19 – Barn Conversion – Week 15

| 29th October 2015 | 0 Comments

Week 15 – 26th to 30th October

Barn Conversion – Summary of Monday through Friday

 

On Monday and part of Tuesday Andy and Joe installed the last timbers in the West End gable and barn hip. As you will have seen from previous pictures the gable end had been mucked about with over the years with a lot of alterations and quick fixes. Andy and Joe have taken great care to put back what would have originally been there using reclaimed air dried oak.

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repairs - Andy Feaver

Andy Feaver carrying out repairs to the West Bay Barn hip

 

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repairs - West bay

The West Bay barn hip undergoing repair

 

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repairs - West bay

The repaired West Bay barn hip

 

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repairs - West bay

The west gable end of the barn after repair

 

Whilst Andy and Joe were busy on the roof Dan and Colin made a start on the alterations to the side extension. Colin cleaned bricks whilst Dan marked out and cut/knocked down the opening for the new French Doors. We used the line of the original window as the key and removed all the bricks below. More for Colin to clean. He was pleased :-)

 

Maddomswood Historic Oak Barn Conversion East Sussex - Brickwor alterations to side extension

Brickwork removed to provide opening for the French doors in the side extension

 

Maddomswood Historic Oak Barn Conversion East Sussex - Brickwor alterations to side extension

Brickwork removed ready for new window opening to be formed

 

Maddomswood Historic Oak Barn Conversion East Sussex - Brickwor alterations to side extension

View of side extension with brickwork removed for openings to be formed

 

Once the French door opening had been cut out and the frame for the old side door removed, Dan turned his attention to the re-build of the SE Elevation of the side extension. Nick Teasel from SE Timber and Damp Ltd had been in on Sunday and had installed the drain for the tanking system. Dan protected this with a lintel and finished off with some brickwork. He was now ready to build up the wall to block the old doorway and create the new window.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Tanking drain to side extension

The drain for the tanking installed and protected by concrete lintel

 

Next Dan built up the brickwork to the top of the window and was ready to install the box lintel once the mortar had time to sure overnight.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Brickwor alterations to side extension

The new brickwork to form the window opening to SE Elevation of side extension

 

Maddomswood Historic Oak Barn Conversion East Sussex - Brickwor alterations to side extension

The internal view of the new brickwork to form the window opening to SE elevation of side extension

Here is a picture of the box lintel Dan installed above the window to pick up the weight of the brickwork and roof above.

Maddomswood Historic Oak Barn Conversion East Sussex - Box lintel

Box lintel

Over the course of the day Dan built up the brickwork to plate level.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Brickwor alterations to side extension

Dan laying the bricks above the window to plate level

 

Maddomswood Historic Oak Barn Conversion East Sussex - Brickwor alterations to side extension

The completed brickwork above the window to plate level

 

Whilst Dan had been carrying out the brickwork I had marked out where the foul drain for the Master Bedroom en-suite needed to go in the floor.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Foul drainage route - side extension

Foul drainage route marked on the floor ready for Dan to instal

 

The wall for the en-suite was to be located below the bottom horizontal section (chord) of the roof truss. I first found the centre of the chord and, using a level, marked this position on the floor for the full length of the wall.

The wall was to be made up of 12.5mm plasterboard to the bedroom side, 100 x 47mm stud, 11mm OSB board and 12.5mm plasterboard to the en-suite side. The total thickness of the wall would therefore be 136mm. The middle of the wall would therefore be at 68mm. I measured 68mm either side of the marks I had made on the floor and made a mark. This would be the location of the wall.

Now for the location of the foul drainage pipe for the WC…. The centre of the pipe needs to be 90 mm from the wall. Orange foul drainage pipe is 110mm in diameter. The radius is therefore 55mm. Wall to side of pipe therefore = 35mm (35+55 = 90).

I marked 35mm from the new wall position and another line at 145mm (35mm + width of pipe 110mm = 145mm) This is where the trench would be dug and the pipe laid.

I had already worked out where the bath, basin and Shower would be going so it was easy to work out the position of the WC and the location of the 90 degree drain fitting.

The bath and basin waste would run in the wall and boss into the WC fitting . The shower would take the shortest route to another 90 degree drain fitting near the exit point in the wall.

I hope this all makes sense….probably not but hopefully the pictures will help.

Once Dan had finished the brickwork above the window he installed the drain

 

Maddomswood Historic Oak Barn Conversion East Sussex - Foul drainage route - side extension

Foul drainage for the en-suite

 

Whilst we had been dealing with the drainage Colin had been tidying the room. He had piled up the remaining bricks ready for cleaning and all that was left to do was cut down the scaffold poles that had been used to reinforce the recently removed drinking troughs.

Whilst we had been busying ourselves on the side extension Andy and Joe had finished the West End gable and had started to replace the softwood rafters through the roof.

They were making good progress but hit two snags…..they called me up for a chat.

Issue 1 – The Structural Engineer had asked that one of the purlins that had been attacked by woodworm be cleaned and then some oak scarfed on to increase the section. They did as instructed but when they had removed the loose and got down to the solid the remaining oak had revealed the rafter joint and if we had scarfed some oak onto the purlin the repair would not look very good.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repair to purlin

Oak Purlin requiring repair

 

I decided to ask the Engineer if it would be possible to fix a steel reinforcing plate to the back (roof covering side) of the purlin to give it back its strength; we would then replace the 3 rafters whose joints had been exposed (2 were softwood anyway) and cut the joints to fit the tight with the purlin. This would be a much more aesthetically pleasing result.

Issue 2 – Andy and Joe were worried about the structural integrity of the major joint where the Roof Tie meets the Principle Rafter, Principle Post and Eaves Plate to the top right of the NW Elevation screen. As you can see from the pictures there had been repairs carried out and, when prodded and poked, there was some loose material. It was decided that even though the fixings were in place and there was no apparent movement to the joint, it would be best to drill and grout the joint as it was not possible to establish the strength of the joint.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repair to tie joint

Repair required to tie beam joint

 

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repair to tie joint

Repair required to tie beam joint

I contacted Rotafix, a structural adhesive specialist based in Swansea. I told them what the issue was and they recommened we use the TG 6 Grout in combination with their TM3 Moulding Mortar.

As it was not possible to carry out any work in that area until we had heard from the Structural Engineer (he as due to visit site on Monday) and the Adhesive had been delivered by Rotafix, we decided it would be best for them to concentrate on carrying out the repairs and replacements to the East End gable. This would require the replacement of several rafters and the installation of new purlins.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repairs - new purlins

Purlin and rafter repairs – East bay

 

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repairs - new purlins

Purlin and rafter repairs – East bay

 

Maddomswood Historic Oak Barn Conversion East Sussex - Oak roof repairs - new purlins

Purlin and rafter repairs – East bay

 

Electric and Plumbing Installation meeting

On Thursday at 5pm I met Paul Mitchell from Electricare Ltd and Tom Sutton from TPS Plumbing and Heating.

I have worked before with Paul on my Brenchley project. He is brilliant and has all the knowledge and skill to complete easy or complex installations on big and small projects.

I am new to Tom and him to me. He had responded to my advert on MyBuilder back in July and when I met him he came across as very knowledgeable and just the sort of person I would like to work with. He was very interested in the project and he suggested I look at Robbens for the Underfloor Heating. He obtained a quote for me and at the same time I looked online and elsewhere. The price was more expensive but once I had met the rep (Tom arranged this) and negotiated a 15% discount, the overall price and all the guarantees plus on-going support swung the deal.

I requested the meeting as I was drawing up the programme for brickwork, carpentry leading up to 1st fix electrics and plumbing. I needed to know the durations and how they planned to carry the works.

Paul said his electrics would be laid on top of the slab prior to the 100mm insulation and screed. Due to some of the routes requiring access through the roof and external skin it was decided that we would install only the 12.5mm plasterboard and 11mm OSB to the roof and external skin prior to his arrival. He would take half a day to route his cables; the roofing and weatherboarding could then proceed with him working below. His work would take 2 weeks.

Tom said that he would lay his plumbing pipework on the 100mm insulation, grooved into the top 25mm; he would then lay the Under floor Heating within the grids on top before the screed was poured. His work would take 3 weeks with the first week overlapping with the second week of the electrics.

It was agreed that prior to their arrival all floors and stud walls would need to be in. I drew up the programme accordingly with what I believed to be a comfortable amount of time for all the necessary works to be completed prior to Paul and Tom’s arrival. I showed this to Andy and Dan so I can obtain their agreement to the time I had given. I then contacted Paul with his start date of the 7th of December and Tom with his of the 14th of December.

It was now very important for me and Louise to agree prior to their arrival the exact location and type of each light, switch and socket along with Shower, WC, Bath, Basin and sink.

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Phew…the end to a busy week.

Over the weekend I will be drawing up a material order to enable the completion of the carpentry, brickwork, insulation and roofing; once ready I will send this across to Jewsons with dates for delivery throughout November and December….I don’t want it all to come at once so I have broken it down to arrive in time for each activity.

 

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Category: Construction Phase, Maddomswood Barn, My Projects, Property Developing

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