Thursday, March 28, 2013

How to build a garden railway (or "If I knew then what I know now")

With over six years' experience under my belt, I have now reached that point where, if I was to start all over again I would be more likely to know what to do - with the precise science of hindsight! I well remember, when I first started, I scoured the Internet for information about how to build a garden railway and bought all the books and videos I could find (See Where did I get my ideas from). This posting is to repay all the decent advice I gathered and to offer a few suggestions of my own based on experience. As with all my postings, I do not profess to be an expert, but I hope my jottings may be useful for someone else setting out on this adventure.

This posting is divided into 9 sections:
  1. Planning the line
  2. Landscaping
  3. Preparing the trackbed
  4. Choosing and laying the track
  5. Plants
  6. Power
  7. Rolling stock
  8. Detailing
  9. Operation

I've made a couple of videos  summarising the process of building my railway which you might find interesting - the first is short and focused while the second is longer and provides more detail.




I spent ages (literally years) planning my railway. As you can see from my early scribblings, I toyed with all sorts of ideas until eventually hitting on the design which seemed the most promising (See Planning the Railway or How to plan a garden railway )



Once I hit on the basic layout, I thought of ways in which it could one day be extended. Then split this into different phases, so what once I did the initial landscaping, I would have in mind what might happen next.

What have I learned?

  • Visit other peoples' garden railways (eg Bekonscot) and see what others have done by viewing DVDs (eg Garden Railway Magic etc.)
  • Read as much as you can about garden railway modelling and learn from others' experience.
  • Brainstorm as many ideas as possible, before picking the one which seems most promising
  • Include at least one continuous run of some sort, so a train can be left to run around a circuit whilst doing the gardening or having a barbecue
  • Don't be too over ambitious in the early stages, but plan in possible extensions to keep interest going as more funds become available
  • Decide on a prototype area or region, to help focus the sort of stock to be purchased (and avoid investing in things which are inappropriate)
  • Phone up or visit the main stockists (ie Garden Railway Specialists, Glendale Junction, Kent Garden Railways, Scottish Garden Railways) to find out what second hand bargains they have in stock. I bought a job lot of secondhand track from one supplier for quite a bit less than it would have cost on eBay!
  • Consider joining one of the Garden Railway Associations to make contact with other like-minded modellers - eg Association of 16mm Narrow Gauge Modellers - G Scale Society 


It is not necessary to make changes to the design of your garden to be able to accommodate a railway, but sometimes it is worth considering.


I decided to go for a wholesale reorganisation of the garden to accommodate my looped-eight design. This involved wheel-barrowing somewhere in the region of two tonnes of earth and manhandling around three tonnes of sandstone in one of the wettest summers since records began. However, the resulting railway is a lot more interesting than the original garden design would have accommodated. I was determined to include a water feature, and opted for a method of construction which was very much trial and error (see How I constructed the stream). However, I am very pleased with the results.




What have I learned?

  • Putting the layout on raised beds has definitely been worthwhile. Although there is some stooping involved, much of the maintenance and operating can be done in a standing position. I'd say the minimum height for comfortable operation is 30cm (12") and 60cm (24") is quite comfortable. And, of course, when I become old and decrepit, I will probably appreciate it even more
  • I did toy with the idea of hiring a mini digger, but the cost of £120+ a day seemed excessive. However, in hindsight it would have saved a lot of time and effort, and probably saved my knee ligaments from the damage caused by jumping up and down on the spade.
  • I wish I'd bought more rock. Two tonnes plus what I dug out of the garden seemed like an enormous quantity at the time, but it soon disappeared. I have considered moulding rocks from concrete (eg see Making concrete rocks and cliffs), but a friend donated a trailer load from a defunct rockery he was dismantling.
  • Try to keep the line as level as possible using a spirit level or laser level, but if gradients are required, then keep these as shallow as possible (see How I laid the track and Making the Grade)

I laid my track on concrete blocks (See How I laid the track). I decided this was likely to be more flexible than shuttered concrete, particularly if ever I wanted to change the layout of the line and as I had some 'breeze blocks' left over from constructing a lean-to. For some of the line, the track has been mounted on wooden fence rails and posts (See How I constructed the extension). I had some of these left over after removing a fence along the side of the garden and hence, initially, this cost me nothing.



A lot has been written about various types of track foundations with various claims made for the relative merits of the various approaches. As I was using flexible track which has a tendency to try and straighten itself out, I wanted something quite substantial to which the track could be fixed. Those who have rail benders or use preformed track sections tend to go for more prototypical chippings or gravel laid in a weed-proof trough. I've not experienced any problems with drainage and in only three places have the blocks sunk. In one place, the sandstone retaining wall gave way, and hence the soil beneath the block was displaced and in the other two cases I did not firm up the soil beneath the blocks. I've changed the layout in a couple of places (by adding new stations) and been able to lift the blocks without problem or combined the existing blocks with others. The original blocks are weathering nicely and in many places are not visible.

Other types of track foundations

Concrete
A trench is dug and/or shuttering is made defining the route of the railway and concrete is poured in. Once set, the track is glued, screwed or simply placed on the foundations.

Source: http://www.forum.gscalecentral.net/download.axd?file=0;221135&where=msg
Gravel
A trench is dug, lined with some sort of weed barrier fabric and filled with layers of gravel. Pre-formed track sections are laid on top of the uppermost layer of gravel. Sometimes lawn-edging is used to line the trench to keep things neat and tidy.

Source: http://i25.tinypic.com/xo2xeh.jpg

Wood
Wood (these days mostly decking planks) are laid on the ground and track is glued or screwed to it. Soil is piled up to the top of the planks and ballast is laid loosely (or glued) between the sleepers to disguise the trackbed.
Source: http://ovgrs.editme.com/files/Lily/LillyN.jpg

What have I learned?
  • If using blocks or a concrete foundation then firm up the foundations beneath the blocks and spend plenty of time levelling them (using a spirit level). I use a mixture of sand and soil on which to bed the blocks. I could have laid a bed of cement for an even firmer foundation but I prefer to retain the flexibility for times when I change my plans.
  • Fill the gaps between the blocks with cement to prevent weed growth. I stuffed wet cement into the gaps with rubber-gloved fingers and a small trowel.
  • I used paving slabs for the base of Bickerton Station, largely because I had a couple available and because I wanted storage beneath. Although drilling holes for the rawlplugs was difficult (I blunted three masonry drill bits), the firm foundation has proven to be highly effective for the pointwork, unlike other stations where it has been difficult to keep the pointwork level apart from through the use of fillets of roofing felt.
  • I have used roofing felt between the track and the wooden fence rails for the most recent sections of raised track but not on the original sections. It's too early to say if the sections protected by the felt are going to last longer but logic would suggest they will.

 I decided from the start that I would use G Scale or 45mm gauge track. This was because, at the time, I had a fairly onerous job and I wanted to be able to run trains fairly quickly by buying ready made locomotives and rolling stock. Also, I knew I would not be able to afford live steam locomotives and felt more confident with using track power as I had spent most of my life modelling indoor railways. I am also very interested in narrow gauge railways and there are plenty of models and kits available in 16mm scale - which would mean 45mm track would (nearly) represent three foot gauge.

Other choices I could have made include:
  • 32mm track, 7mm : 1foot scale (1:43) - standard gauge models (0 scale)
  • 32mm track, 16mm: 1 foot scale - 2' narrow guage (SM32)
  • 32mm track, 7/8" : 1 foot scale - 18" narrow gauge (7/8" scale or SE32)
  • 45mm track, 10mm : 1 foot scale - standard gauge (Gauge 1)
  • 45mm track, 13.7mm : 1 foot scale (1:22.5) - metre gauge (G scale)
  • 45mm track, 15mm : 1 foot scale (1:20.3) 3' narrow gauge (Fn3)
  • 45mm track, 7/8" : 1 foot scale (1:13.7) - 24"gauge (7/8" scale or SE45)
There are many other gauge/scale combinations which are suitable for the garden - for more information see- http://www.rmweb.co.uk/community/index.php?/topic/41313-new-to-garden-railways/

I've used five different types of brass track quite successfully together - LGB, Aristocraft, Piko, Trainline and Tenmille.

My initial choice was Tenmille, as I intended to use their larger radius points throughout - which were cheaper than the LGB equivalents. Unfortunately, I was unable to buy their pointwork and so had to go for LGB. At first, I used the special Tenmille to LGB rail joiners, but more recently have found that standard LGB rail joiners (with the tab removed) to be fine. The Aristocraft rails appear to be cast from a different sort of brass to LGB and Tenmille which is softer (hence more inclined to kink when bent) but tarnishes less easily - and hence takes less effort to clean.

I was disappointed with the Aristocraft pointwork, which seems to use steel screws rather than brass or stainless steel. Hence the screws rust very quickly. Otherwise, they perform the job just as well as LGB (and are cheaper). The point motors for Aristo need an AC input, whereas the LGB need DC - hence the two are incompatible if you are intending to have your pointwork electrically operated. Since I started building the railway, I have also used pointwork from Piko and from Trainline45 and found them to be equally compatible.

Coming from an 009 and 00 gauge background, I prefer to use flexible track, which can be shaped to fit the location, rather than the other way round. I've not really experienced any problems with laying flexible track in the garden, except on one occasion when I had a rail joint in the middle of a fairly tight curve.


This was quickly remedied by replacing the faulty section with a new length of rail (See Progress Report 15)

I've bonded all the joints with soldered 'jumper' leads (See How I bonded the rails). I found this needs a hefty 75 watt soldering iron as a weedy 25 watt iron doesn't pack out enough heat. I understand gas-powered irons can be effective and highly portable but have never tried one. 



One reason why I opted for flexible track was to cut down the number of rail joints needing to be bonded - it can be a time-consuming process but to my mind, well worth it. I understand that some opt for graphite grease in the rail joiners to assist with electrical continuity and/or use rail clamps which are clearly a more expensive solution than soldering but are less fiddly and make lifting track easier should track formations need to be altered.


Source: http://www.svrronline.com/images/100_1907.jpg


What have I learned?

  • I decided very early that I wanted to model a narrow gauge railway on 45mm track and focused my purchasing around this decision.
  • It's OK to mix track types - LGB rail joiners are fine for all combinations of track
  • Aristo track takes less effort to clean than LGB or Tenmille
  • Flexible track needs to be fixed in place quite firmly (unless you have a rail bender - which I don't) - but try to avoid having rail joints on curves (unless you have a rail bender)
  • Try to avoid fixing points down as it can distort them. Rely on the plain track either side to hold the points in place
  • Bond all rail joints using a heavyweight soldering iron - but ensure the 'jumpers' allow for the expansion and contraction of the track - particularly where long flexible track sections are used

I'm not really into plants. I tend to buy whatever I can find that seems reasonably priced, shove it in and wait to see what happens. However, I have found, through trial and error, that some plants seem to be particularly successful and are in keeping with the miniature landscape.


For more detailed information on my experiences see What types of plants seem to work best. (pending).

What have I learned?

  • Keep looking at private an public gardens to pinch ideas. Not far from where I live is a private garden which is planted exclusively with heathers and conifers. Some of my ideas have originated here. You could always visit Bressingham Gardens in Norfolk. Plenty of ideas for gardeners with the added bonus of live steam railway exhibits.
  • When visiting the garden centre, read the plant labels carefully. Look for plants with small leaves, a slow growing rate and whether they will tolerate the growing conditions in the part of the garden you are intending to place the plant.
  • Keep experimenting. Nature is very good at providing you with feedback on how successful your choice of plant has been. If something becomes too vigorous, cut it back, move it or remove it. If something dies, pull it out and try something different.

Having now explored all forms of track power and converted my locos to battery power, I now know a lot more about what seems to work and what doesn't. I have not yet explored live steam - but that may be an area for future experimentation.

Track power

Pros
The great advantage of track power for someone such as me who has spent over 40 years modelling railways indoors is that it is familiar. It also provides a fairly reliable means of powering locos and, with DCC (Digital Command Control) offers a lot of flexibility - there's no need for isolating sections or complicated systems for reverse loops etc.

Cons
The two major disadvantages of track power are the need for scrupulous track cleaning and the need for supplying power into the garden through wiring. If you opt for DCC another consideration is expense - DCC systems for large scale garden railways are considerably more expensive than those for 12 volt indoor railways - decoders for each locomotive can cost upwards of £50.

Track power with remote control

For a while I ran my trains with a transformer/controller and control panel situated in an outhouse.


However, I quickly found that it's preferable to follow trains around the garden for both practical and aesthetic reasons and having to keep dashing inside whenever something needed controlling became somewhat of a chore and so I invested in an early version of the Aristocraft Train Engineer and a more powerful transformer.



Eventually, I swapped this for LGB's DCC MTS system when I found the additional wiring needed to isolate passing loops was becoming too complicated. I did consider having isolating switches mounted adjacent to each station section but the increased flexibility offered by DCC in being able to use one wireless controller to operate all the locos and the electrically operated turnouts won me over to what some in the hobby consider as 'The Dark Side'.



As you can see I have still retained an analogue controller which has to be completely isolated from the DCC system but would allow me to run trains if something dramatic happened to the DCC system.


Battery Power

This is a new venture for me and I am still exploring its potential but battery-powered locos do offer some advantages over track-power (see http://youtu.be/pKznXSHVTIE and http://youtu.be/8VcfKxg8YBE )]

Update - February 2016
In the three years since this posting was originally written, I have completely abandoned track power and converted all my locomotives to battery power with radio control. I have become so enthusiastic about the virtues of radio control that I have now set-up my own small online business making and selling transmitters and receivers based on the Deltang system - see http://rctrains.co.uk/  The comments below were made three years ago, when I was still experimenting with battery power and radio control.

Pros
  • Minimal track cleaning - although the track needs to be cleared of debris and overgrowth, the rails do not need to be spotlessly shin
  • If you choose the right equipment, battery power can work out to be less expensive than, or at least comparable to track power
  • Provided the gearing is appropriate, locos can be made to run at very realistic slow speeds without jerking over dead sections in the track
Cons
  • Some approaches to radio control can become expensive  - in addition to a transmitter and receiver for each loco, a motor controller needs to be purchased which, for something reliable and realistic, can be at least as expensive as a transmitter.
  • Good quality rechargeable batteries can be expensive and will ultimately need to be replaced as they deteriorate
  •  While some systems can be plug and play, some knowledge of basic wiring and electrics is required to make the most of radio control
Update February 2016 - I have now created some posts providing information on battery power for garden railways
 I have also learned a great deal from Greg Hunter's web pages about electronics and battery control used on his Sandstone and Termite Railway in Australia - http://www.members.optusnet.com.au/satr/electronics.htm 

Clockwork Power

Once this was one of the principal sources of power for large scale railways. It is surprising in today's eco- conscious world that this form of power is not still used more widely. I was first inspired to venture into the garden by reading about the Reverend Peter Denny's Trepolpen Valley Light Railway in the Railway Modeller in the 1970s and 1980s.
Image courtesy Railway Modeller - www.pecopublications.co.uk
 The principal method of motive power on the TVLR was clockwork. The stations were carefully positioned to be a clockwork spring-wind apart with gradients organised to initially slow fully wound locos down at the start of their journeys and to assist locos as they came to end of their journeys. Although clockwork power is used infrequently today  there are still a few advocates......

 

 Live Steam

I have very little first hand experience of running live steam locomotives and so I would advise you to seek advice from those who know more than me, such as:

Tag Gorton (1996) Steam in Your Garden: An introduction to live steam narrow gauge railways for the smaller garden. Atlantic Transport  / Garden Rail - ISBN 0-906899-67-2 

This is considered by many to be the definitive guide to garden railway live steam. Tag Gorton has been the editor of the Garden Rail magazine for many years and has had the privilege of running and test running a great number of live steam model locomotives. This is a highly practical and down to earth guide.



7. Rolling stock

Like many others modelling on 45mm track, I started with an LGB starter set which provides good value for money. The locos which are supplied with the starter sets are more than adequate and when I decided to start constructing my own rolling stock, provided a useful chassis on which to build. In fact all my scratch-built and kit-built locos are presently on starter set loco chassis.



The reason I began constructing my own models was principally because there were very few ready-to-run (RTR) models available which would enable me to create a railway based on British narrow gauge railway practice. Another incentive was that of cost, and also the satisfaction gained from creating my own models.


Since I started, more British ready-to-run rolling stock has come on to the market, primarily from Accucraft, and the range and quality of kits has improved markedly from such suppliers as Brandbright and IP Engineering

What have I learned?

  • Before starting accumulating loads of miscellaneous rolling stock, I decided on a hypothetical location for my railway. Some modellers decide their railway will be a representation of a modern day heritage railway and use this to justify a range of stock from various period.
  • I also decided from the start what type of railway I was going to model. I have certainly not regretted this as it has saved a lot of time and effort.
  • Initially, I bought items of rolling stock off the shelf so I could have something up and running as soon as the track was laid. Although this stock was not appropriate for the type of railway I wanted to model, I let my imagination compensate. As time has progressed I have slowly remodelled or replaced the stock to better represent that which would be found on a rural British 3' gauge railway.
  • I am happy to go for representations of stock rather than true scale models. I tend to compromise between realism and robustness. As long as it looks about right, I am happy.
  • I did some research on the numbers of locos, passenger coaches and goods stock which British narrow gauge railways held (see How much stock did each narrow gauge railway have?) and then used this to help guide what I should run on my railway. As would be expected, the number of locos, carriages and the levels of each type of goods stock depended on the amount and type of traffic which was carried. For a line of my type, I reckoned on 4 locos, three coaches, and around 40 miscellaneous items of goods stock, plus two rakes of tipper wagons for the copper ore traffic (see Stock list). Any more stock and my sidings would be overloaded. 
  • I will probably end up with 8 locos as I want to have a roster of track powered locos and a roster of battery-powered locos to give me some flexibility. Eventually I may opt totally for battery-powered locos if they turn out to be successful.



8. Detailing

 Once the hard work of landscaping and track-laying had been completed, one of the greatest pleasures comes in detailing the railway - adding those finishing touches which brings the railway to life. I am not aiming for creating a complete miniature world in my garden and prefer to see my model as a garden with a railway, rather than a model village such as Bekonscot. My focus is therefore on creating small pockets of detail, mostly around each station, although I have detailed the corner where the railway disappears behind the sheds (see Progress Report 27). Rather than creating tunnels, which would have been inappropriate for the locality in which my model is based, I have used two road bridges to mark the break between the 'seen' and the 'unseen' parts of my railway.

Bridges

There are three under-bridges, two over-bridges and a flyover on my railway. The overbridges have been cast in-situ from concrete (see How I cast two bridges in concrete), while two underbridges are basically wooden planks with cosmetic sides - one representing a viaduct (see How I constructed a viaduct - pending) and the other representing a steel swing-bridge (see How I constructed a swing-bridge). The other two bridges use the low-cost plastic LGB girder bridge which I have skewed to fit their locations (see How I skewed an LGB girder bridge).

Platforms

There are five stations on my railway - four have cast concrete platforms (See How I cast platforms in concrete) and one is made from timber covered in roofing felt (see How I made a wooden platform).

Buildings

Initially, I bought some resin kits for the station buildings (See How I constructed the station buildings) but I have also adapted a children's toy (see How I made a station building from a child's toy), used a pottery building from Stanton Abbey Pottery and scratchbuilt my own buildings from wood, clad in coffee stirrers and plastic sheeting (eg see How I made the engine shed).

Signals

Signals are not essential for narrow gauge railways - many of them used no signals at all and relied on the principle of one engine in steam. However, as my railway has quite high levels of traffic and can have three trains running on it at any one time, I decided it needed to be properly signalled. As I have five stations, this meant I needed 20 signals for even the most minimal level of signalling. To save costs I constructed my own - see the April 2013 edition of Garden Rail.



Vehicles

Because I have set my railway in the early 1930s, I am fairly restricted as to the model vehicles which I can buy off the shelf and so I am having to buy carefully, adapt children's toys or make my own. I have accumulated a mixture of steam-powered, petrol-driven and horse-drawn vehicles which I deploy mostly in station areas during the summer season. (see Progress Report 41 and scroll down)

People

The figures on my railway come from a range of sources. Many of them are resin cast figures purchased from ModelTown as they are relatively cheap. However, the detailing on them is fairly rudimentary. I have a few plastic Preiser figures, but these are quite expensive, and I have some cast whitemetal figures from several different sources such as Brandbright. I have also started sculpting my own figures from over-hardening clay. The first few figures which I produced are just acceptable if viewed from a distance, but I am gradually beginning to improve my techniques (see How I sculpted some figures - pending).

General clutter

The accumulation of general small details to adorn station areas and the copper mine, such as benches, porters' trolleys, fire buckets, bags, cases, barrels, oil drums, crates, sacks, tools and equipment, etc. is something which is ongoing - and probably will be for ever. I pick most of these small items up at Garden Railway Fairs such as that held annually at Llanfair Caereinion, but I also make my own from odds and ends and scraps.


What have I learned?

  • Basically, the more detail which is added the more alive the railway becomes.
  • Buildings need to be weatherproof and durable, Resin or plastic buildings are the best and these I leave out all year. Wooden buildings are more susceptible to the weather and so these are brought in during the winter and put out again in the Spring.
  • Figures need to be firmly fixed down otherwise they get blown or knocked over or even stolen by jackdaws! Again, these are brought in during the winter as they usually need some re-painting. I drill a hole in on foot of a figure and insert a short piece of brass rod; the other end is inserted into a hole or small rawlplug if on a concrete platform.
  • To minimise setting-up, I create small tableaux grouping figures and items together (eg outside a station building) which are mounted on plastic sheets.
  • There are plenty of internet sources showing how to sculpt figures from polymer clay - it's worth learning from others with more experience.


9. Operation

I like to operate my railway as closely as possible to prototype practice - though as my model of of a narrow gauge railway, there is considerable scope for individuality! Passenger trains run to a timetable which is based on one used on the Southwold Railway and a daily pick-up goods handles the freight. Sometimes, the last passenger train of the day is a mixed train (see A typical operating session). Freight movements are determined through the use of a computer program which tells me which wagons should be moved to where (see Freight operation). However, there are days when I abandon formal operations and just set a couple of trains running around the loop while I potter around in the garden or entertain friends.

What have I learned?

  • Spending some time planning the layout of the railway means that I can be flexible in how I use the railway. I have a circuit for those days when I want something up and running quickly, I can run trains end to end if I want realistic practice and I have a reverse loop if I want to run trains 'out and back'.
  • Using a timetable and some method of generating freight adds an extra dimension to operating sessions. Trains have a reason to be marshalled and sent to stations. 
  • You don't need a computer program to generate freight movements - on my indoor layouts I use cards for each item of stock and a dice to determine the destination (or whether something stays where it is).

10. The future?

Where next? One of the great things about a garden railway as that it will never be finished. In my case, because I opted for a phased approach, the line had steadily grown in length over the years. Although there is some scope for  further development, I am more inclined to slowly improve what is already there. I have an ongoing ToDo list which includes construction projects as well as general maintenance (see Progress Report 41). One day I will get around to constructing the siding to the water mill and the mill itself! (Now completed, see How I Constructed the mill - December 2017). Some of my rolling stock would benefit from more detailing and every station needs further titivation. You will see above that I have now gone over fully to battery power and radio control and certainly not regretted this move - no more track cleaning!


If you are considering constructing your own garden railway then why not get started. It's surprising how quickly you can have something up and running. However, take heed - this hobby is addictive!

Thursday, December 27, 2012

Bickerton Copper Mine

A brief history of Bickerton Copper Mine

It is thought that copper has been mined at Bickerton and Gallantry Bank since the Bronze Age and by the Romans, but the earliest documented reference to mining in the area is in a report written by J D Brandshagen in 1697 for Sir Philip Egerton.  The sandstone outcrop at Peckforton forms part of the same geology as that of Alderley Edge, where there is also evidence of copper mining (See Copper Mining at Alderley Edge).
Alderley Edge Copper Mine: Source http://www.derbyscc.org.uk/caving/caving_image/JK_trip_20060507_21_resize.jpg
The seams of copper were worked intermittently until the 1860s though there was an optimistic survey carried out in 1906 in a bid to raise capital for a more extensive mining venture.
Today, there is very little evidence of the copper mining industry at Bickerton and Peckforton. It is possible to squirm into an abandoned adit in the hillside above the Bickerton Poacher pub, but the five main shafts to the deeper copper seam have long since been sealed. The remains of the chimney for the boiler serving the pumping engine above the main Engine Shaft can be seen from the A534 road.
The remains of the chimney beside the sealed Engine Shaft (Source: http://upload.wikimedia.org/wikipedia/commons/7/70/Copper_mine_chimney_-_geograph.org.uk_-_713124.jpg)
I have been unable to find any drawings or photos of the copper mine when it was operational, the earliest I've been able to discover shows it in a derelict state taken at the beginning of the 20th century:
Bickerton Cooper Mine circa 1904 (Source: http://www.sandstonetrail.com/wp-content/uploads/Coppermine.jpg)

 The mines

 Although Shaft No. 5 and the Pit were shown in an 1890 survey of the mine workings (Edwards, 1890), only the Engine Shaft and Shafts 1, 2, 3 and 4 are shown in the 1906 survey (Spargo & Thomas, 1906) suggesting these were the only workable shafts at that time. This drawing shows the approximate position and extent of the workings based on these two surveys (click on the image to enlarge).
Bickerton Copper Mine (Based on Carlon (1981) Fig vii)
The Engine Shaft was the deepest, at 156 feet, No. 1 shaft was around 60 feet deep, No. 2 shaft was 35 feet deep, No. 3 shaft was around 110-120 feet deep, shaft No. 4 was somewhere between 117 and 135 deep while shaft no. 5 was 65-70 feet deep. As the the ore zone was inclined at an angle of approximately 80 degrees to the vertical, various levels and stopes needed to be worked from the shafts to access the ore. Shafts No. 4 and 5 were the oldest, and were worked until the beginning of the 19th century. Only Shaft 3 continued working after the mid 1800s. The pit between shafts 4 and 5 was later used as a well.

It is assumed that the mine shafts at Bickerton were relatively dry as the pumping engine over the Engine Shaft was a modest affair. Over the years, advice had been sought from Cornish mining engineers and so it is highly likely that the mining practices at Bickerton would have been heavily influenced by those carried out in Cornwall.
The type of pumping engine house possibly used at Bickerton (Source: http://farm5.static.flickr.com/4079/4798065476_e74ec2c1ee.jpg)
As the main shaft used for the extraction of ore was Shaft No.3 it must be assumed there was some sort of winding engine situated nearby, though this is not documented in any of the sources consulted.
Steam powered winding engine used in copper mine (Source http://s0.geograph.org.uk/geophotos/02/32/38/2323827_775bb0fa.jpg)
Through the 18th and 19th centuries various schemes were put into effect to develop the mine but by the turn of the 19th century, the mine had been left unworked for around 35 years. Edmund Spargo's survey of 1906 concluded that by widening and deepening the main shafts the mine could easily be expected to yield around 18000 tons of copper which would net a profit of around £1.1m (equivalent to around £115m today)! The Bickerton Copper Mines Syndicate Ltd. leased the mines for three years in 1907 but seem to have carried out very little work and was dissolved in 1911. In 1917, UK Minerals Development took out a three year lease of the mine but again very little work took place. During the 1920s, three local men worked No. 3 shaft intermittently using a bucket, rope and hand winch and unearthed some rich pieces of bright blue crystalline azurite.
Azurite and malachite (Source: http://upload.wikimedia.org/wikipedia/commons/9/97/Azurite-Malachite-59275.jpg)
By the 1930s the mines gradually fell into decay until the shafts were filled and sealed in the 1960s and what remained of the mine buildings were demolished in a road widening scheme in 1977.

 The minerals

There were two veins of copper-bearing rock in the mine at Bickerton which varied in width from eight inches to five feet, with an average of 2½ feet. There was also thought to be cobalt, lead and silver deposits in the seams. In 1802 a sample of ore from Bickerton was sent to the Mineralogical Society for analysis which pronounced there was 9% copper in the sample in the form of copper sulphide and copper carbonate. However, another analysis in 1806 found the ore varied in quality from 0% to 2½%, whereas another in 1862 found there was between 19¼% and 25% of copper and 18 ounces of silver per ton of ore.

The minerals present in the ore were malachite and principally azurite, though there were also traces of chrysocolla, melaconite, bornite and covellite. These were deposited in an almost vertical fissure of white sandstone, similar to that found at Alderley Edge, Clive, Pim Hill, Whixall and Eardiston.
Mineralised sandstone from Alderley Edge (Source: Minerals UK)

 The copper mining process

Until the middle of the 19th century, copper was extracted and processed mainly by hand, but thereafter mechanisation played an increasing role. By the early 1930s, when my model is set, pneumatic and hydraulic mining equipment would have been used, though this would also have been supplemented by hand tools and the use of explosives. As the shafts and galleries were very narrow, it seems reasonable that the narrowest gauge of railway would have been used to transport the ore and spoil beneath the ground. Railway tracks were found in the mines at Alderley Edge - though these are associated with later restoration work.
Copper Mines at Alderley Edge (Source: http://www.mine-explorer.co.uk/photo_cache/mines/Alderley-edge_2547/Alderley-edge_22468.jpg)
By contrast, in the Parys Mine in Anglesey there were no underground railways in the copper mine owing to the corrosive effects of contaminated water on the equipment (see Parys Underground Group - Railways). As we have seen above, the mines at Alderley Edge and Bickerton were relatively dry and it is more likely they would have used underground railway trucks to transport the ore and spoil if the mines had been further developed.
Tub from the Saint Veran Copper Mine in France (Source http://www.aditnow.co.uk/photo/Personal-Album-1-Image-067)
Once extracted from the mine the ore was crushed and then ground before the copper-bearing minerals were further extracted using an oil flotation process where the impurities rose to the surface and were skimmed off. The ore would then be smelted and refined.
Copper Processing (Source: www.bgs.ac.uk/downloads/start.cfm?id=1410)
 Once the ore had been removed from the mine and crushed, any rock which held more than 5% of copper could be sent directly to the smelters while any below that could be treated using the wet acid process which would produce copper sulphate (used as a crop spray).

The (fictional) history of the Peckforton Light Railway

To provide my 16mm scale garden railway with a realistic context, I have made some hypothetical propositions and just a few flights of fancy. However, where possible, these have been based on facts and reflect what might have happened, given the certain favourable conditions. My fictional inventions are shown in italics, the rest is factual.

In my imagined history (see A History of the Railway), the local landowner, Lord Tollemache, decided to invest in the copper mines following the optimistic report produced in 1906 by Spargo and Thomas. As a consequence built a three foot gauge railway to transport the mined ore and spoil to the mainline Crewe to Chester railway via the former Beeston & Tarporley Station. Bentley Tollemache succeeded his father, Wilbraham, as the 3rd Baron Tollemache in 1904 and as such became the owner of the Peckforton Estate which included Peckforton Castle. Peckforton Castle was built in the middle of the nineteenth century by his grandfather, John Tollemache (see History of Peckforton Castle). It was designed in the Gothic style by the architect Anthony Salvin and was described in 1858 by Sir George Gilbert Scott, the architect of St Pancras Station, as "the largest and most carefully and learnedly executed Gothic mansion of the present."
Peckforton Castle shortly after completion in 1851 (Source: http://www.dicamillocompanion.com/images/Houses/database/Peckforton_Castle.jpg)
Bentley Tollemache was actually a keen amateur engineer and I like to imagine that, as a consequence, he would have been very enthusiastic about constructing a narrow gauge railway to serve his pet project, the mining of copper on the edge of his estate. I also hypothesise that he would have constructed a 15" minimum gauge railway to handle freight within his estate, inspired by that constructed by his near neighbour, the Duke of Westminster at Eaton Hall (see Eaton Railway) and influenced by the work of Sir Arthur Heywood (see Historical Background to Minimum Gauge Railways)
Source: http://www.eatonestate.co.uk/NR/rdonlyres/914E2056-B26C-4216-9DD2-3E2E28C8E274/8142/Katie.jpg
I am assuming that as the ores were relatively copper-rich at Bickerton (if Spargo & Thomas are to be believed), once extracted from the mine they would then crushed before being loaded into wagons for transhipment to be processed and smelted elsewhere - maybe near the sister mines at Alderley Edge. I am also assuming that Lord Tollemache was a canny businessman and that he would have identified a ready market for the non-copper-bearing spoil. The sea defences along the Dee Estuary were being reinforced during the period in which my model is set and hence there would have been a call for crushed rock and rubble from a range of sources.
The Dee Estuary (Source: http://www.gutenberg.org/files/29787/29787-h/images/p033.jpg)
 My model of the mine assumes that more than one shaft would have been enlarged to allow for the mechanical extraction of the copper ores. Furthermore, additional shafts will have been sunk along the ore line to gain access to other rich deposits of copper-bearing ores. These shafts would have been interlinked at the surface by a 15" minimum gauge railway using internal combustion powered locomotives. Rock from the workings would be transported to the crushing and sorting machinery housed in sheds adjacent to the pumping engine and old mine workings beside the Engine Shaft. The pumping engine would have been updated, but remained steam driven, whereas the crushing, sorting and conveyor mechanisms would have been powered by diesel engines.
Ore crusher (Source: http://www.bricscrushingplant.com/images/solutions/gen/36.jpg)
 Although the image above shows a modern mobile ore crusher, the technology has not changed radically over the years and a similar, albeit stationary, system of crushing would have been in use in the 1930s. The ore is loaded into a hopper on the left and is fed into the crusher mechanism, which crushes the ore between fixed and movable jaws. The crushed ore is then conveyed to a loading hopper (see How I constructed a wooden loading hopper).

By 1932, when my model is set, I'm assuming that the viably workable seams were becoming exhausted and so there was proportionately more spoil being extracted than copper ore. As a consequence, there was less money available for carrying out repairs and the railway and the works were beginning to fall into decay. However, the tourist potential of the area was becoming more lucrative as the healing powers of the mineral waters in the Peckforton Hills were being exploited and the largely unspoilt scenery around Beeston and Peckforton Castles proved attractive for Bank Holiday visitors from Manchester and Birmingham.

Bibliography

  • C.J. Carlon. (1981) British Mining No.16:- The Gallantry Bank Copper Mine, Bickerton, Cheshire
  • H. Dewey. T. Eastwood. (1921) MGS Special Reports, Vol. XXX: Copper ores of the Midlands

Monday, December 24, 2012

Progress Report 44

At this time of year I tend to find that railway maintenance and development goes into tick-over. Rather than becoming immersed in a grand project, I am more inclined to tinker with several ongoing tasks. The major project on hand at the moment is the construction of buildings for the copper mine which are taking up quite a bit of space in the conservatory which I also use as a workshop. The sheer size of these structures means that each job takes some considerable time. There is also a fair degree of waiting between jobs as glue, paint or filler dries and/or hardens. During these interludes, I usually turn to other jobs - some of which I regret to say have to be non railway-related. Since the last progress report I have, however, engaged in a few other activities - constructing a wooden loading hopper from a kit, sculpting some figures in oven-hardening polymer clay and purchasing a kit for a battery-powered diesel outline loco.

Mine buildings - update

Since the last progress report I have grouted and started painting the stonework to more closely resemble the local sandstone. I experimented with various sorts of grouting and eventually opted for a mix of cream and brown tinted waterproof grout which was left over from a couple of household tiling jobs. The grouting not only fills the gaps between the blocks, it also gives them a bit more texture.

The corrugated iron sheets have been given a couple of coats of red 'oxide' primer and a start has been made on weathering them using acrylic paints and Scenic Rust which I used successfully to weather the tippler wagons (see How I weathered some LGB tippler wagons).

Originally, I cut down some 32mm gauge SM32 track to 16.5mm gauge for the minimum gauge feeder line, but this looked over scale. I have since bought some Peco 0-16.5 'crazy' track and although this is under scale, it more closely resembles the sort of lightweight rail which would have been used for a minimum gauge mine railway.

One day I aim to build and indoor Gn15 railway to maybe represent the imagined estate railway which my hypothetical history suggests would have been constructed at Peckforton Castle by Lord Tollemache, after having been inspired by his near neighbour's line at Eaton Hall (see A short history of the railway). As you can see, I have accumulated a few items of rolling stock over the past few years. My visits to various minimum gauge railways across the UK has made me become a lot more aware their history and the influence of Sir Arthur Heywood and Henry Greenly (eg see The Perrygrove Railway).

Loading hopper

A chance find on eBay led to the purchase of a prefabricated German wooden kit for a loading hopper. I had always intended to construct a set of wood and steel loading hoppers for the copper mine and this kit has somewhat short-cut the process.

The hopper will eventually be located over the track leading from the copper mine to the exchange siding at Beeston Market (see How I constructed buildings for the Copper Mine) but as this will require some widening of the timber trackbase the hopper was temporarily sited on the timber yard siding at Peckforton for the photo shoot.

There is still some detailing and light weathering to be completed on the model but for now I am pleased with the outcome (see How I constructed a loading hopper)

Bespoke figures

I have been trying for some time to find appropriate figures in various poses to make a few small tableaux on my railway without success. I have found with commerical figures that either the poses are not what I want or the clothing is not appropriate for an English narrow gauge railway set in the early 1930s. After an abortive attempt to construct my own figures from polymer clay (see Creating atmosphere - Progress Report 31), I consulted various sources on the internet and have been improving my skills. I certainly can't claim to be a Rodin, a Henry Moore or an Antony Gormley but my figures are slowly beginning to resemble something vaguely human.

[Awaiting photo]

The knack seems to be getting the proportions right in the early stages and then having considerable patience and time to sculpt features and details. I have found this is the sort of job I can do while 'watching' TV in the warmth of the living room on these cold and dark winter evenings.
Once I have perfected my techniques to what I consider to be a reasonable standard, I will share my results via another posting. However, this might be some time in the future, given my slow rate of progress so far.

Diesel loco kit

Another chance purchase through the G Scale Central forum resulted in the arrival of a 'Jessie' diesel locomotive kit made by IP Engineering.
Source: http://img36.imageshack.us/img36/6893/bt7wmmkkgrhgoheyejllly8.jpg
As this kit is no longer listed on the IP Engineering website I assume it is discontinued. However, the kit I purchased seems to be complete and also includes various additional detailing parts. Once completed this loco will be added to the slowly growing roster of battery-powered locos which I am accumulating (eg see How I constructed a railmotor). My ultimate plan is to have a complete set of locos for both DCC and battery power to hopefully extend the opportunities for operating sessions through the year as the track cleaning process required for track power can become tedious prior to a brief operating session (see How I clean the track).