Made Local: How a Glazed Stoneware Basin is Moulded and Made
See how Robert Gordon manufactures basins fit for royalty, from the raw clay to a glazed object of beauty
Forty years ago, Robert ‘Andy’ Gordon walked into a rickety 3 x 2.5-metre tin shed, cut a lump of clay and began to turn his potter’s wheel. That day Pack Track Pottery – later Robert Gordon Australia – was born. From little things, big things grow and today, Robert Gordon is one of Australia’s last large-scale potteries, and has recently begun producing basins. We follow the creation of these beautiful fixtures.
To begin, natural clay is sourced from a quarry in NSW before being processed by a clay supplier in Dandenong, Victoria. The clay has a stoneware ‘body’ with a natural colour.
Master moulds are formed by hand using simple tools that resemble knives. These new shapes are created and developed on the thrower’s wheel or slab roller.
Each one carries the unique characteristics of a form moulded and sculptured by the craftsperson.
Master moulds are formed by hand using simple tools that resemble knives. These new shapes are created and developed on the thrower’s wheel or slab roller.
Each one carries the unique characteristics of a form moulded and sculptured by the craftsperson.
Image by Jarrod Barnes. The moulds are made from plaster and are in numerous parts so on completion, the potters can deconstruct the mould and release the pot.
The slip is poured into the mould, sink holes made and the walls built up to an appropriate thickness.
They are then left to dry. The mould is then deconstructed to get to the basin.
The slip is poured into the mould, sink holes made and the walls built up to an appropriate thickness.
They are then left to dry. The mould is then deconstructed to get to the basin.
Image by Jarrod Barnes.
Bisque firing drives off the water and carbon from the clay and melds the clay particles together.
After firing it’s impossible to add water to the clay to re-work the object; it is now in its final shape.
The resulting basin is hard yet slightly porous so is able to absorb the small amount of water in a glaze solution. This allows the glaze to stick to the basin, ready for firing, to melt and fuse the glaze.
Bisque firing drives off the water and carbon from the clay and melds the clay particles together.
After firing it’s impossible to add water to the clay to re-work the object; it is now in its final shape.
The resulting basin is hard yet slightly porous so is able to absorb the small amount of water in a glaze solution. This allows the glaze to stick to the basin, ready for firing, to melt and fuse the glaze.
Image by Sarah Collins.
It is of great importance that when the basins are taken out of the kiln (at both the bisque and gloss stages), the process is not rushed.
As a result, the kilns are cooled overnight and slowly opened in the morning. At Robert Gordon, kilns are not opened until they cool to 180 degrees. They slowly take the kiln cart out and let it cool to room temperature until it is safe to handle.
It is of great importance that when the basins are taken out of the kiln (at both the bisque and gloss stages), the process is not rushed.
As a result, the kilns are cooled overnight and slowly opened in the morning. At Robert Gordon, kilns are not opened until they cool to 180 degrees. They slowly take the kiln cart out and let it cool to room temperature until it is safe to handle.
Bobby Gordon and master mould maker, Glauco Urbanucci; the dream team behind Robert Gordon Interiors’ products.
Browse beautiful bathrooms on Houzz to inspire your own basin style
Browse beautiful bathrooms on Houzz to inspire your own basin style
Image by Sarah Collins.
Robert Gordon has ten different glazes, all made and developed in-house by a ceramic engineer. They are made of a variety of ingredients, such as silica and oxides. The company designs and develops all its glazes on-site. Owning their own stains and materials allows them flexibility of design.
Robert Gordon has ten different glazes, all made and developed in-house by a ceramic engineer. They are made of a variety of ingredients, such as silica and oxides. The company designs and develops all its glazes on-site. Owning their own stains and materials allows them flexibility of design.
Image by Jarrod Barnes. A finished basin in the Storm glaze. Each high-fired stoneware basin is designed to last a lifetime.
The basins-in-progress are then gloss fired at approximately 1280 degrees for nine hours. After this firing, the basins are checked for quality to ensure there are no imperfections. They also have their ‘feet’ cleaned on a grinding machine to ensure they are level and can sit flush on top of vanities.
The basins-in-progress are then gloss fired at approximately 1280 degrees for nine hours. After this firing, the basins are checked for quality to ensure there are no imperfections. They also have their ‘feet’ cleaned on a grinding machine to ensure they are level and can sit flush on top of vanities.
Image by Jarrod Barnes.
Glazed and fired. Australian-made basins stacked and ready to be shipped.
Your turn
Do you have a beloved piece of Robert Gordon pottery? Tell us in the Comments below. And don’t forget to save your favourite images for inspiration, like this story and join the conversation.
More
See another great Australian manufacturing story at Made Local: The Fiery Creation of a Cast-Iron Skillet
Glazed and fired. Australian-made basins stacked and ready to be shipped.
Your turn
Do you have a beloved piece of Robert Gordon pottery? Tell us in the Comments below. And don’t forget to save your favourite images for inspiration, like this story and join the conversation.
More
See another great Australian manufacturing story at Made Local: The Fiery Creation of a Cast-Iron Skillet
Over the years, Robert Gordon Australia has been synonymous with beautiful homewares including vases, mugs and tableware.
But it was Robert’s son, Bobby, who kneaded the business model. With degrees in architecture and fine art, Bobby developed an eye for functional beauty, from which he developed an interest in taking the language of ceramics – his family inheritance – into home design. To pursue this, in he launched Robert Gordon Interiors.
And it was under this banner that in recent years, the pottery has begun to produce larger fixtures such as basins and light fittings in its Pakenham, Victoria, factory.
Here, we delve into the creation of a Robert Gordon basin as it come to life through a six-stage, six potter, two-week long journey.