23 – Barn Conversion – Week 18

| 16th November 2015 | 0 Comments

Week 18 – 16th – 20th of November

Barn Conversion

Monday

I arrived at 7.00am this morning to make final preparations for the concrete pour for the barn slab. The over site had been prepared but there were some dips that needed to be filled with broken tiles.

NOTE: Concrete costs a lot of money. The rate I was paying was £97 m3 + VAT. If the over-site has been over dug by even 15mm across the whole are, in this case 79m2 (15.2m x 5.2m), then this amounts to 1.18m3 of concrete. Accurate excavation saves money so it is worth taking time to get it right and add hard core if you do over dig.

William the Concreter arrived on time – 0800am. Colin, Dan and I were armed with rakes and shovels. The lorry was manoeuvred to as far into the opening as possible; it still meant we had to drag the concrete at least 7m to the far corner. Back and side breaking work. 11m3 of concrete was poured and distributed in 45 minutes. The picture and video below will give you come idea of what was involved.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Concrete pour to the main slab of the barn - 3 men moving concrete around with rake and shovels

Concrete Pour – Main Barn Slab

NOTE: Concrete pouring can be made easier by using a concrete pump supplied by the concrete company. These however cost about £350 + vat so should only ever be used when the cost will be set against a saving in time/labour.

Dan and Colin enjoyed a chat whilst the lorry went back to the yard to collect another 3m3 which is what we estimated was needed to finish the job.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Concrete pour to the main slab of the barn - Dan and Colin having a chat

Dan and Colin having a well earned break after the concrete pour

 

The slab was poured and tamped down all before breakfast. Good going by all concerned.

 

Maddomswood Historic Oak Barn Conversion East Sussex - completed concrete slab in the main barn

the completed concrete slab in the main barn

 

Whilst we had been hard at work with the concrete Andy and Joe had been finishing the joints for the Oak Plates for the top of the SE Elevation walls.

Dan laid them on a bed of mortar before Andy and Joe fixed them down using lateral restraints.

 

Maddomswood Historic Oak Barn Conversion East Sussex - Lateral restraint strps attached to blockwork

Lateral restraint straps attached to the Oak Plate and block wall

 

We are now ready for the new air dried oak rafters for the rear out shuts to be cut to size and fitted.

Now all the ground works have been completed Dan sets himself up to start the face brickwork to the dwarf walls. He first starts with the pier to the side of the North West Opening.

 

Maddomswood Historic Oak Barn Conversion East Sussex - face brickwork to the dwarf walls

Face brickwork adjacent to the NW opening

 

Maddomswood Historic Oak Barn Conversion East Sussex - face brickwork to the dwarf walls

Face brickwork adjacent to the NW opening

Tuesday

Today Joe and Andy finally finish all the repairs and renewals to the studs and rafters of the original Oak Structure. The plates on the newly built SE Elevation walls are fixed down on fully cured mortar so it is now possible for them to start cutting and installing the new Air Dried Oak rafters. Each one will need to be cut bespoke due to the wavy nature of the plate at high level.

NOTE: The Structural Engineer specified a range of repairs and renewals and I added the replacement of all the softwood timbers to this; however, as the structure was exposed it was clear that there were more repairs and renewals than originally anticipated. I would recommend that when you calculate the costs associated with the repair of an Oak structure you allow for at least another 20%.

Danny continued the brickwork to the NW Elevation dwarf wall.

 

Face brickwork to NW dwarf wall with 50mm of full fill insulation in cavity

Face brickwork to NW dwarf wall with 50mm of full fill insulation in cavity

 

Wednesday, Thursday and Friday

The next 3 days are going to be dominated by the installation of the Air Dried Oak Rafters to the Out-shuts and the face Brickwork to the dwarf walls, inside and out….. Brickwork and Rafters….Rafters and Brickwork

 

Maddomswood Historic Oak Barn Conversion East Sussex - air dried oak rafters being sanded and cut ready for installation

Joe sanding the Air Dried oak rafters prior to installation

 

Maddomswood Historic Oak Barn Conversion East Sussex - air dried oak rafters after installation

The air dried rafters being installed

 

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

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