40 40 Sask a tc h e wan wan Hi s to r y y • • S prin g g 2004 2004

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a r ray ray o f f ph o t ogra ph s. s. T h ese ese r ecor d s s came came fro m m t h e e

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pl a nt' s s foundin g g in in t h e e ea rl y y 190 0's 0's until until i ts ts cl os ur e e in in

comp l ete ete se t t of of o p era ti o n a r l ecor d s s dat in g g fro m m t h e e

p u bli c c re f e re nce . . T h is is fon d s s includ es es an an asto ni s h ing l y y

t h e e Clay b a nk nk B ri c k k Pl a n t t fo n d s s i s s n ow ow ava il a bl e e for for

T h e e Sas k atc h ewa n n Arc hi ves ves i s s pl eased eased t a o n nou n ce ce t ha t t

by by Dana Dana Turgeon Turgeon

Fonds Fonds

Brick Brick Plant Plant

The The Claybank Claybank

Archives: Archives:

Looking Looking into into the the dramatically and salts in the soil started to attack and dissolve the building foundations. Two tornadoes stripped roofing off some structures and caused damaged to th e historic landscape. Miraculously, no major structural damage resulted from these wi ndstorms. Efforts to save the plant have involved both public and private agencies. The Claybank Brick Plant Historical Society was established in 1993 to help generate community support and to develop and deliver an interim interpretive program. A t the same time, the federal and provincial governments entered negotiations on a cost-share program to fund repairs to the property. In 1999, an agreement was reached and Parks Canada agreed to contribute Sl million for specific work items over a fi ve-year period. As part of the agreement, the Saskatchewan H eritage Foundation needed to raise matching funds as well as come up with a strategy to raise the remaining dollars to complete the project, estimated at several million. By the end of 1999, m any of the basic repairs were completed, most of the drainage problem had been addressed, and work was beginning on converting the Bunk H ouse into a V isitor Center. 1

Appraisal and Acquisition

Staff from the Saskatchewan Archives (SAB) was ba11k B1irk plm1/ rirca 19 20 's. Sr\B R-r\28438 The Clr!)' 1 involved in the 1989 heritage assessment of the Claybank Brick Plant site, when the site was being recession kept the plant closed until 1916, when it evaluated by the province of Saskatchewan as a potential reopened under the name Dominion Fire Brick and Clay heritage property. Acgui sition of the records o f the Products Ltd. In 1954 it was purchased by Redcliffe Claybank Brick Plant took place over a two-year period. Pressed Brick and was renamed D ominion Fire Brick Initial appraisal of the records took place in 1998, but as and Clay Products (1954) Limited. In 1955 controlling outbuildings on the site were repaired, additional records interest was purchased by A.P. Green Fire Brick were discovered. T he last accession was brought to the Company of i\Iexico, !-.lissouri. By 1962 J\.P. Green had SAB in 2000. complete control of the plant, although the company continued to operate as Dominion Fire Brick and Clay T he records that eventually became the Claybank Brick Products (1954) L imited until 1970. In 1971, the Plant fonds posed m any c hallenges for appraisal Claybank Brick Plant became a subsidiary of A.P. Green archivists. When th e Province of Saskatchewan first Refractories (Canada) Ltd. Faced with d'.vindling market took over the site in 1992, many of the outbuildings share, changing technologies, outmoded eguipment and were in poor condition. Some records had been stored corporate downsizing, A P. Green closed the Claybank in leaky buildings and had suffered serious damage from Brick Plant in 1989. Before its closure, the Canadian water and mould. Other records had suffered rodent Broadcasting Corporation filmed the Plant in fu ll damage or had been stored in dirty areas. Balancing the operation. A t that point in time, the fate o f the plant poor condition of the records was the fact that they itself was uncertain . records covered almost the whole time period of the plant's operation. T he plant's last owner, A.P. G reen, donated the complex to the province in 1992. D esignation as a Provincial Processing Heritage Property and as a ational Historic Site soon followed. However, designation alone does not save Processing of the Claybank Brick Plant fonds began in heritage sites. In this instance, the s truggle to save the the s ummer of 2000 under a Young Canada Works Claybank Brick Plant was with Mother Nature. The grant, a joint project of the SAB and the D epartment of outbuildings began to deteriorate as the water table rose Municipal Affairs, Culture & Housing. Over that Looking into the 1\ rchives • Spring 2004 41 summer, records were cleaned, and most of the from frequent use. These delicate documents had to be architectural drawings and maps were processed and encapsulated in Mylar to prevent future damage. The recorded in a database. When the summer ended, encapsulation of architectural and technical drawings processing was temporarily suspended. By 2001, was completed over the summer of 2000. Each map or processing began anew under the now-defunct SAB architectural drawing was then described and entered Backlog Project. into a database.

The Claybank Brick Plant fonds posed many challenges There was also a sizeable number of photographs during processing. The first step was cleaning and included with the Claybank Brick Plant fonds. These assessment of the materials. Almost all of the records photographs were placed in Mylar sleeves for protection, were dusty and dirty. Some items were also greasy or and were then placed in archival envelopes. Descriptions grimy. In addition, some of the records had been of the photographs were entered into a database. exposed to rodent feces, which are linked to the potentially fatal disease Hantavirus. Ivfost records were Altogether, a total of 10 Archives staff members were cleaned under a fume hood using brushes and a vacuum directly involved with processing. They cleaned the cleaner, and staff used paper masks and other records, created item-level descriptions of drawings, respiratory equipment to minimise their exposure to maps and photographs, created a textual file list, Han ta virus. performed preventive conservation techniques on fragile materials, and created a full description of the records In addition to the already mentioned problems of water for public use. and mould damage, many of the records were fragile due to years of use and improper storage while other The Claybank Brick Plant fonds materials were awkward to handle because of their size. Mould is especially problematic in an archival setting, The Claybank Brick Plant fonds represents an because it can spread to other uninfected records. It also astonishingly complete set of records concerning the poses a respiratory hazard to people. Because of these operation of the Claybank Brick Plant over its ninety­ factors, mouldy items, fragile items and awkward-to­ odd years of existence. These records include textual handle items were microfilmed. This project was records, architectural and technical drawings and completed in 2000. Unfortunately, due to the poor photographs. conditions of most of these materials and the health hazards posed, most of the original records had to be The fonds contains the original blueprints for most of destroyed after filming. the outbuildings on the Claybank Brick Plant. Also included are many maps and drawings of the rail spur The Claybank Brick Plant fonds contained many rolled and the hills themselves, including details on the documents. Some of these were architectural drawings composition of the clay hills. There are also a number of the rolled records were daily and maps, while some of photographs of the plant's buildings. logs of the plant's activities. The daily logs were cleaned and then flattened using a special archival press. These The Claybank Brick Plant manufactured a wide product were then placed in oversize boxes and stored flat. Many line that included face brick, building tile, sewer tile, terra of the architectural drawings and maps were quite fragile cotta, and pottery, but its primary product was fire brick. Fire brick was brick manufactured fo r use in locations where heat resistance was important. Claybank clay was world-renowned for its extreme heat resistance; Claybank bricks were used in locomotive engines, furnaces for steel and manufacturing industries, and in the Royal Canadian Navy's Corvette-class warships.

'< -5 The Claybank Brick Plant fonds contains a large number :l« of technical drawings. .Most of these were used in the v -5 ...... construction of fire brick. Because fire bricks were used 0 c to line fire boxes of locomotives or ships, or were used ·o0 u in the construction of large furnaces for manufacturing, ~ 0 u the shapes were not uniform. Often the bricks had to be fo order to protect tbe delicate bl11ep11.nts, Dana T111geon encapsulates tbe111 in created so that a curved oven or furnace could be built. 1\t[}lar sleeves. 42 Saskatchewan History • Spring 2004 The photogmphs a11d dmwi11gs 1i1 the collectio11 rerMI sig11ijicr111t i11.fo1matio11 abo11t the histOI)' ef the plrmt a11d the people who worked there. Top: ll:?orkme11 fire 11p 011e ef the kilm Middle: A sketch ef the roof angles for the ro11stmctio11 ef r1 11e111 ki/11 !3ollom: The elCJborCJte millll(!)' tmcki11g i11 the rlqy pits

Consequently, many of these drawings are fo r "one-of­ a-kind" hand moulded bricks designed t o serve a particular purpose.

The Claybank Brick Plant also manufactured face brick that was used to construct buildings all over North America. The Bessborough Hotel in Saskatoon, Hotel Saskatchewan in Regina, Gravelbourg Cathedral in ,,.­ ./ ,,_ Gravelbourg a nd the Chateau Frontenac in Quebec City are just a few notable examples of buildings constructed / 0;~\ .f./ of Claybank brick. Among the records of the Claybank Brick Plant, there are numerous photographs of the face 1 brick products available from the Claybank Brick Plant. ,/ . 1, -i, P' / · 1~1 I...... Many of these photographs are from a show album , ~ .•.. (, designed for sales. The photographs from this album are \ . .. - ~ / astonishingly clear and detailed, and will greatly interest architectural or urban historians. Claybank face brick received its desired colour through the use of coal heat. T herefore, when the beehive kilns were converted to natural gas in the 1960s, face brick production was halted.

The records of the Claybank Brick Plant include most of the sales, shipping and receiving records for both face brick and fire brick production. These records ./ . , .. , ;. ~! encompass nearly all of the changes in plant ownership. ' I 6 1· v The sole exception are the papers related t o the early < J,{ , i" ;•, I years of plant operation when Tom Mc\"'\!illiams ran a ~ 1· ' 1 · J c one-person business selling bricks and clay. There are also extensive records on exploration, prospecting, engineering, and testing o f clay, as well as "recipes" for ...: various brick products produced at the plant. There are many advertising or promoti onal materials for the plant's products, mostly dating from the 1960s and 1970s.

Bricks were fired in ten round, downdraft kilns, also called beehive kilns. Each kiln took one week to load, one week to fire and cool down, and one week to unload. Until the 1960s, each of the thousands of bricks was loaded by hand. T he kilns burned lignite coal until the 1960s, when all but o ne was converted to natural gas.

Kilns periodically had to be rebuilt. The Claybank Brick Plant fonds contains records concerned with the rebuilding of the kilns at the Claybank Brick Plant. There are also many architectural drawings and technical drawings of the kilns themselves.

Because of its relative isolation, the Claybank Brick Plant

Looking into the Archives • Spring 2004

2004 2004 ing ing r Sp • • story story i H Saskatchewan Saskatchewan 44 44

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Endnotes Endnotes

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