With a proven track record in specialist glazing for heritage and conservation projects, Ion Glass has delivered bespoke installations for historic sites, churches, and listed buildings across the UK.

Their latest commission at Caerphilly Castle showcases the company's ability to integrate contemporary glass technology into some of the nation's most architecturally significant structures.

As part of a £10 million conservation and refurbishment programme managed by CADW, Ion Glass was appointed to design, manufacture, and install a series of bespoke arched glass doors for the newly restored Great Hall. The project forms part of a wider initiative to transform Caerphilly Castle—the largest castle in Wales and one of the UK’s finest examples of mediaeval military architecture—into a leading visitor destination.

Dating back to 1268, the Great Hall has been carefully refurbished to reflect the grandeur of its original design, while also providing 21st-century functionality. Ion Glass worked in close collaboration with conservation specialists, architects, and stonemasons to create glazing solutions that would enhance accessibility and usability without compromising the building’s historic fabric.

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The installation included four distinct sets of doors, each designed and engineered for its unique setting:

• A pair of internal arched glass doors forming the main access to the Hall within a new entrance lobby, featuring a decorative manifestation in keeping with the castle’s heritage.

• A single-leaf glass side entrance door to improve visitor flow.

• An emergency exit door installed within the original stonework and set in a bespoke hand-built oak frame.

• Double arched glass doors at the head of the newly reopened water-gate passage, leading down to the southern lake and restoring an entrance unseen for centuries.

Every arched opening was individually measured and precision-engineered to ensure a perfect fit within the irregular stonework. The doors were manufactured from 12 mm clear toughened and heat-soak-tested safety glass, complemented by satin stainless-steel fittings and handcrafted oak frames that interface precisely with the mediaeval masonry.

The result combines modern performance with authentic craftsmanship, allowing Caerphilly Castle's Great Hall to function as both a heritage showcase and a contemporary event venue. This project underlines Ion Glass's expertise in delivering innovative glazing solutions that respect historic context while meeting today’s standards of safety, durability, and design.

For more information about Ion Glass and to visit their extension portfolio of projects visit www.ionglass.co.uk.

Tel: 0345 658 9988