Chapter 134: The Brickmakers of Althoff

The first successful clay-firing trials had produced considerable excitement among Althoff’s craftsmen, although Raymond quickly discovered that making a handful of promising bricks was considerably easier than establishing an industry capable of supplying an entire city.

Three mornings after Roderic Vann presented his findings, Raymond visited the newly designated brickmaking grounds southeast of the Residential District.

The location had been selected by Talia and Ormond because of its proximity to the clay deposits, access to a service road, and sufficient distance from occupied neighborhoods to minimize smoke and other disturbances.

What greeted him was hardly an impressive industrial establishment.

Several temporary shelters stood beside a broad clearing where workers were preparing clay, constructing drying racks, and excavating foundations for additional kilns. A small experimental furnace occupied one corner, surrounded by neatly arranged samples bearing identification marks.

Roderic stood beside the furnace with Kael and three experienced potters, discussing the results of their latest experiments.

"Your Excellency, welcome to Althoff’s newest industrial venture," Roderic greeted him, gesturing toward the busy clearing. "I’m afraid it doesn’t look particularly remarkable yet, but we’ve made encouraging progress."

Raymond examined a stack of reddish bricks resting beneath a shelter. "Considering we were worrying about running out of construction materials a few days ago, I would say this looks rather beautiful."

One of the potters, an elderly craftsman named Osbert Kellen, chuckled at the remark. His hands were stained with clay, and his apron bore the marks of years spent working around furnaces.

"Your Excellency has an unusual appreciation for bricks," Osbert observed respectfully. "Most nobles prefer to admire finished buildings rather than the materials used to construct them."

Raymond picked up one of the samples and examined its surface. "Finished buildings are difficult to admire when nobody has enough materials to finish them."

Roderic smiled before directing his attention toward the testing records. The initial experiments had revealed that clay from different deposits behaved differently during drying and firing. Some mixtures cracked easily, while others produced uneven surfaces or weakened when exposed to moisture.

The craftsmen had therefore begun adjusting their preparation methods, combining selected clay samples with measured quantities of sand and experimenting with drying periods.

"We’ve identified two mixtures worth developing further," Roderic explained. "One produces reasonably durable bricks suitable for ordinary construction. The other appears promising for roof tiles, although we still need to improve consistency."

Raymond inspected several curved tile samples arranged nearby. Their shapes were slightly irregular, but they demonstrated the possibilities of producing roofing materials locally instead of purchasing them from distant merchants.

"How soon can we begin manufacturing usable quantities?" he asked.

Osbert rubbed his chin thoughtfully. "That depends upon the kilns, my Lord. The experimental furnace is useful for testing, but it cannot produce enough bricks for a proper building. We’ll need larger firing chambers, reliable fuel supplies, and workers who understand how to manage the heat."

Roderic nodded in agreement. "We’ve prepared designs for two production kilns. They should allow us to manufacture larger batches while comparing different firing arrangements. I recommend beginning with those before committing funds to further expansion."

Raymond glanced toward the unfinished kiln foundations. "Then let’s begin properly. I want reliable production before impressive numbers. A thousand poor bricks would only create a thousand future problems."

The craftsmen appeared pleased by his response. Osbert immediately began explaining the difficulties of controlling heat throughout a large firing chamber, describing how bricks placed near the hottest sections could behave differently from those closer to the entrance.

Raymond listened with genuine interest. Although he understood the general principles of brickmaking from his previous life, he had no intention of pretending that a few memories made him more knowledgeable than craftsmen who had spent decades working with clay.

Instead, he asked questions and encouraged them to develop practical solutions suited to Althoff’s available materials.

By the following week, the brickmaking grounds had become considerably busier. Workers excavated clay from approved sections of the deposits, transported it to preparation areas, and mixed it according to instructions established by the craftsmen.

Others shaped bricks using wooden molds, arranged them beneath ventilated shelters, and transferred sufficiently dried batches toward the kilns.

The work was demanding, but it created employment opportunities for residents who possessed little previous experience in specialized trades.

Several former agricultural laborers joined the clay preparation teams, while younger apprentices learned molding techniques under the supervision of experienced potters. Carpenters supplied molds and drying racks, and Corvin’s logistics personnel arranged regular deliveries of fuel and equipment.

The operation was becoming an industry involving far more people than the craftsmen standing beside the furnaces.

Raymond returned several days later accompanied by Mara Kest and Lucan Veyr, both of whom were eager to examine the finished materials.

Mara selected a brick from an approved batch and inspected its edges. "The dimensions are reasonably consistent. That will make construction easier, provided the next batches maintain the same standard."

Lucan examined another sample before addressing Roderic. "Have you tested how these perform when used with our available mortar? I would prefer to establish suitable construction methods before assigning them to important public buildings."

"We’ve begun those tests," Roderic answered. "The early results are encouraging, but I recommend limiting initial use to approved structures while we gather more information about long-term performance."

Raymond nodded. "That sounds sensible. We shouldn’t suddenly replace every stone wall in Althoff with bricks simply because we’ve learned to manufacture them."

Mara spread a construction schedule across a nearby table. "Even limited production could help considerably, Your Excellency. Several residential buildings and warehouse extensions can use suitable bricks for selected sections, freeing dressed stone for foundations, drainage works, and structures that specifically require it."

"Exactly," Raymond replied. "We’re not trying to eliminate stone construction. We’re trying to stop every project from competing for the same limited supply."

Lucan agreed, adding that locally produced roof tiles could eventually reduce demand for imported roofing materials. However, he insisted upon further testing before approving widespread use, particularly in buildings where poor roofing could cause expensive damage.

Their discussion soon turned toward production costs.

Corvin had prepared an estimate covering clay extraction, wages, fuel, kiln maintenance, transportation, and equipment. Although the new operation required substantial initial investment, its location offered an important advantage.

The clay deposits lay within the County, allowing materials to reach the production grounds without lengthy merchant journeys or repeated purchasing negotiations.

"Once production becomes consistent, we should be able to supply certain construction projects at a lower cost than importing equivalent materials," Corvin explained. "But the savings will depend upon maintaining efficient operations and avoiding unnecessary waste."

Raymond studied the estimate. "Then establish proper records for each batch. I want to know how much clay we’re using, how much fuel we’re burning, and how many finished bricks pass inspection."

Roderic inclined his head. "I’ve already instructed the supervisors to record failed batches separately, Your Excellency. We need to understand why materials are being rejected rather than simply hiding the losses."

"Excellent," Raymond replied. "A failed experiment teaches us something. A failed experiment nobody records just wastes money."

As the operation expanded, Ysabel Merrow began receiving inquiries from private builders interested in purchasing locally manufactured bricks. Raymond approved limited commercial sales, provided public construction requirements remained the initial priority.

He also instructed the Administration to establish fair purchasing arrangements rather than granting one merchant exclusive control over the new industry.

The decision pleased local craftsmen, many of whom saw opportunities to establish workshops producing specialized tiles, decorative masonry, and other clay products once the basic manufacturing process became reliable.

For Raymond, the benefits extended beyond reducing construction expenses. Every new workshop created employment, every employed resident supported local commerce, and every successful industry made Althoff less dependent upon distant suppliers.

The city was gradually developing the economic foundations necessary to sustain its own growth.

Nevertheless, progress remained uneven. Some firing batches produced excellent results, while others contained cracked or misshapen pieces. Rain occasionally interrupted drying schedules, and the larger kilns required careful supervision before their output could become dependable.

Roderic refused to rush the process, even when construction foremen began requesting more bricks than the operation could supply.

"Tell Mistress Mara that I would rather deliver five hundred sound bricks than eight hundred questionable ones," he informed a messenger one afternoon. "If she wants stronger walls, she must allow us to manufacture proper materials."

Fortunately, the latest production batches finally began demonstrating the consistency everyone had been waiting for.

Several days later, Corvin arrived at Raymond’s study carrying updated inventory records. His expression was noticeably brighter than during their previous discussions about material shortages.

"Your Excellency, the brickmaking operation has delivered its first substantial allocation of approved construction bricks," Corvin reported. "Combined with improved stone deliveries from the quarry, we now have enough materials to release several projects that were previously suspended."

Raymond looked up immediately. "Which projects?"

"The eastern warehouse extension, two residential construction sections, and portions of the public building works," Corvin answered, consulting his ledger. "Mistress Mara has already been informed. She’s preparing to recall the affected construction teams."

Raymond leaned back in his chair, satisfaction spreading across his face.

For weeks, Althoff’s greatest difficulty had been finding enough materials to keep its growing workforce occupied.

Now, with the first locally manufactured bricks entering the supply chain, several delayed construction projects could finally resume.