joinery experts, we came up with a detailed plan, which was reviewed by the National Trust teams before heading off to our local Conservation Officer, for listed building and planning consent.

Due to the nature of the planned repairs and the importance of the staircase we needed to tread carefully, to ensure this one-off opportunity to fix the stairs didn’t fail.  

Step two

Permission is granted 

Once permission was granted, a team of experts began the much-anticipated work. The structural engineer, building surveyor and regional conservator worked side by side, bringing in relevant specialists, when needed.  

This included the specialist craft team from Clumber Park – a band of two specialist joiners who lovingly took the staircase apart, conscientiously carried out all the repairs, and then - one piece at a time - reconstructed the staircase. At one point, the staircase was stacked in a state room (numbered and labelled) like a giant puzzle ready waiting for some keen-eyed individual to put back together.  

Step three

Uncovering history

We discovered that whilst the extant appearance of the staircase is regarded as one of the finest surviving examples of its period, the underlying structural carpentry is rather crude and 70 per cent of the timberwork is reused from an earlier building (evidenced by empty mortices and cut joints).

This a classic example of only using the best quality materials for the areas that were to be on show, and making do otherwise to save costs.

Step four

A team of experts from every field  

We brought in Cliveden Conservation who surveyed the plasterwork which surrounds the Great Staircase and assembled a very complicated set of scaffolds and supports, to ensure that no damage would occur when the staircase work was taking place. They ensured the irreplaceable plasterwork remained intact and undertook the cleaning and assessment of the lath and plaster soffit. 

Step five

Archaeology  

Archaeologists Jessop Consultancy were brought in to survey the staircase before, during and after the works. It’s not often you get to see inside a staircase, so we were very excited to see and hear about what they found when the treads and risers (the steps) had been lifted. Their findings included dirt, nails, a plank with integrated wheels which was probably part of an early bell-pull system and a bone button.

Step six

Local supplies

As the repairs began, we used the neighbouring Calke Abbey for the supply of oak and we used a regular supplier for the fabrication of a huge metal girder, which now sits within the staircase, ensuring its fully supported for years to come.  

It was a mammoth (and nerve-wracking) effort to get the metal girder in through the historic Saloon window. It was lifted and guided through with an army of Trust staff, from Hardwick Hall stonemasons.   

Step seven

A fine art

A team of experts from Crown Fine Art Handlers removed all the paintings on and around the Great Stairs, to ensure they weren’t damaged with the work taking place. When the paintings were down and safely stored in the Great Hall, they were inspected, cleaned and catalogued.   

Step eight

Strengthening and moving  

The team from Hog and Fitch Conservation Cleaning and Collections Care ensured the protection and supervision of strengthening work – they moved what could be moved, and protected what had to stay in place. They also took photos, cleaned up after everyone and were on hand for troubleshooting.  

Step nine

The end is in sight

At the end we used a specialist decorator, Steve Lambert, to touch up some of the paintwork in the areas that had been disturbed by the work. This was a chance for the famous Sudbury yellow paint to be used again on the Great Staircase (who else has a Farrow and Ball paint named after their walls?).