In the heart of County Durham, nestled in the picturesque town of Staindrop, stands the majestic Raby Castle. This 14th-century marvel, renowned for its stunning grounds, walled gardens, and deer park, remains one of the most intact castles in British heritage. In 2022, Raby Castle embarked on an ambitious redevelopment project known as ‘The Rising’, aiming to breathe new life into this historic landmark while supporting the local economy, encouraging local business’ to be part of this monumental project.
Enter MSF. When approached to tender for not one, but two significant areas of this prestigious project – the Vinery and the Coach House – we knew this was an opportunity to showcase our expertise and push the boundaries of washroom design.
We began work on the washroom refurbishment project back in February 2024, with a target completion date set for the end of May. The main challenge we faced was working within the constraints of a historic building, as the client felt passionate about preserving the original interior structure. Maintaining the integrity of the walls, which had to remain in their original state, required careful planning and execution.
Fortunately, we were able to form a strong working relationship with both the contractor and the client. This allowed us to truly understand their vision and do everything in our power to bring it to life. The whole project really showcased the skill and expertise of our manufacturing team, who have over a century’s worth of combined experience. Though we faced a few challenges along the way, experience from previous projects enabled us to effectively overcome any obstacles we faced.
This article delves into our journey at Raby Castle, highlighting how we transformed the washroom spaces in both the Vinery – a stylish eatery inspired by a traditional Victorian glasshouse – and the Coach House – a reimagined retail and exhibition space, housed in the preserved horse-drawn carriage store.
Let’s explore the challenges, innovations, and triumphs that made this project a true landmark in our company’s history. Almost as much of a land mark as Raby itself.
Expanding Our Expertise: Solid Surface Cubicles
One of the most exciting aspects of the Raby Castle project was our foray into fabricating cubicles entirely from solid surface material. In total we crafted sixteen pilasters, cubicle dividers, and doors using HI-MACS Solid Surface in the colour, Alpine White. The result was a sleek, modern look that perfectly complemented the renovated spaces of both the Vinery and the Coach House.
A crucial, technical challenge we encountered was the client’s preference to forgo the traditional head trim that typically bridges the pilasters and dividers, often found in public or education-based washrooms. Consequently, we affixed the dividers and pilasters directly to the ceiling to create a seamless wall of cubicles. The only opening was the 15mm shadow gap between the top of the door and ceiling.
Without the experience and expertise of our manufacturing team, affixing the multiple, substantially heavy panels to the original ceilings in both the Vinery and the Coach House would’ve proven to be an immense challenge. But our skilled fabricators and installers were more than capable to execute this with precision and efficiency.
They ensured the panels were fabricated to weigh as little as possible, to prevent putting unnecessary strain onto the ceilings. This approach also meant our installation team had a far better experience when it came to fixing the dividers and pilasters firmly in place. It’s a great example of how our manufacturing expertise, combined with our collaborative approach, allows us to tackle even the most complex projects with confidence and success.
In regard to hardware, the client opted for stainless steel finishes throughout. This included all ironmongery – specifically, the hinges, locks, and cubicle feet – which were expertly installed by the MSF team, and complemented the contemporary style of the cubicles.
Introducing the Mirrorbox: Innovation Meets Functionality
This project also saw the debut of our latest product innovation: Mirrorbox units. These cutting-edge 600mm fixtures seamlessly integrate a soap dispenser and hand dryer within a stylish, mirrored cabinet. Complete with engraved bubbles and air flow symbols to indicate the two differing functions. This clever design not only enhances the aesthetic appeal of the washrooms but also improves functionality, creating a more streamlined user experience.
In the wake of the Covid-19 pandemic fewer touch points in public washrooms is vital to reduce the spread of germs and harmful bacteria. Installing a Mirrorbox unit is a stylish, yet practical solution, which minimises the threat of infection throughout the washroom.
While Mirrorbox units have been a new addition to washrooms over the past few years, we struggled with finding a unit that suited not only our customer’s needs, but also our own requirements where our product development portfolio is concerned. We discovered that most Mirrorbox units on the market were 700mm wide with a ‘garage-door’ style opening, which unfortunately would not suit the tap placement for this project. As a result, we engineered our own Mirrorbox unit to ensure we hit the client’s brief.
Working alongside some of our own washroom customers, and various other companies within our supply chain, we were able to successfully manufacture a 600mm wide module Mirrorbox unit with a standard side opening door. This worked perfectly with the 600mm tap spacing for the Raby washroom project. However, it also aligns with our standard range of washtroughs and vanities, which are typically produced in 600mm increments.
Bespoke Solid Surface Vanities and Splashbacks:
To further elevate the washroom design, we installed bespoke vanity units crafted from HI-MACS Alpine White solid surface, complete with integrated HI-MACS CB483 basins.
The stylish vanities were complemented by striking splashbacks made from Krion Solid Surface in Atlantic Blue Star, which included a coved design for effortless cleaning and a smooth appearance. By reducing the areas that would normally require grouting or silicone, the design also lessens the chance of spreading germs in the washroom area.
Coordinated Finishes Throughout
Attention to detail was paramount in this project. We fabricated urinal panels using HI-MACS Aurora Ecru, a heavily veined and pigmented colour, with a warm, neutral tone that added depth to the colour palette. The IPS toilet panels were crafted in the same matching colour, ensuring a cohesive and polished appearance throughout the washroom spaces.
Specifically in the Coach House area, where cubicle space was limited, cohesion played a massive role as we were tasked with creating a seamless WC access flap, so when necessary, the integrated plumbing system for the toilet can be reached.
As the HI-MACS material was directional, with a soft vein running throughout the sheet, it was important to ensure the vein ran in the same direction and aligned where the access panel was positioned. Our eagle-eyed fabricators ensured that this small, yet striking detail was thoroughly thought out prior to the fabrication process.
A Testament to Teamwork and Skill
The scale and complexity of the Raby Castle washroom project truly showcased the exceptional talents of our MSF team.
Starting with Graeme Kavanagh, our Managing Director leading the way, assisted by the sales, customer service & estimating team, who diligently analysed countless drawings to ensure the clients vison was truly brought to life.
From the initial design & programming phase executed by our CAD technicians & CNC operators, to our skilled manufacturing team, who worked tirelessly to create each of the individual components of the washroom, right through to those involved in the installation process, who spent days and weeks both in the factory and onsite, meticulously tidying up the finer details.
All of our craftsmen demonstrated their expertise in working with a variety of materials and creating bespoke solutions to meet the unique requirements of this historic venue. It truly was a remarkable effort from all those involved.
Conclusion: Setting New Standards
The Raby Castle washroom project demonstrates our capabilities of full cubicle fabrication and introducing innovative products like the Mirrorbox to our product range, we’ve positioned ourselves as leaders in comprehensive washroom solutions. This project not only allowed us to contribute to the preservation and enhancement of a cherished historical site but also set new standards for what can be achieved in modern washroom design.
As we reflect on the success of the Raby Castle project, we’re excited about the future possibilities it has opened for MSF. We look forward to bringing our skill set and innovative approach to more projects, continuing to push the boundaries of washroom design and functionality.
Do you have a challenging solid surface project on the horizon ? Why not get in touch with us by calling 01325 308444 or sending an email to Sales@msfl.uk.com – a member of our team will be more than happy to assist with any solid surface requirements.
For further information on the various solid surface services we can offer, have a read of some of our other case studies linked below.
- Raby Castle Washrooms: A Landmark Project for MSF
- Gillani Noor Trust (Normanton Stoke Mosque)
- Bankside Western Yards Washroom Case Study
- Grey Onyx Kitchen Worktop Installation.
- IQ Shoreditch Kitchen Tea-points.
