Week 51

Ben had the drone out and it’s great to finally see the roof in its glory. Here’s a visual progress report from the get go.

And these….

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Tony had the fire on early in the week, so he kindly invited Ben and me to have a look at making balusters. Each of these is completely hand made by drawing out the bar to a point, then curling it very carefully to match the test piece precisely. Incredible work and much labour involved. Tony has Dave in to do the hammering and finishing, and anyone with eyes can see that their years of working together on projects like this make it seem so easy, but in fact it’s a lot of unspoken expertise involved to make each baluster. There are a lucky-13 curlicues that are framed by straight ones going either up or down. Should be amazing to see when it’s done.

The joinery company making the stairs have been brilliant in supplying Tony with scale drawings of each piece. Colin has travelled from Andover to Betchworth (more than once!) to deliver the drawings and talk about the work with Tony so that the joined up staircase between the two completely disparate trades are installed seamlessly at the end of April. Can’t wait!

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Tony and Dave working to draw the bar into a point

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checking the curve by eye
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bending vice

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forest of balusters
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a proper working forge
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sorry, can’t stop taking photos of these

Meanwhile onsite, the wood floor arrived. Usually, they hoist the planks up box by box, but the ceilings are a little high for that here, so they were hoisted up two planks at a time–it took a while.

First the guys prime the floor, then they lay a layer of latex which acts as a barrier between the concrete floor and the wood. They mix this bucket by bucket onsite. Then a really thin membrane of foam is cut to shape, and finally the floor is put on top.

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the wood arrived, hooray!
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primer coat
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latex milk
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mixing gear
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pouring latex on a primed section of floor
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spreading around by hand
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Gillian’s room with the finished floor

The services are being installed gradually. We’re waiting on the water board to come and inspect its trench, so although James doesn’t like leaving it open for health-and-safety, it has to be left until they drop round. The boiler should arrive soon; the flooring guys need it so some heat can get into the floor to dry it out. So we were very pleased to see the gas company arrive and install the meter in the hedgehog box around the side of the house. After the drama of last week’s engineer unable to install, this took a grand total of 10 minutes and the guy was off. And the three-phase upgrade for the electrics will be in the middle of April.

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not a hedgehog
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ready for electrics

The Sparks are in cutting holes in the ceiling. There is so much to this electricity piece, and we haven’t even chosen any fancy fittings yet. Here’s a challenge for you: next time you’re in a place with small LED ceiling lights, go ahead and have a look at the geometry of their placement. The glossy mags always say to hire a light designer because you yourself as a layperson could never hope to achieve a good effect: what you’re lighting, how you’re lighting, when you’re lighting, controls….. The Sparks want things in grids, as do the architects. We’ve opted for a DIY approach to tweaking Dave’s placements just a little in order to centralise some of the fittings around architectural features like doorways and cupboards. I’m no expert at this, and I hope that I will remember fondly this m.o. when I’m not too upset at the finished product but instead, basking in the glow of the thousands of pounds saved that I didn’t pay to the lighting designer. (Fingers crossed, obvs.)

The guys use their laser sights and chalk lines to get the rows straight. This doesn’t please the decorators who then have to wash off the chalk because the dye runs into the paint, especially if the paint is white. Like on a ceiling. Where the lights are. Duh.

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takes a day to set out
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and another couple to drill

The non-herringbone panels on the side of the house are coming together. I had a total 4 am brain-fade about the side panels which are not at 90 degrees, but rather are offset and parallel to each other. I texted James about it suspecting they’d have to rip off the half-laid panel, but he replied with a photo of the plans which clearly show the bricks in parallel. Glad someone’s on the case! And note to self: consult the plans before hitting the panic button.

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brick slips

But there are still a bunch of gaps in the design. The biggest one is the fireplace, and Steve came up from deepest Sussex again to speak with Dave and me about how to accomplish what we’re after for the surround. We’ve made it enormously complicated, and probably unfeasible from an engineering point of view. We’d like a floating stone mantle–but how to fix it? Lots of head scratching, and to be honest I’m about to give in to a simpler design. This room was never designed to live in, mostly to look at, and this is disappointing as we should have thought about it more from the start. The windows are too close to the fireplace wall to put units in, and the building regulations put so many restrictions on measuring out non-combustible zones that it’s all very tiresome. We’re at that last 20% that takes 80% of the effort. But it will be beautiful, the workmanship is great, and it’s only complicated because we the clients are trying to squeeze too much in. Much better to simplify, pare back and let the features in the room breathe a bit. Watch this space.

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blank wall, blank heads

Another bug-bear is the garage roof. The guys have done a brilliant job at getting the end to just kiss the fence, so the dimensions are perfect. But how to support it is another kettle of fish. The original (built, then unbuilt) brick pier was a thing of beauty, but it didn’t give us very much room to get around. So we’ve opted for an oak post on a smaller plinth instead. In the meantime, there is a slightly bendy Accro holding the roof up at the spot where Terry says holds the max load. But this still leaves us a little short on space to get around. Do we place the final post off the sweet spot either towards the building or away from it and add a stiffening bracket? Can we? Or do we suck it up and just stick a post in?

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jury is out on replacement to bendy Accro

Last week’s tile-hanging design query was bottomed out, but this ended up being just a case of making sure everyone was looking at the same revision. The flare at the bottom will be great, and the roofers will fit in the tile hanging when they next have a gap in their diary. It’s a stand alone piece, and not mission critical–which is refreshing!

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flare supports

 

Week 35

The main structure is up and sorted and the building is Dry. Dry is a Big Deal. Even though there are large gaping holes where the windows will go (on 9 January), these will be boarded up over Christmas, and the rest of the structure is Dry. The guys are now finishing off the fiddly bits of the roof on the outside and putting up the frame for the ceiling on the inside.

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fiddly bits and covered subframes
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subframes in the sitting room
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one in and one not

The roof and all the subframes are attached to the concrete by these enormous brackets. Terry assures me that there will be no roof blowing off on this house. The lead will be installed in the coming weeks.

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west bathroom windows
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west-most bedroom

James is making up the inserts for the angled brick sections. We had a meeting with the reluctant warranty company about the design early on. They were quite rightly concerned about water ingress in the junction between all the materials sitting in the oak frame in case the structure settled. We worked then with Dave to create a multi-layered system of composite board, epoxy resin, insulation and compriband that will prevent any drips or drops from getting through. It is very complicated, and James has been pretty keen to get stuck in to building them. They look good so far!

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pre-insert
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brick inserts, pre-brick
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inserts and insulation from the inside of front gable
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inserts from outside

The ceiling is also complicated: the trusses go up really quickly, but then there is much time spent creating a set of noggins in between each truss to support the plasterboard ceiling that will be installed soon.

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east-most bedroom: trusses & noggins, boarding & flooring
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ceiling with loft boarding and dormer window

There are two extra guys on site this week who installed all the subframes and boarded them up. The goal is to get the building dry enough to set the underfloor heating in screed before we all disappear for Christmas. That will give the floor two weeks to set and dry.

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can you spot the elf?

I think everyone is feeling buoyed up by the progress made recently. This was never going to be an easy house to build, and many of the painstaking pieces of the structure seem to be happening all at once. The guys remain cheerful onsite, they help the neighbours with heavy lifting, they’re keeping the place amazingly tidy given the freezing weather and the early nights, they joke around and it seems quite jolly. It’s got a good vibe and looks a nice place to work.

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festive site

We signed off for the kitchen this week (hooray!). That will be 14 weeks. The sanitary ware has been ordered (8 weeks), the floor sourced, and the stairs being drawn up. Many more decisions to be made after our Thursday meeting–I’ve got a 14 point list of urgent items of homework for Monday, and many more pending. But we’re vaguely adhering to our modified schedule which is good. I don’t want to be the one holding up the game. A busy weekend to come….

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Ben’s been playing onsite

Week 21

We’ve come a long way in this build….

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The guys had a lot going on after the bank holiday: steels, cranes, personnel changes, rain. They’ve been steadily going upwards and we’ve been cracking on with decisions. We’re mostly there on bathrooms, kitchen, fireplace and roof tiles. We’re getting there on flooring and wall tiles.

The steels arrived on Wednesday. There are over 50 pieces in this build. There is a slight hiccup with the sizing of some pieces in manufacture, and after much checking some of them will need to be re-installed next Wednesday before the upper floor goes in.

The overhang on the west side of the front elevation is coming along nicely, and the steel is placed on the piers to take the load for the upper brickwork.

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overhang from the living room
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front elevation of the living room

The overhang on the west side of the house near the garage is larger and leaves a gap from windows to piers big enough to walk under. I’d better get on an plan the landscaping out the front in case we want some raised beds before it all gets paved over.

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west front elevation
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bird’s eye view looking into kitchen
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the garage in all its glory
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more steels across the entire build
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kitchen space

Roof tiles are very difficult to choose. We’ve spent some time looking through brochures and spent about a week developing a good mix of shades to make the whole project seem weathered–like it had been there for decades. When we presented our carefully considered combination to the builders, he said we were nuts. Why spend all that extra on something a) you won’t see, and b) will fade within a year? So we have decided on a single dark tile for the roof and another single reddish tile for the hanging bit on the west flank. Tick.

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we’re going for the left hand bunch

 

Week 15

Friday

Nothing much has happened on site for a number of reasons, but it allows me a chance to catch up with the pace. Who would have thought there would be so much detail in a fireplace? And how does one address skirting around it? Garage doors–they need to know the size of the frame now so they can build the brickwork around it. There’s enough going on in life outside the build what with the family business busier than ever, me starting in it (again!), the usual end of school shenanigans, Pokemon Go taking over the world and Britain voting out of it, horrible weather, and keeping up with invoices, that actually this hiatus might be a godsend. Hopefully we’ll see more activity next week.

In the mean time, I’ve been playing around with a new app.

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Enough of that silliness.

Ben brought his drone around in the afternoon to take a few snaps.

Tuesday

How did we get to week 15??

It’s been raining and the brick gang have been doing other things elsewhere. The dummy window frames have arrived along with some concrete lintels and a load more insulation. Nic will measure all the frames to make sure they match the windows exactly. The bricks will be laid around them.

The foundations for the front porch were poured yesterday. These are only 1.5 metres deep, and that’s it for concrete foundations! Whoop whoop!

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artsy lintels
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window frames to measure and match
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more and more and more and more rain

It’s great to see the window frames evident in the interior blockwork. Hopefully we’ll get up to first floor this week?? Maybe next week in reality….

Week 5

Friday

Today has been about waiting for the building control inspection and the concrete, and fingers were crossed for most of the day that they would arrive in that order.

The sides of the trenches were temporarily shuttered with big sheets of ply. The first steel reinforcements went in just fine: Jamie dropped them in using the digger and Lee coordinated. The grids have little plastic feet on them so they sit nicely in the trench.

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the first steel footing

The footings will be about 800 mm of concrete then a couple or so courses of blocks, then bricks. The guys talk about concrete arriving in cubic metre loads.

I met Poppy the security system too.

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Thursday

We had a peep down the well today, and the guys are amazed at how clear the water is. Back in the day, we used to fill the paddling pool up with the well-water using Chas’ irrigation pump. All the neighbourhood kids would come round and it’s a drag that we are no longer off metering. Apparently all new houses require a water meter.  But the swimming pool was awesome, if cold!

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down the well

The well water wasn’t the only thing filled with water though….

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where’s that pump?

The water table is pretty high where we are! Luckily, Nic has a pump just like ours and he’s drying it out before the building control guys come round to have a look. It needs inspecting before concrete is poured.

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steel footings being discussed by Jamie and Lee
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the “kitchen” in our bike store

Ben brought his drone down and he got a lovely shot.

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Ben and his DJI
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that’s a whole lot of nuthin
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nerd and Nic

Tuesday

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Macrame with steels

The steel reinforcements arrived onsite. They’re single lengths and need to be formed into the shape of the foundation channels. The guys have had a little bonfire today while waiting for the steel, and they intend to start digging tomorrow.