Historic Designs, Modern Solutions: The Black Country Museum Expansion
8th January 2025
Recreating history is no small feat, especially when it involves bringing iconic Black Country buildings back to life. Joe Dudley, a seasoned timber engineer with over 16 years of experience, took on this challenge at the Black Country Living Museum’s Forging Ahead Project. Tasked with blending historical accuracy and modern engineering, Joe’s expertise turned long-lost landmarks into stunning, sustainable structures that tell the story of a bygone era.
Joe played a pivotal role in the museum’s largest development since its opening in 1978. The expansion added a new visitor welcome centre, learning spaces, an industrial quarter, and a recreated 1940s-1960s high street. Wyckham Blackwell was commissioned to replicate several iconic buildings using timber solutions, with Joe overseeing the design and delivery of intricate trusses, joists, and rafters. His leadership ensured the project preserved the historical integrity of each building while meeting modern construction requirements.
Reviving Iconic Buildings
Among the recreated structures, the Lea Road Infant Welfare Centre stands as a replica of its 1960s counterpart in Wolverhampton. Its design featured a high vaulted ceiling and large dormers, achieved with metal-web joists and lattice-style girder trusses, providing both structural support and aesthetic accuracy.
The Cricketfields Brickworks, part of the 1950s industrial quarter, replicated the Brockmoor Brickworks from Brierley Hill. This required the installation of eight oak feature trusses, oak purlins, and softwood rafters to replicate the tall, industrial-style design.
The recreated 1940s-1960s High Street showcased a terrace of shops, including a music shop, newsagent, and bank. Joe’s team supplied nail-plated trussed rafters and metal-web joists for these buildings, carefully managing varying roof pitches, eaves details, and load requirements to ensure both safety and historical authenticity.
The Elephant and Castle Pub, originally built in 1905 and demolished in 2001, presented one of the most complex challenges. Its intricate roof design, featuring large dormers, differing levels, and prefabricated gable panels, was painstakingly reconstructed to reflect its original grandeur – resulting in a striking centrepiece of the museum’s expansion.
Innovative solutions for complex designs
The Forging Ahead project required innovative engineering solutions to address challenges like incomplete architectural drawings. Joe relied on historical images and collaborated closely with the museum’s team to guide the design process. Prefabricated elements, including timber-frame gable panels, streamlined construction and reduced on-site work while maintaining the structural and aesthetic goals of each building.
Safety first in construction
Safety measures were a key consideration throughout the project. Joe incorporated two-tier truss designs to facilitate safe installation at height and utilised plywood platforms for stable working conditions. High-level scaffolding and crash decks ensured safe access for workers across all structures, while podiums between feature trusses enabled the secure installation of brackets and braces.
Sustainability at the Core
Sustainability was integral to the project’s approach. Joe prioritised timber and engineered timber products over steel, minimising environmental impact. All materials used, including oak and softwood components, were sourced from PEFC and FSC-certified suppliers, ensuring the project adhered to responsible and sustainable practices.
Collaboration and Teamwork
Joe’s ability to work collaboratively with the museum’s team, architects, and contractors was crucial to overcoming the technical challenges of this complex project. From designing intricate structures to ensuring smooth on-site installations, his leadership and coordination ensured the project’s success.
Joe’s work on the Black Country Living Museum demonstrates the adaptability and effectiveness of timber solutions. By combining historical research with modern engineering, he proved how timber can preserve architectural heritage, deliver sustainable results, and meet the demands of complex construction projects.
About Joe Dudley
Joe Dudley is a highly experienced timber engineer with over 16 years at Wyckham Blackwell. Starting as a trainee trussed rafter designer in 2008, he has progressed to Design and Sales Manager. Joe’s career is defined by his technical expertise and dedication to delivering practical, cost-effective solutions across bespoke housing, large-scale developments, and commercial projects. His work consistently blends precision, sustainability, and innovation to achieve outstanding results.