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A recent Freedom of Information request to Cornwall Council has revealed an extraordinary case of planning delay -a single residential application that took 1,114 days to gain approval. That’s not a typo; that’s three full years! While this is an extreme example, it is far from unique. Planning delays are nothing new, but they’re getting worse.


Across the country, developers and contractors are being forced to sit tight while local authorities work through backlogs, staff shortages, and ever-growing red tape. While we wait, the world moves on. Material and labour costs rise, client budgets shrink, and value engineering takes centre stage. The result? The steady erosion of specification quality, the abandonment of British-made products, and the growing dominance of cheaper, imported materials that often compromise on durability, sustainability, and long-term performance.


Rear view of a rustic brick house with a tiled roof, skylights, and chimney. Patio in front and green hedges on the right, under a clear sky.

1,100 Days and Counting


According to local reports, the Cornwall case represents one of the most egregious examples of planning inefficiency in the UK. But it’s not a one-off. Across England, statutory targets of 8 to 13 weeks are now more often missed than met. Some councils have average wait times of 40–50 weeks for major applications. When planning approvals drag on for years, a project’s commercial viability is often the first thing to suffer. Prices calculated at feasibility stage no longer hold water by the time shovels are in the ground. According to BCIS, construction costs are expected to rise a further 12–18% by 2030. Labour shortages, inflation, and fuel costs are driving prices higher every quarter. That’s bad news for clients, and it’s even worse news for the UK’s manufacturing sector.


Value Engineering: When the Budget Wins and Quality Loses


With protracted planning delays inflating project costs, contractors and specifiers are increasingly being asked to revisit materials and systems. Every line item is now a target. That premium rooflight? That solid oak floor? That UK-made heritage brick? All are up for replacement.British manufacturers, once the default choice for quality-conscious clients, are being swapped out for lower-cost, and often overseas alternatives that promise 'the same look' at a fraction of the price.


Rustic brick house with slate roof, wood storage, and a large potted plant. The patio overlooks a green lawn under a partly cloudy sky.

But as many contractors will attest, these substitutions often come with hidden costs: which can include reduced lifespan, increased warranty claims or contravening planning approval. One example of the pressures facing UK manufacturers can be seen in the conservation rooflight market. Specialist producers, who manufacture bespoke rooflights in the UK using durable materials such as 316L stainless steel and sustainably sourced hardwood, design their products specifically to meet the strict requirements of heritage projects and to blend seamlessly with traditional architecture.


Yet these high-quality solutions are increasingly being replaced at build stage by imported plastic or aluminium products that claim to be a suitable alternative but actually fall short on appearance and longevity. In some cases, this occurs even where planning conditions call for a traditional aesthetic, as cost pressures prompt substitutions. Worryingly, such changes are being approved or overlooked more often, even under the supervision of conservation officers. The result is a gradual erosion of the very principles that conservation policy is meant to uphold, ensuring heritage buildings are restored or maintained with materials that protect their integrity, character, and long-term resilience.


The Hidden Cost of Cheap


The long-term consequences of this shift are manifold. For one, heritage projects risk being compromised by inappropriate materials that don’t weather well, don’t match existing architecture, and don’t stand the test of time. Many of these substitute rooflights, have less resistance to corrosion - especially in coastal locations where 316L stainless steel would have offered decades of resilience.


Bright room with a white ceiling, exposed wooden beams, two skylights, and white pendant lights. Natural light casts soft shadows.

Secondly, the loss of specification quality is impacting the UK manufacturing sector at scale. Every time a British-made product is swapped for an imported one,it chips away at jobs, skills, and investment in domestic capability. Companies who make the effort to design, manufacture, and assemble entirely in the UK, are often being priced out not because our products are too expensive, but because the system is forcing clients to make impossible choices.


And finally, these changes are undermining sustainability goals. British-made products travel fewer miles, often use more responsibly sourced materials, and can be supported and serviced locally. Yet in the scramble to save money and meet tight deadlines, these benefits are too often overlooked.


Skylight with wooden frame set in sloped ceiling, view of cloudy sky. Wall painted light purple, round ceiling light below window.

A System in Crisis


At the heart of the issue is a planning system that simply isn’t fit for purpose. Local authorities lack the resources to process applications in good time. Developers are forced into multiple design iterations to meet shifting guidance. And even when permission is granted, it may come too late for a project to proceed under its original budget. Earlier this year, the Government announced an increase in planning fees - ostensibly to help councils recruit and train more planning officers. But the benefits of that investment are still years away. Meanwhile, contractors on the ground are left trying to reconcile spiralling costs with clients who are out of cash and out of patience.


What Needs to Change?


If we’re to avoid long-term damage to our built environment and to British industry, the system needs reform, and fast. Starting with streamlining and digitising planning applications, particularly for smaller or heritage-sensitive projects, would ease pressure on already overstretched planning authorities and significantly reduce the time taken to gain approval. A more efficient process would not only benefit applicants but also free up resources within local authorities to focus on more complex cases.Clearer and more consistent national guidance on materials is also essential.


Room with glass ceiling, exposed brick, and wooden beams. Blue cabinet with bottles, dining table with flowers. Bright and airy ambiance.

Where conservation rules apply, traditional or like-for-like materials should be enforced without compromise. Allowing clients to switch to inappropriate alternatives undermines the very purpose of conservation policy, risking the loss of heritage character and setting poor precedents for future developments. Supporting British manufacturing should be a priority for all parties involved in the planning and building process. Encouraging, or even requiring, local authorities, architects, and clients to specify British-made products wherever practical not only safeguards jobs but also ensures higher standards of compliance and quality. It is also a forward-looking approach that helps to protect the long-term integrity and sustainability of buildings. Finally, better education for both clients and builders is vital.


Many substitutions are made with the best of intentions but without full understanding of the consequences. Providing clearer information on the long-term implications of cutting corners could help avoid expensive remedial works, regulatory breaches, and the gradual erosion of our built heritage.


Bright modern kitchen with skylights, white cabinets, and a large island. A dining table with wooden chairs and plants adorn the space.

Quality Shouldn’t Be the First Casualty


When planning takes years, and budgets balloon by the month, it's tempting to slash specifications to make the numbers work. But in doing so, we risk building homes and public spaces that fall short of both their potential and their obligations, architecturally, environmentally, and economically.


British manufacturers don’t just make products - they contribute to our heritage, our economy, and our reputation for excellence. If we want to preserve those values, we must tackle the systemic delays that are driving the industry toward the lowest common denominator. Because once you lose a manufacturer, you rarely get them back.


If you’re a developer, builder, or architect grappling with rising costs and material substitutions, consider the long view. The cheapest option today may not be the best investment for tomorrow. If you'd like to find out more about quality British made conservation rooflights for your project, please contact the Stella Rooflight team on 01794 745445 or email info@stellarooflight.co.uk    www.stellarooflight.co.uk

Here Simon Helm, Studio Manager at Haddonstone, gives an insight into the traditional design and sculpting methods used to create the company’s bespoke architectural and garden stonework products.


Haddonstone Design Studio

 

How long have you worked at Haddonstone?


I joined the company in 1988. I studied art and design at university and decided I wanted to focus on sculpting after working on a restoration project at Lamport Hall. I saw Haddonstone as a good company which could develop my sculpting skills; and to earn money too was a bonus!  I worked on the factory floor for a couple of years learning the processes and then moved into the design studio.  I’ve now been managing the design studio for over 25 years.

 

How would sum up your role?


I design, sculpt and create bespoke pieces that will be cast in stone.  Once the design is completed, photographs are sent to the client for approval before we make the production moulds. I sculpt smaller, more intricate projects in modelling clay then make the mould from the model, whereas larger, architectural pieces are modelled in wood or plaster which are then used to make the fibreglass moulds. I like to use traditional methods when I design – no AI or 3D printer sculpting here! 

 

Haddonstone Design Studio

 

What is your favourite part of the job?


I love designing and sculpting the original model and realising the 3D design. It’s good to see the finished result and know that it will still be around many years after I’m gone!


Do you work with clients directly on projects?


Clients occasionally visit the studio, but it is more normal for the client to liaise with the sales team. 

 

What’s the most unusual piece of work a client has requested?


We were asked to scale up a traditional lion finial for the entrance to a grand property in the Middle East. We were presented with an original that was about 28 to 30 inches high, and the client wanted it to be recreated as a seven-foot statue.  We didn’t have the machinery to do it on site, so we worked with a company with a huge CNC machine. The rubber jacket alone weighed 70 kilos!  We saw photographs of the finished statue in situ, and it actually looked quite small!

 

Haddonstone Design Studio

How long does it take to make a new mould?


That depends on the project. A small simple mould can be made in a few hours, whereas on the other end of the spectrum it can be 12 weeks. One project was to recreate a replacement for a damaged griffin statue. The client had two, so we created a mould from the undamaged one, taking 12 weeks. It’s really important when making moulds for poured pieces not to trap any air, so we use different types of rubber depending on the piece.

 

How many moulds are in the archive?


Haddonstone Design Studio

We hold 1000s of moulds in the archive. These include many hundreds of masters and, for commonly produced pieces such as balusters, we keep multiples of these. As space is limited, we tend to keep moulds for bespoke pieces for up to six months.

 

How many times can a mould be re-used?


That depends on the mould. The fibreglass cases we create to hold the rubber mould for the stone to be poured into last for about ten years. On a complicated mould, the rubber will normally last 18 – 24 months. We replace commonly used moulds for features, such as balusters, every eight to ten years.

 


How many people work in the mould shop?

Haddonstone Design Studio

At the moment, there are three. This has varied over the years depending on what projects we are working on. The tendency at the moment is for more contemporary architectural pieces rather than more intricate stonework. Before our operation in the USA set up a mould shop, we were also making moulds for the team there.

 

How long does it take to train a new member of the team?


To learn the basics takes six months to a year but, in this job, you never stop learning. Decent pattern makers and model makers are in short supply in the industry, so we are lucky to have long-serving, well trained members of our team.


For further information, call 01604 770711 or visit www.haddonstone.com

David Barrow, Managing Director of Haddonstone, looks forward to the company's 55th anniversary next year - continuing to embrace innovation, collaboration, and growth


2026 will mark Haddonstone's 55th year in the architectural and garden cast stonework business; and every step of the way has seen the company thrive in a world of shifting design trends, technological advancements, evolving standards and regulations, and economic highs and lows.

David Barrow, Managing Director of Haddonstone,

Housebuilding in the 21st century is as much about creating quality places in which people want to live, as it is about the construction itself.  We are all encouraged to value sustainability, quality and 'kerb appeal', as much as functionality and space; and so, it's no surprise that we are seeing a resurgence of interest in beautiful, traditional and classical architecture.  This is where Haddonstone has always excelled, in manufacturing authentic and high-quality cast stonework for both new build properties, and in restoration and replication projects.


2025 has been a busy year so far for Haddonstone - which is reassuring after a challenging few years for the sector; and while worldwide economic uncertainty continues apace.  We have seen a noticeable increase in private clients instructing their architects, builders and contractors to include traditional stone design elements, such as porticos, window and wall dressings into their plans. Housebuilders and their clients are increasingly appreciating how high-quality cast stone detailing can elevate a home's character and value; both here in the UK and in the USA, where our two businesses are flourishing.


At the heart of our ethos are the same traditional values that have remained steadfast throughout the past 55 years.  We place integrity, quality and innovation front and centre, and this is why our clients return to us time and time again. Our standard and bespoke products are handmade to order in our own manufactories in Northamptonshire and Colorado, USA, by a team of craftsmen who are experts in their field and can deliver the quality of cast stonework that our clients demand.


Investment in our manufacturing facilities means that, not only do we meet client demand comfortably, we also make sure we are ahead of advancements and standards. An example is a £300k site expansion a few years ago which doubled the size of the TecStone (wet mix) shop floor (TecStone now accounts for 60% of all the stone produced) giving Haddonstone 50% more manufacturing space from before. As part of the same project, the timber mould shop space was expanded to accommodate a CNC spindle machine which can control the creation of precise and complex wooden shaped inserts for our moulds.


Looking forward to next year, we all hope for a stable economic picture. As a business, we will remain steadfast in our commitment to produce the high-quality cast stonework that Haddonstone has become synonymous with, whilst continuing to invest in both our team and our manufacturing infrastructure. I look forward to building on our successes, embracing new opportunities, and continuing to serve our clients with the excellence they expect from Haddonstone.For further information, call 01604 770711 or visit www.haddonstone.com

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