AS York's Theatre Royal prepares to reopen next week following its £6 million redevelopment, business editor Laura Knowlson finds out how York construction firm William Birch & Sons has delivered the theatre's biggest project since it was first built in 1764.

FOUNDED 110 years after the Theatre Royal was first built, William Birch & Sons was appointed to carry out the extensive refurbishment of the theatre, brining new life to the historic attraction for the first time since 1967 in a project that has involved unforeseen construction challenges.

Employing a team of around 100 people, the family owned construction company, based in Osbaldwick, has been onsite for more than a year, working on the former location of one of the most important medieval hospitals in England, St Leonard's Hospital.

Prior to the William Birch team getting to work it was initially thought that very little of the hospital foundations remained, but it soon became clear that some significant elements had lain uncovered for a very long time.

Robert Pell, contracts manager at William Birch & Sons said: "York Theatre Royal is a fascinating building on many levels, built up like a patchwork over different time periods.

"Even the logistics of accessing the building have proved challenging, sited where it is in York’s centre and in such close proximity to its neighbours.

"We knew from the start of this project that there were a number of ‘unfounds’ that were likely to be revealed as we began peeling back the layers, and indeed the significant remains of St Leonard’s Hospital have been the biggest find here."

York Archaeological Trust has been investigating and recording the finds beneath the theatre, and carefully retrieving and cleaning artefacts of interest. A stone gateway has been revealed which is believed to be the original stage entrance for the theatre, and a stone-lined well discovered, along with a cobbled yard.

Ben Reeves, chief archaeologist on site from York Archaeological Trust, said: "It is amazing that, considering all the alterations to the theatre since 1764, so much of the medieval hospital has survived under the stalls and elsewhere within the building.

"The remains are an exciting and important discovery for both archaeologists and the public, offering an opportunity to investigate and understand more about one of the City’s most fascinating and little understood sites."

The Theatre Royal project includes works to a number of different areas around the theatre building, but primarily the main auditorium and works to the front of house to improve leisure facilities for visitors.

The existing front colonnade to the building is currently external, however the work will see it glazed to complement the iconic arches and brought within the building complex to create seating and café/bar areas. Once completed, theatre goers will see the biggest changes in these areas, although there are many more changes going on behind the scenes to turn the theatre into a modern and efficient facility, with a new and state-of-the-art stage, upgraded lighting and improved audio-visual equipment. New seating is also planned for several areas, along with improvements to the stalls to enhance performance viewing quality.

The existing stage at York Theatre Royal has been levelled to improve the versatility of the space, enabling the theatre in future to be able to programme a wider variety of productions, such as dance.

The theatre’s basement has also been lowered by 600mm to allow a removable mid-section of the stage with head room and also pop-up stages as needed.

Work to the main upper theatre gallery has included a complete remodelling and reprofiling for better viewing angles, with significant structural and joinery work. The dress circle has also been reprofiled to provide disabled access, and carpets have been replaced in the upper dress circle. Gallery fronts to all three levels at the theatre have required remedial strengthening work and structural improvements, along with lighting bars and brackets. The back of the top two galleries now has new steel supports and specialist plastering to ensure it remains in keeping with the existing theatre, which has been time-consuming work for the William Birch team.

Mr Pell explained: "There was no Christmas break for some of the specialist craftsmen within the team.

"We’ve reprofiled the stalls, which will now meet the line of the first dress circle, and created a new tiered floor as opposed to the previous sloping floor. It’s really beginning to take shape now."

William Birch & Sons have also been busy with external work at the theatre, with new masonry, repair and replacement of defective stone where necessary, as well as a stone cleaning and reroofing programme. Every roof slate has been replaced, two flat roofs replaced and the theatre’s rooflights are now electrically operated.

Liz Wilson, chief executive at York Theatre Royal, which is due to open on April 22, said: "York Theatre Royal contributes to the world class cultural offer in the city through ambitious theatre productions, support for innovative artists and companies and promoting a culture of achievement with a community of collaborators, whether artist or citizen.

"This project will support this work in all its glorious diversity and will bring the flexibility essential to a truly sustainable organisation that will continue to grow and evolve."