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Beam and Block


Red Kite

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Its been a few weeks since the last post but for us its not been a quiet time - we hear from friends who now watch daytime TV at a very leisurely pace - if only!!!! As we are at a point where we have a few days breathing space this is the first of several posts to catch up with ourselves.

 

After the scaffold went up round the outside of the build in preparation for the timber frame the next step was to lay the concrete floors as a 'lid' to the basement and sub floor and a ceiling to the next floor up. This consists of long concrete pre-cast beams spaced out across the supporting lower levels and in filled with concrete blocks. This has been a bit fraught as the design is complex (as is everything in our design!) and we are on our second B&B supplier and have taken a 5 week hit to the schedule. Anyway it was on its way and you can see that the first steps were to load in lots of the infill block (hard to source in todays climate) and a temporary plastic scaffold or 'fall arrest' deck to give the guys a platform to work from and also to prevent them falling 3m onto the concrete slab. This is great stuff (if a little wobbly at times!) and you can see it being laid out as yellow plastic posts and black plastic deck. All was well until the fall deck contractors lorry demolished the front pier of the garage and brought down a load of blockwork. Luckily the steel garage lintel had not been fitted otherwise this would have been even more spectacular. So a bit of rework and it all looked OK for the steel and then the beams.IMG_20200330_184834853_HDR.thumb.jpg.9256c1a3413385751beae6a744194a66.jpg

 

These beams are really heavy - hence the crane, but progress is amazing and they laid the entire floor in a day. Again the gremlins struck and the crane went into 'limp mode' and would only move really slowly but they managed to finish the beams and lay most of the blocks. Next step is filling in all the odd sizes of blocks and then setting out and building the 'plinth' blockwork for the timber frame to sit on - both the internal and external timber frame walls come up from the B&B floor on a level plinth. Again things on our build are complex and on Plot 1 the plinth is 250mm high filled with 150mm of PIR insulation and 100mm of screed, while on Plot 2 its 150mm (50mm of insulation and 100mm screed) - the screed and insulation are fitted at a later stage so all the rooms will look taller than they will end up. If only life was simple all the timber frame would start at this 'plinth' level, however there are some MBC steels and glulams that come down below this to  bolt down to the reinforced concrete below and its been an endless and fraught process to make sure that this will all fit together seamlessly on the day - fingers crossed!

 

Plus there are a thermal blocks under the doors and floor to ceiling windows. There are to give a thermal break and are very strange foamed glass (called Foamglass) block that are very light and take a huge load and are really expensive, plus there are three sizes of blocks and we have some of all of them!!!! The Architect wanted Foamglass all way round the outsides of both building and that would have been great - but we really couldn't afford them! So the next bit in the video after the beams is the brickies laying a load of blocks and thIMG_20200407_191113570_HDR.thumb.jpg.8c5314aedad13c96362555f33cc1bf60.jpgen we can see where the internal walls will come, and how the room shapes start to look: on a bare floor they seem a bit small but that will likely change as the volumes are enclosed with walls.

 

The last thing you see is the scaffolders back again and putting up the scaffold for the front and middle of Plot 1 - they had to work around the brickies but it all seemed to work. So for a timber frame house there is an alarming amount of concrete, steel and blockwork and an awful lot of insulation.

 

So finally after a last minute rush and lots of issues that needed resolving we are ready for the big day tomorrow where MBC arrive on site and start erecting Plot 1 - what a journey but this is something we have been waiting to see for months and months. So exciting and we cant wait for them and another crane to arrive with a house on a lorry.

 

 

The latest video is called Beam and Block plus all the older ones can be found here :-

https://www.dropbox.com/sh/th9f6e3cel5dm1q/AAAfsWdAH184J75bCNUUtzVra?dl=0

Our internet is a bit slow at the moment so it may take a few hours (or even days!) to sync up to Dropbox so if you dont see the  time lapse video pop back in a day or so - its quite fun to see something starting to take shape above ground.

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Can you still achieve the u values with 50mm insulation of is it different with is being above a basement?

Looks good

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Those crash decks are really annoying, especially when you have small rooms / corridors to do.  I am sure it could be managed another way but the bean bags are not much better.  Did you go for beam and block for structural reasons?  I have done timber frame over a basement and did a timber floor, just to cut down on a contractor.

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Oz07 - the basement has part of it as warm habitable space, and part is cold garage so the insulation is complex - the habitable space has 150mm in the basement floor, and the garage has (at least - it varies!) 100mm in the roof (under the B&B). This is all overlayed with 50mm above the B&B. So minimum is 150mm (between cold and warm) which achieves the U values. The reason its all 50mm above the B&B is to get a level floor at 1st floor level, and in the basement the 150mm in habitable vs none in the garage gives you the step down into the garage you need for fuel spill etc. Inevitably there are some cold bridges and less than optimum junctions but overall its not bad - and with all of this there are diminishing returns on refining those junctions. Passive House it aint - but pretty well insulated it is! And all PIR not EPS - though SAP reckons that using Phenolic would have made no difference.

 

Given the benefit of hindsight the overall design adds complexity at every turn in every element (different insulation, beam thicknesses, wall design etc etc) and before going to detail design we should have taken the opportunity to simplify it as much as possible. Some of the complexity comes from our basic requirements (like an underground garage dictated by the side topology and planning restrictions) plus the inevitable evolution of the design as it gets modified and refined, but after that we wish we had stood back and looked at it carefully - if we knew then what we know now! Having said that it all looks like it will work! If you want the really ugly details this is probably a blog post in its own right!

 

Mr Punter - B&B was mainly structural as there are some large spans (6+ m) - but it could probably have been done in timber pozi joists (doubled up) that might have made the insulation simpler. Our GW contractor was OK to do B&B plus masonry, but not sure MBC would have been up for a timber floor - so we did avoid an extra contractor. Working with only two was complex enough - cant imagine how hard it would have been with a third.  Another of those - 'wish we had known' things was that the B&B itself is complex in that it has different beam thickness's (140 and 215) running is different directions! which means that there are different heights of supporting walls to get to a flat floor. It might have been simpler to go to all 140mm thickness and throw some more steel in, or over engineer and go for thicker 215 beams everywhere.  That cost versus complexity trade off, plus a SE who didn't really grasp the concept of value engineering! Plus of course a huge dose of ignorance / naivety  on our part - ho-hum you learn the hard way! And its been really interesting learning, though everyone seems to assume we know what we are talking about, so come to us to resolve the inevitable issues - what the American term 'drinking from the fire hose'!

 

More on those crash decks in the next post!

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