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  1. We had our final inspection yesterday and building control were happy with the house. Just awaiting on an EPC certificate and we should have our completion certificate next week. We had a little tidy up before the inspector arrived so probably the ideal time to upload a few pictures. Landing and upstairs - not posted much here as this was covered in a earlier blog entry. Considering we put in outline planning in 2009 when we were 23 it's been a long time coming and a great relief to know it's nearly all over. I intend to post a couple more entries with the last bits of outside work and one about the costing/finance. Thanks for all those who commented over the years and answered odd queries, much appreciated. The to do list of actual jobs is getting short now. Proper downpipes – ordered Gravel - ordered, coming on Monday
    22 points
  2. This will be the last entry for our self build blog. Our plan We originally commenced a self build as there was no affordable housing for us to get on the housing ladder. The approach for the self build, was whether we could build a better-quality house than what we could purchase from a developer for the same cost. This was later refined to achieving a lower mortgage if possible. For the self build we decided to split the project into three chunks. 1. Obtain outline planning, purchase of site – this allowed us to know that a build was possible. 2. Put in services, access, design – this was the first actual work and made an area of croft ground into a valuable plot for lending purposes. Commence the build over two years - using subcontractors and our own materials to eliminate any margins and ensure tight control over the specification. Doing this would allow us to complete the project and prevent us being stuck unable to finish it. What did it cost? The total cost for the project was just over £196,000 (net of VAT). This includes the land, services, professional fees, overheads and the actual build costs. I’ve summarised all of my costs into a pie chart below. How was it funded? · A small electricity grant £1,550 · We obtained a croft house grant for £38,000 · The final mortgage of £74,500 · The remaining balance of £81,950 was funded by savings from employment, which started when we were 23 and finished when we moved into the house in July 20 at 33. · Most of the work we carried out was decorating and general labouring, therefore contributed a small amount of sweat equity to the project. What is the final result? The surveyor provided a valuation back to the building society of £265,000. This was pleasing as sometimes self builds can be more expensive then the total project costs or just about breakeven. Prior to building we were aware of building cost being measured per m2. However, during the build process I realised that this method of reviewing the financial performance of a self build had room for error, as the calculation could be skewed depending on the quality of the finish. For the purposes of our project this would be £1,420 or £1,230 excluding (land, professional fees and overheads). I came to the conclusion that the best method for us is calculating the final cost per month (mortgage, utilities, council tax, insurance) to live in the house. I set a target of £500 per month and I am pleased that we have been able to achieve this. I feel this is a good measure as I wouldn’t want to live in an expensive house that has a huge mortgage. Often at the end of Grand Designs and other tv shows, the presenter asks whether they would do it again? For us I would say, yes, of course. When I look around, every single item in the house was researched, compared, purchased and gradually put together. The thought, time and energy that we have put into this build has created a much deeper connection to the property. Our blood, sweat and tears are in the very fabric of the house. The hardest part of the process was when we were focussing on saving as much of our income as possible to ensuring a low mortgage. We made many sacrifices to ensure we reached this end goal, but we knew these relatively short term sacrifices would have long term gains for our family. For the actual building of the house, we chose a two year build schedule from starting on the foundations. This allowed us planning time between build stages and made the build process more manageable. It also allowed us time to do some jobs ourselves such as fitting insulation, interior decorating etc. We enjoyed taking time to do the jobs we were confident in doing well ourselves. Perhaps we could have taken on the more tasks, but I’ve come to the conclusion that it made more sense to work a bit of overtime and pay a contractor to do the work well, rather than us doing a job slowly and at a reduced quality. In the future, we would consider another self-build, perhaps in thirty years when I will be semi or hopefully fully retired. So until then… See you next time and thanks for reading.
    20 points
  3. There was not much in the way of progress from the last entry as we were already close to moving in. The plumbing was completed in the last entry and connecting some final electrical fittings was done soon after. After a decade since putting in outline planning it was time. Our furniture delivery has taken longer than anticipated and we are living with a bean bag for the living room seating and a mattress on the floor for our bed. But we are here. The first few days were spend getting used to living in a new space. As a family four we had spent the last six years living in a relatively small space, it is now great to have a room for each of our children and an extra bathroom. I am pleased with how the house is performing from an energy use point of view. We don’t typically get really high temperatures here and the external average temperature has been about 12c over the last few weeks, the house temperature has remained a comfortable 20c. I have been monitoring our electricity units on a daily basis and we are using between 9 to 10kw which is promising as my hope is that we can go six months or so in the year without heating. The real test will come in the winter as the electricity usage will probably be double, but we plan to make good use of our centrally placed wood burning stove. Once we are furnished, I’ll post some more photos. For the moment just enjoying the new house with the family. The next jobs are: - Ordering decking for a small decked area and for our access ramp - Spreading gravel around the house site - Gardening - Putting more material on the access road - Order some down pipes Thanks for reading.
    20 points
  4. So after a month or so in the house, the time has provided us with an opportunity to reflect on what we have achieved and what if anything, we would change or could have done differently. In truth there is very little if anything that we would change. The rooms flow, the doors open in the right direction and the lights can be switched on and off in the appropriate places. Even the WBS has proven to be a worry that wasn't worth worrying about, as it's position within the hearth is no longer an issue due to it being vented through the back as opposed to the top. Some jobs have been completed such as the down pipes and a few jobs remain outstanding but nothing that has an impact upon our daily lives. One such job is the porch that needs to be slated. Thankfully I still have some financial leverage over those various trades so I know they will return. Our satisfaction I suppose, has to be routed in the preparation work, the research and being a member of this superb forum. None of these elements should be underestimated. Therefore I would like to sign off this blog with a heartfelt thanks to all those who have contributed, not only to my issues over the past couple of years, but to all the other threads, as they too are just as relevant / enlightening. I have also attached some images which complete the project, namely the WBS chimney installation and the erection of the much mentioned porch. For a final time, thanks for reading, and given the date, seasons greetings to you all. Paul.
    19 points
  5. Following on from the last entry we had our final inspection and were on the cusp of getting our completion certificate. A few final documents were uploaded and a certificate was received from building control. We had built a house. A few final jobs were completed following the last blog entry. I order 20 tonnes of gravel from a quarry on Skye and then barrowed it down the access and spread it around the house. I also had enough to put some at the top of the access as well and fill a couple of bulk bags. The last job for the joiner was fitting the downpipes. We used the cast iron effect ones as these provide a bit more of a decorative look compared to the standard glossy pipes. We seeded the ground at the start of lockdown and now after a summer of growing the grass is coming on nicely. The grass seed cost very little money. It cost us around £15 to do all around the house. We are pleased with how the house fits into its surroundings. Our pallet wood shelter was finished and I’m currently building up the wood stocks. I am also storing fresh cut wood for the future years. These old CUPA slates crates are useful for this. As we are now heading into colder times of the year, we have had an opportunity to have a few burns from the stove. I’m really pleased with how well it is performing. The stove is bang in the middle of house surrounded by thick concrete block with a lime render. It heats the entire house and the increase in room temperature can be felt twelve hours or so after the last log goes on. I wouldn’t however recommend fitting a stove in a self-build unless you put some serious planning into how you will actually use it. Even a small stove could easily over power the heating need for a living room. Solar gains produce our base heating, keeping the temperatures to around 20c and the daily electricity usage at 10kw. We don’t have any underflooring heating or radiators. If we reach a long cold spot and need a quick boost, I plan to wheel out an oil electric heater or use the towel heaters. . What’s next. I need to crunch the final numbers. I also need to put a final layer on the access road but might put this off until the winter. Thanks for reading.
    17 points
  6. Well, it’s been quite a while since my last blog post but we’ve not been idle but I do admit to having been slack in updating the blog. At the end of the last blog we had a superstructure and the roofer was about to begin his journey up the scaffolding. This is where that tale begins….. ’Twas a sunny November morning when all was quiet that a white van man arrived at our site to felt, batten and slate our sloping roofs. And he wasted no time at all in cracking on with it after the site orientation was complete. With his dad along to help with the battening it didn’t take long for the membrane (or ‘felt’ if you’re a roofer) and battens and counter battens to be done. After discussions with our BCO it was decided that we would fully fill our rafters and use a breathable membrane (Proctor Roofshield) attached to the roof trusses and then 25mm x 50mm counter battens and then slate battens which gave us 50mm ventilation. This allows us to not need soffit vents (or indeed soffits) which fitted in to the design of the house better and also meant we don’t have to worry about creepy crawlies living in the soffits. We started with the southern elevation so that the solar PV array could be installed and the roofer (Chris) fitted the first few rows of slates and some flashing leaving it ready for the solar team to arrive before moving on to the northern elevation So while Chris was busy working on the north side of the house the solar installers arrived and fitted our GSE trays. Once done they started to fit the panels. But it was then discovered that the company who did the ordering ordered the wrong size GSE trays and the panels wouldn’t fit. So the solar installers took all the trays down and left site after wasting a day’s work. Meanwhile the flat roofers attended site to single-ply membrane our flat roofs and balcony. A great bunch of guys from a company recommended to me by Chris so I had every confidence of them doing a great job, and they didn’t disappoint. DPM, PIR, OSB then single-ply membrane. First roof which will have a wildflower green roof being overlooked by our bedroom balcony Second roof above our utility room which links the house to the garage which will have a sedum roof They will return a little later on in the blog to install the green roofs. Meanwhile the solar installers returned after the correctly sized GSE trays had been delivered and managed to fit it all in a day. We think it looks brilliant. 28 x 375W LG panels, each with Solaredge optimisers as we have lots of trees around us. And when they’d finished each panel was giving out 1V and was confirmed each was working by being shown the 14V on each string in the loft. Job done for now until we get electrics first fix done and they can come back and fit the inverter. The only real issue we had with the solar is that the panels were resting on the slates making them lift up in places. I created a thread about them (https://forum.buildhub.org.uk/topic/24530-slate-tiles-lifted/) and after much discussion and deliberation I decided to simply use black CT1 to stick them down which worked nicely. A bit of a bodge but you can’t tell from the ground and a lot less disruption to timelines than other solutions. While all of that was going on Chris was busy slating the northern elevation and it was all coming along nicely. During that I had another discussion with the BCO about vent pipes. I asked if I could have one by the STP but she was adamant that I had to have one through the roof. When I mentioned I didn’t want a pipe sticking out the top of the roof she said that they do slate vents. A quick google search revealed what she was talking about and I purchased the item and it was installed. Looks fab and from the ground you can barely notice it which is just what I wanted. And now the solar PV install was finished he could move on to the southern elevation. But while he was doing that the flat roofers came back and installed our green roofs. The wildflower material So that’s those finished although we were still waiting on a Velux roof light for one of the roofs which was delayed but the flat roofers came back to install that for me and finish off that roof a bit later. They also installed our patio paving slabs which we think look ace. So, back to Chris and he’d now finished the main house roof slating and it finished off around the PV panels nicely. He did make a start on the garage roof but as we were still waiting on Velux windows he couldn’t finish that so he left site and would return once the Velux’s were delivered. During that period our windows and doors arrived! We used Norrsken for these and went for alu-clad triple glazed windows and sliders. The majority of our windows are fixed and we had quite a small profile for the frame which means more glass. The installers, Elite Installations Nationwide (https://www.eliteinstalls.co.uk) were brilliant and Jim and his team were a joy to have on site. They brought their spider crane with them which made lifting our windows up to the first floor a breeze for them. We decided to be bold and went for a red front door. We love it. As the window install was done the week of Christmas the installers couldn’t finish them all in time before the Christmas break so we wished them a safe trip back to York and would see them in the new year. Happy new year!! (Belated). With the new year came the return of Jim and his team to finish off all our windows and doors. Once they were installed it made the house feel so much more like a house. Closing the front door had a feel of shutting out the outside world and we were (almost) water tight at last. We also eventually received our Velux roof light and sloping and vertical windows. So the flat roof was finally completed and so was the garage roof. So we are very nicely watertight at this point. All that’s left now is the time-lapse video for this period of time. Sadly our camera only shows the south side of the building so we only get footage for stuff that happens on that side but it still makes for an interesting watch and I hope you enjoy it. Until next time.
    15 points
  7. Good news! I today obtained planning permission and so I am starting my build blog. Thanks to everyone on BuildHub for your help and support so far. I have already learnt so much from this forum, all the way from questions when I was viewing the plot and every stage since. And an especial thanks to all the Buidlhubers that I have had the pleasure to visit so far. You have all been warm and welcoming and your advice and inspiration has been invaluable. Thank you! Thank you! My plot is in Cambridge, quite central, near the banks of the river Cam, just behind a row of college boathouses. It is opposite an ancient common and in a Conservation Zone. It is a garden plot that constituted the end of the long garden of a large late Victorian villa. Access is from a narrow access road (not owned by anyone) which runs behind the the boathouses. The plot itself sits behind a mature horse chestnut tree, whose roots I must preserve. The plot is is about 300 m² and is in flood zone 2. The dwelling will be a modern bungalow, 2-bedrooms, near passive house, with a green roof and clad in buff brick slips. Here is the timeline until today: 10/3/18, first visited the plot, advertised in Rightmove as a house. 13/4/18, my offer to buy it was accepted. 24/4/18, I made my first visit to BuildHuber to start my long learning journey 29/4/18, visited my second Buildhuber 31/5/18, the plot already had planning approval but before buying it I started a process for a re-design with the seller 4/7/18, visited my third Buildhuber 26/7/18, visited my fourth Buildhuber (and watched her build, with five additional visits to date) 19/8/18, visited my fifth Buildhuber 6/9/18, I finalised price negotiations with the vendor 18/9/18, plot topographic survey 26/11/18, submitted for planning permission 17/12/18, completed on the purchase of the plot 7/1/19, planning application formally accepted by council 11/2/19, visited my sixth Buildhuber 26/2/19, consultations revealed I needed to redesign the pitched roof to be a flat green roof to meet SUDS requirements 12/3/19, met the tree officer with my arboriculturalist on site 30/3/19, taking advantage of a neighbouring development having the road open, I installed a temporary electricity supply to the plot 2/4/19, engineers supplied drainage calculations including green roof 6/6/19, vendor approved the revised design with flat roof (deed's required it) 20/6/19, visited my seventh Buildhuber 29/7/19, visited my eighth Buildhuber 23/8/19, visited my ninth Buildhuber 19/9/19, council advised that my application is scheduled for the 2 October planning meeting 24/9/9, council advise that my application was bumped to the 6 November planning meeting 6/11/19, planning application approved unanimously, with two councillors choosing to comment that they particularly liked the design. One objector spoke against. Next step: build a house …
    15 points
  8. A busy November saw all the trades coming good, albeit some were cutting it fine for the moving in day – 30th November – However, we have moved in with all the services up and running. Having said that, BT and Openreach have missed the deadlines and as a result we are without any internet, phone line or TV for at least a week! Also the master bedroom built in wardrobes are still be fitted. The landscapers have finished their work, providing us with a patio area and a driveway area which will see plenty of activity. Look closely and you should see the hedging that has been planted. 330 separate plants in all. This was a planning condition and the hedges are a mixture of Hawthorn, Beech, Holly and Maple. Locally referred to as native hedging. The turf will be laid next Spring. Our Air Tightness test was conducted by a guy from Perth - a good couple of hours away. We never set out to achieve such low levels because we didn’t want the capital outlay of such a system as well as the infrastructure it requires. Our score was 4.9 which in our eyes is very good. There are a number of minor jobs which I need to do such as touching up the paint work here and there; re-oiling some wood in places but all that can wait until we have given the whole place a deep clean. The main external jobs outstanding are the erection of the oak framed porch and the downpipes. Both of which should be completed within the next 10 days or so. Anyway, this was not a self build in the true sense of the words but it was project managed by myself and built using a main contractor and sub contractors after the TF had been erected. I hope you have not only enjoyed reading about our project but have found some useful bits of information within the blogs in order to assist yourselves with your projects, whatever that may be. Overall my experience has been a good one. It hasn’t been without its difficulties, such as additional unforeseen expenditure and additional expenditure as a result of our mistakes, or due to us changing our minds! Such examples include ordering the wrong door frame - we failed to realise we hadn't ordered a threshold suitable for level access - a mistake that cost us £1k. Changing our minds over the 3 toilets we had ordered. They simply looked lost in their respective environments so 3 new ones were ordered at an additional cost of £850. A failure to get a full grip of the scaffolding cost an additional £1k and a failure to budget correctly for the foundations and dwarf wall for the carport cost an additional £4k. Final facts and figures - Build schedule – 6 months from the day the TF arrived. Cost per sq metre - £1850 – includes everything, and I mean everything - from the scaffolding through to the landscaping and it includes the car port and porch [ still to be erected] but not the land or fees. Only two skips were used throughout the build – everything else was removed by us to the local dump or burnt on site – best investment was a £25 oil drum which we used as an incinerator. Thanks for reading - Paul.
    15 points
  9. Thought I'd do a short blog on the Polycarbonate tunnel we built. Our big field suffered with no storage, and location meant containers were very expensive to transport. so one option was to build a polytunnel, which we have planning permission for. again due to location, 500m from the coast 73M AMSL I wanted something sturdy. so looked at off the shelf packages. in the Highlands and Islands the PolyCrub is seen as the mecca. Designed in the Shetland isles, guaranteed to withstand 100MPH winds etc etc. due to the ability to get CROFT grant assistance on these, the price is, IMHO, artificially high CIRC 6K for 4M *6M.. this wasn't going to happen, so after looking at many photos I designed my own.. Basic principle is hoops of MDPE pipe secured to posts in the ground, then 3*2 timber used as horizontal support, with Polycarbonate sheets secured to this timber. the bottom sides are then clad. My design was to use 65mm Black MDPE pipe, and secure the timber with coach bolts and penny washers through the pipe. this way I get a guaranteed fixing that won't pull out , and it still allows for flex in the whole structure. 4m wide x 6M long, but this can be extended. My ground has bed rock close to the surface, 300-500mm below ground, so just knocking in post wasn't going to be secure enough to withstand the winds, also where I was sighting the tunnel its on sloping ground, so I couldn't get it level. I cleared the area to removed the top vegetation and a bit of the top soil. and dug 14 holes. then due to rock levels I then core drilled the rock to allow for the post to be deeper. We then set these in concrete, (at the same time as doing the slabs for the cabins.) The next day we had a look and I wasn't too happy with the security of the posts, so slight change of plan, we created a plinth. basically I used some 6x2 either side of the posts, with a slight angle, then filled this with concrete (again we used ready mix at the same time as back filling the treatment plant) this added about 300kg of concrete to each side, and joined all the posts together, and gave us a solid plinth at the side. No Photos of the next stage but we cut 7M lengths of 63mm pipe, this when placed over the posts gives approx. 500mm dwarf walls and a 6M polycarbonate sheet, giving a head height of around 2.3M. we used a plumb bob to get the centre line on each hoop and drilled an 8mm hole through the pipe and secured the top 3x2 treated timber to al the hoops. One thing we found was that the MDPE did not bend uniformly, this may have been due to slight errors with the posts being plumb. The resultant timber (which was not very straight), snaked from hoop to hoop. after head scratching and re thinking. I decided it was a poly tunnel and to get on with it. we used 7 lengths of timber jointed with half lap joints to extend the length to 6.5M. if using a clock analogy the timber was placed at 9,10,11,12,1,2,3 positions, with the 9 & 3 o'clock being 500mm off the ground, also ensuring the 9 & 3 o'clock timbers were approx. 5.8M apart circumferentially. Then it was a case of securing the polycarbonate sheets to the timber. each sheet is joined with some soffit H joint strip. (you can buy a clear joining strip for the sheets but for a 6M length it was around £65. the H strips proved extremely difficult to connect the two sheets together, or should I say impossible. so I cut off the back edge on one side and used some glazing sealant. this way we could attach the strip to the polycarbonate prior to bending over the tunnel. and each sheet 'H' strip basically lapped over the previously installed sheet. day 2 we had the basic structure. It was noticeable that the curve was not symmetrical, so putting the door frame header in by securing to timbers at 11 and 1 o'clock was not level. I overcome this by using a ratchet strap attached to the 11, and 3 o'clock timbers and tightening until timbers at 11&1 o'clock were level. I then put the two door jambs in (concreted at the base) and cut to the length required and secured to the header. This worked and the tunnel was now more cylindrical. I framed the rear by baring 3x2's off the horizontal timbers. Last steps were to clad the base, I used 4*1 treated timbers that were screwed into the MDPE pipe and wooden posts. then used strips of visqueen to create a more sealed dwarf wall, this will help prevent driven rain from the winds getting inside. over this I used Larch timber backs* to create a vertical cladding All in with hardware, polycarbonate, timber, concrete the project cost £1200. not cheap, but its solid as a rock. It withstood the first Autumnal storms this week with winds hitting 50MPH. Its also very warm inside, even now as the temperature is falling. Larch timber backs are the offcuts from the saw mills and are reasonably priced as scrap. we purchased a pack of timber backs, approx.40 lengths of larch timber with bark in 4.8M lengths for £100. these are not uniform and taper etc, but as i only needed 500mm lengths it was straight forward to make it work.
    14 points
  10. It's been a while since my last blog, but we've not stopped, the days are shorter and the weather skipped autumn🍂 and dived into winter with a few storms and loads of rain. Our windows are budget friendly triple glazed UPVC, and composite doors. The external EPS was sealed at the cill with EPDM airtight tape, the tape has reinforcement in it and can be moulded, it does crease but creates a water tight junction and sticks like the proverbial to the EPS. We created a cheek reveal with an additional layer of 50mm EPS and sealed the upvc frames against this, I then ran a bead of sealant against the face and edge of the EPS giving two seals. Then when clad a third seal. I used soudal air tight foam and I thinks it's LMA sealant, soudal's airtight solution. The winds gave good opportunity to test for air leaks when had several days of 35mph winds. This proved a good test with a smoke pen. The internal frame was sealed with soudal sf40 which adheres very well to the upvc and timber blocking, when cured it is like rubber. The cladding is larch boards in 2 widths 150mm for the bottom layer and 100mm for the top. We finished the top of the windows with a custom palistol coated drip The bottom of the EPS footing was finished with reclaimed slate. Inside we are having a cold roof. We needed to add 25mm pir under the truss cord to satisfy the tightened regulations in Scotland. We tapped the foil boards with foil tape, and the perimeter boards were pushed to touch the wall plate. Then used airtight foam between the PIR and internal IFC wall creating a seal. Under the PIR I used plastic membrane that I spray glued to the PIR, and this draped down the perimeter walls. The under ceiling was battened and counter battened, this created a service void for the cables and not penetrating the loft. The plastic was jointed with EPDM airtight tape on joins and walls. Cables were put inside Flexi conduit that was cut into grooves in the ICF. (All water pipes were run under the slab.) This picture shows the detail for the airtightness and the service void. MVHR ducts (7 plenums ) were run in the loft, and under 400mm of loft roll. The manifolds are also under the loft insulation. I made these airtight using the same EPDM tape. I made gaskets out of the plastic with a circle cutter and stretched it over the plenums, then air tight tape to seal everything to the plastic/ PIR. The walls also needed some IWI to meet the tighter regs, so decided to go with 25mm PIR. This also added another seal for the plastic airtight layer and walls. The poly steel ICF has these metal plates at 150mm ctrs that allow the cladding battens to be secured externally and the plasterboard internally, we used self tapping drywall screws and insulation discs to hold the PIR in place before installing the plasterboard. Picture for detail below. At this stage we've got a large airtight box. Now it's a case of installing the stud work. I lined the plant room with pre painted 12mm OSB, and the bathroom with 18mm OSB ( a Scottish building regs requirement needing the ability for future hand rails etc) Electrics are simple, a few Ethernet points and sockets and spotlights. One pendant over the dining( and if I get my way, and budget allows pool table). The only penetrations from the loft are a light, PV cables, TV aerial, and 4g antenna cables. These are in conduit and sealed both ends. All other cables run in the ceiling void or stud work. I've put a few sensors in the studwork for future Arduino projects to accompany the in slab sensors. The plant room is compact, and work in progress. The PV is up and running and to date produced just shy of 300KwH in 5 winter weeks With the first fix complete it was time to plasterboard, we got 80 boards delivered Wednesday midday, just as storm Babet hit, it was too windy to bring them in, I tried, I failed so it had to stay outside 😭, covered in plastic, tarpaulins, scaffold boards and the obligatory ratchet straps. 3 days of constant 35mph gusting 50mph gave opportunities to check for airtightness. I managed to install the flush shower tray during this downtime. Once the storm blew though we got the boards inside and cracked on, the open plan lounge, diner, kitchen was boarded first and as soon as it was complete I skimmed the ceiling, 11 boards was too big for me and my tennis elbow, that coupled with not plastering anything for several years. I split the room in two and used several layers of scrim tape to plaster up to, then remove the scrim tape and skim the 2nd part. It worked well, and it's painted and the join is seamless. The next few days we mixed it up skimming in the morning and boarding in the afternoon for the next day. Today is day 182 of the build, this is basically from the cleared site that was down to rock with the pecking already done. Currently the house is fully skimmed, most of the ceilings have been primed and painted white and we started the kitchen install today. All the bathroom is here waiting to be installed, and some appliances are here most arriving this week. This has been pretty much 7 days a week, with only around 12 to 18 days off to earn some money and pay off some labour debts. We're hoping to move in, in 2 weeks with a working bathroom and kitchen 🤞, the static has now reverted to ice box during the night🥶
    14 points
  11. Sorry for the delay since the last blog. Things have been very hectic keeping a track of everything that is going on with the build and holding a job down ! As we approach end of January and move into February there are lots of things going on simultaneously on site including battening the roof in preparation for the roofers, finishing of fitting the smartply in preparation for blowing in the insulation and fitting the windows and doors. The first window goes in on 30th January. Many of the side reveals to the windows have splays to help spread the light from the window. We are using Green Building Store Progressions windows and Green Building Store Ultra doors. The Progression windows are expensive, but the narrow sight-lines give a lovely contemporary look and very little of the frame is visible outside, so it should be as maintenance free as you can get and seems like a good investment. The Ultra doors look very similar to the Progression doors and are of a similar thermal performance but are more cost effective to purchase. From the 12th - 15th February, the Warmcell insulation is blown into the frame. I hadn't realised, but you can do this before all of the windows are fitted, as long as the boarding out is completed inside and out. By 21st February all windows and doors are fitted. A lot of time has gone into ensuring the windows are fitted properly and are as airtight as possible. In parallel, the brick plinth is built. Whilst you won't see all of this once the ground levels are built up, I am really pleased with the quality of the job. Next job is and fitting the Aquapanel in preparation for the rendering. The roofer we had lined up pulled out at the last minute, but we are able to get a local firm with a good reputation to take their place at short notice. We took a lot of trouble selecting the roof tiles and we are particularly looking forward to seeing the tiles laid. The roofers are on site beginning of March after a small delay due to rain to do the counter-battening and lay the tiles. The roof is a pretty simple shape so the roofers make quick progress. We are using plain clay smooth machine-made tiles made by Dreadnought tiles and supplied by Ashbrook Roofing. We found out about them at a self build show we attended and have had great support from both Dreadnought and Ashbrook. We are using two colours - 70% staffordshire blue and 30% blue brindle mixed randomly. Before you know it, the roof is in place. Big Day on 8th March as it is our first Air Test. We'd put 0.3 air changes per hour (ach) @ 50pa into phpp so we were hoping for something similar or better. Results were: 0.08 ach @ 50 pa 0.11 m3/hr/m2 @50 pa Absolutely delighted with the results. Given building regs are 10 m3/hr/m2 @50 pa and Passivhaus standard is 0.6 ach @ 50 pa, this is over 90 times better than building regs and over 7 times better than Passivhaus standards and a great testament to the attention to detail shown by the build team. Flashings between the wood cladding and the render are fitted. These were made by a Herefordshire based fabricator. Work continues fitting the cladding. We are using Douglas Fir, supplied by Ransford which is literally 5 minutes down the road. Once the roof has been laid and the weather allows, the rendering starts. We are using the Weber system, with a base coat applied first followed by a thin silicon based top coat which will be sprayed on. The roof and detailing around the dormer window are completed Once the cladding is complete and before the scaffolding comes down, we need to treat the cladding. The gable ends need a fireproof coating due the proximity of other houses, so it's one coat of primer, two of Envirograf and two of Osmo. The front and back of the house get one coat primer and two of Osmo. It's one of those jobs that costs more and takes longer than expected. We hadn't planned on having to to apply so many coats of product and in my naiveity I thought it would be a layer or two of fireproof coating on each gable. The wood looks a little orange at the moment but that is typical when new and it does weather down nicely which is what I plan to allow the wood to do. Hopefully to osmo will help even out the weathering but I have no plans to keep on applying it. The guttering is attached whilst the scaffolding is still up (Lindab galvanised) The scaffolding on the house comes down and goes up on the garage to allow the roof to be completed on the garage. The second coat of render is sprayed on and the shell of the house is now complete.
    14 points
  12. And so almost another month has gone by but progress is still being made on the build and, just as importantly, hubby and I got away for a week's holiday in northern France just as the warm weather hit. After our abject failure at R&R over Christmas, it was wonderful to have a really relaxing break without illness or stress and come back refreshed for the final push on the build, which is just as well as there's a busy time to be had over the coming weeks. In the last blog entry, I detailed some of the painting and kitchen fitting that had been going on and there's been more of this recently. I've been getting the colour coats onto the walls upstairs but haven't managed to complete a room yet apart from the kitchen, but I'm generally pleased with the neutral colour choice. I say generally, though, because in the lounge, the different light in there makes the wall colour bring out the warm tones of the internal window frame finish which makes them look a slightly odd peach colour. It's not awful and I'm not going to change it now, but if we ever redecorate (hah!) it will be something I check before committing. For the more vertiginously challenged amongst you, you may wish to look away now, as here's a view from the top of my internal scaffold tower when I was putting the colour coat on up to the vaulted ceiling above the gable window in the guest bedroom. And here are the colour choices. The purple will be on one wall only. It looks a bit garish at the moment but once the room has its furniture and soft furnishings in, it should tone well and add a bit of life to the room. Cutting in and painting up to the high vault was a bit of a challenge, but I got there. I really didn't want to get any colour spatter onto the white ceiling so opted to use paint pads rather than a roller and I was pleased with the outcome. They give a good finish over the sprayed mist coat and are far less physically demanding than a roller. I was painting upstairs as the flooring guys were in downstairs putting in the karndean (same choice as upstairs) and it kept me productive but out of the way. Given all the work that went into making the dropped section of the ceiling in the lounge area, I wanted the floor to echo this but not in too obvious a fashion and so the team took a laser reference from the inner square of the lounge feature and reversed the direction of the planks, using a feature strip to create a subtle border. First, though, they had to screed the floor with a latex self levelling compound. In preparation for this, I needed to turn off the UFH a few days before they arrived to make sure the screed didn't go off too quickly due to the heat of the slab. I turned it off on a Friday afternoon and they started work on the following Tuesday and it was just about perfect. Once the screed was down, the floor was scraped to make sure it was completely level and then primed. After the priming, the planks were put down. Here is the snug - I went in the weekend before the flooring guys arrived to get the mist coats and ceiling painted as it's far easier to do when you only have to mask the windows and not worry about any other area. Here's the long view of the kitchen/lounge area: And here's a close up of the feature border underneath the ceiling feature: Moving on from the flooring and painting, my joiner, Harry has been busy at work on the kitchen. In particular, he was working on the large walnut work surface for the island. I decided months ago that I wanted solid walnut for the island but then, as I'm sure happens to many, I had a last minute dither and started looking at other materials instead. In the end, I decided that granite or other stones really didn't give the colour tones that I wanted and laminates weren't wide enough. I sourced the walnut from Worktop Express as they were very competitively priced for what I wanted, and delivery was quick. I looked at using their online template service, but it was just too tricky to get the different profiles right and, in the end, decided to get Harry to make up the island top on site. It was absolutely the right choice as he's done a lovely job on it. Here's a photo of the finished top with the induction hob surface mounted into it. A word on the hob. You can recess the work surface so that the hob is flush, but I preferred it to be surface mounted, sitting proud of the walnut, purely from a cleaning point of view and so I don't have to spend ages digging out crumbs and bits of food debris from around a flush recess. These are the two worktops as they arrived from the supplier, waiting to be joined together. Harry routed along their length, used a biscuit join and then glued and clamped. The worktops being clamped. They look and, indeed, are lighter in shade than the first photo as they come treated with one coat of Danish oil. Harry put a further two coats on once he had sanded the finished surface. The area where there appears to be a base unit missing and where the surface projects beyond is intended as a breakfast bar area. There will be a supporting leg on the near right hand corner. Because the kitchen and island are large, I didn't want anything to be too matchy-matchy and wanted to break up any monotonous areas. Also, I didn't fancy walnut as the worksurface leading off the sink as I think that's asking for trouble in the long run. So, I went hunting through laminate choices. Way back when I was first considering the kitchen, I had been thinking about using large format tiles with a metallic type finish as the splashback, but it was proving to be a gruelling and not very fruitful search. When I eventually revisited this part of the kitchen a couple of months ago, I came across some laminates with exactly that type of finish, nice long runs (I need a 4m run for the back work surface) and with matching splashbacks. I also wanted to line the recessed area under the island with the same material to make it more durable and give a contrast in materials and textures. I sourced the laminates from a firm called Rearo and dealt with their Newport branch. They were lovely to deal with and very helpful. Here's the splashback applied to the breakfast bar recess. Harry beefed it up and packed it out with some ply and then put the laminate edging onto the ends to give a substantial look. Whilst we were away on holiday, my splendid general builder and neighbour, Drew, got on with putting the rainwater goods up. I'd ordered in soffits and fascias from Fascia.com as they had the width I needed in anthracite grey to match the slates and windows, as well as vented soffits, which save a lot of bother and look much neater. The guttering is all deepflow and was mounted onto black fascia board. I looked at other colours of guttering, but none of them were quite right and black guttering is so ubiquitous that the eye kind of slides past it. Having it mounted on the fascia board also reduces the visual impact of the brackets that can look a bit clunky. Whilst he was up there, Drew also mounted our swift boxes and bat boxes. We were required as part of our bat licence conditions to put a bat box somewhere on site, but this is something that we had planned to do all along. Also, there has been a dramatic loss of habitat for swifts that migrate to the UK to breed in the summer and we wanted to make provision for these too, in the hope that we're lucky enough to attract them to our site. These fabulous birds migrate 6,000 miles to reach their summer breeding grounds and are the fastest birds in level flight. Once they have fledged, the only time they ever land again is to sleep and recover from their migration flight and to feed their young. They are the most fabulous birds and I would urge anyone to make provision for them wherever possible. If anyone wants details of where to buy some brilliant swift boxes, PM me and I'll send you the details. Here are the boxes, all sited on the western corner of the north facing wall. Finally, today marked a milestone in the house progress - the scaffolding is coming down. Our foul and surface water drainage works start on Wednesday and the site needs to be clear to allow access for that. Any remaining work at height can be done from ladders apart from the cladding, but I will hire a separate mobile tower of some sort for that work once I've had a chance to identify what will be most suitable. The stone cladding arrived a couple of weeks ago, ready to go up once the drainage work is done, more details of which will follow in the next post. Here's the south face gradually being revealed. The crates to the right of the picture are the stone cladding. Here's the east face slowly coming into view. And another view of the same. Work planned for this week is more plastering, more painting (if I get the chance as I'm the plasterer's labourer this week), groundworks and starting to move some young trees to the site that we've been nursing in pots at home for 12 months. Next week, the en-suite bathroom will be started, the kitchen finished and the utility room kitted out. Plenty to do yet. TTFN.
    14 points
  13. Apart from the “picture from the mound” timelapse blog entry, there’s not been much of an update since mid September 2022. So, get your preferred hot drink (maybe a SteamyTea), and settle back for the next instalment. Where were we? SWMBO was still in recovery from her foot infection - you remember? The one that might have killed her? The second floor ICF had been installed, and the concrete poured. I’m still going to spare you any pictures of the foot, but here is a concrete pump truck instead. So, next on the list - a roof please. But before that, the final steel beams had to be installed [FX - thumbs twiddling in the foreground and whistling can be heard as we wait for the steelworker once again], but it wasn’t too long a wait, and by mid October 2022 we had the beams installed. In late October and early November I set to work with the ground worker to do some backfilling, and of course on the days I chose to have the digger onsite, Cornwall delivered some of its traditional autumnal weather so any attempt to properly compact anything was nigh on futile. In the meantime, more joists, endless sheets of T&G OSB, vapour barrier, 160mm deep sheets of PIR insulation, and some of the biggest screws are readied for ordering. The joists arrived in and in early December I had my supervisor and client (SWMBO) back on site 🙂, and she has graduated to being a mountain goat. She now refers to the site as her "happy place", even though we have a strong suspicion that the infection was started by a visit to a local beach. By mid April, with help from some now local family members, we’d installed the roof joists, and in mid May we were ready to start boardin’, vapour barrierin’, and insulatin’. The GRP was installed in mid July 2022 (by others). I’d also been readying the Great West Wall (GWW) to have the triple glazed sliding doors and windows installed (by others), and this took place in mid August, just in time for my significant birthday. There were some fitting errors, but I have to take my hat off to the installation company, they have been back to rectify their work, and have supported me with making the suppliers change some of the sliding door fittings as they were just not correct despite their protestations. In October, we had the mains electric and meter moved from their temporary location to inside the house. Over the ensuing autumn and winter months, we’ve been installing some of the final internal partition walls, running water pipes, installing more insulation around the GWW windows, and recently started on the ventilation ducting following some core drilling being undertaken (Tip: always ask for a hole to be drilled that is about 10mm bigger than you need - expanding foam is your friend. I donate my scar tissue to you all 😂) In December, I got made redundant. No worries, this may actually be a blessing in disguise. Next up on the list: Finish ventilation system Finish insulating the GWW Finish backfilling Electrics Floors Walls ASHP and HWC Kitchen Bathrooms The remaining plumbing Outer wall coverings But, in the meantime, we have the small matter of our daughter’s wedding. DOES SHE NOT KNOW WE’RE TRYING TO BUILD A HOUSE!? (Time to end: 2 years 🙂 )
    13 points
  14. In my topic Modelling the "Chunk" Heating of a Passive Slab, I discussed how I used a heat flow model to predict how my MBC WarmSlab heated by UFH + Willis heater would perform. What I wanted to do in this post is to provide a “6 years on” retrospective of how the house and slab have performed as built based on actual data that I’ve logged during this period, and to provide some general conclusions. In this, I assumed 15 mm UFH pipework, but we actually used 16mm PEX-Al-PEX pipework with an internal diameter of ~13mm. At a nominal flow rate of 1 m/s, say, my three pipe loops in parallel have an aggregate flow rate of 0.4l/s or 1.4 m³/hr. At this flow, a 3kW (2.88 kW measured) heater will raise this stream temperature by 1.7 °C. However, when I commissioned the system, I found setting the Gunfoss manifold pump at a high setting (roughly equivalent to this flow rate) gave a very noticeable circulation noise in the adjacent toilet, so I tried the pump on its lower settings and found that the flow was almost inaudible on lowest one with in to return delta at the manifold still only about 5°C, so I stayed with this. The actual as measured delta for two loops of 4.9°C and the third slightly shorter loop of 4.1°C (close enough not to bother balancing the flows out). This corresponds to an actual flow nearer to 0.4 m/s or 0.56 m³/hr by volume. When scaled to adjust for this lower flow rate, the actual measured temperature profiles are pretty close to those modelled. I measured the actual Willis heater’s heat input as 2.88kW. In analysing the actual slab heating rates, I found that this raises the overall slab temperature by some 0.45 °C / hour after the initial start up. Plugging typical specific heat and density figures for the concrete, this is empirically equivalent to heating 25 tonne of concrete (Cmass = Ewillis/ΔT/SIconcrete = 2.88*3600/0.45/0.9 kg), or 10.6 m³ concrete by volume (23000/2400 m³). In the case where the Willis provides heating for the full 7 hour off-peak window (just over 20 kWh), at the end of this heating period the flow input to the slab is +9 °C above the initial slab temperature and the flow return is +4.4 °C. The temperature of the concrete immediately in contact with the pipe will follow this same gradient, with this temperature excess decaying radially away from the pipe centres. By the end of this heating window at the slab surface, there is barely a noticeable difference in the measured temperature of the floor above the out and return UFH pipe runs (perhaps 1°C). These temperatures and gradients are also comfortably within the reinforced concrete’s design parameters. As soon as the Willis is turned off, the internal temperature gradients start to flatten and any unevenness redistributed across the slab; the rebar reinforcing has a thermal conductivity 60 × that of concrete and this accelerates this, so that within an hour or so of the heating turning off, the overall slab is left about 3.1 °C warmer than at the heating start time (actually about 10% less than this, as the slab has already started to dump heat into airspace). In my original modelling topic, I mentioned that my passive slab has ~73m² of concrete 0.1m thick (~ 17½ tonne of concrete with another ~10 tonne of perimeter beams, cross bracing and steel rebar, with the UFH runs laid in 3 × ~100m long standard “doubled back” spirals (common to most UFH designs) on ~150mm centres and roughly 50 mm below the slab surface. (Actually only 75% of the slab is covered by the UFH runs, because of the need to avoid proximity to ring beams, partition walls, areas under fitted cupboard areas, etc..) Nonetheless, this empirical 25 tonne figure is still consistent with the total volumetric 27½ total estimate if we assume that the rebar is effective at spreading heat through the wider slab over this multiple hour timescale. In conclusion, based on this modelling and observation: First recall our context: our house is near passive in class with a lot of internal specific heat capacity. We only need about 1kW overall heater input in the coldest winter months to maintain overall heat balance, e.g. either by a resistive heater such as a Willis or an ASHP. IMO, there are two extreme approaches to house heating: (i) “agile” tracking of occupancy patterns so the living spaces are only heated when and where occupied; (ii) a 24×7 constant comfortable temperature everywhere within the living space. Our warm slab design is very much optimised for this second case, and our slab supplier did a good job in designing an UFH layout to match the slab characteristics to this The slab is covered in “doubled back” spirals with each loop using up a full 100m roll spaced on roughly 150 - 200 centres (and avoiding partition walls and cupboarded areas) so that each heats roughly 15 - 20 m² slab. In our case three loops were enough, and there was no advantage in trying to squeeze in a fourth. Our 3 loops will happily take up 3 kW heat input. Circulation speeds between ⅓ - 1 m/s seem to work well, with the only real difference being the slower the flow speed, the higher the delta between in and return temperatures. The slab does just as its trade name suggests: it can be treated as a huge low temperature thermal store, but because of its extremely high thermal inertia, one that is not rapidly responsive to heat input. In our case, a heat input of 3 kW input will only raise the slab temperature by 1°C over a couple of hours, and radiating 1kW will drop the slab by only 1°C over roughly six hours. In a true passive class house, one key to heating economy is the high level of thermal insulation coupled with a substantial internal heat capacity. Trying to drive such a house in an agile manner is a fruitless exercise, so forget the traditional having room-specific thermostat control; forget having traditional time-of-day heat profiles. It is far easier to treat all ground-floor rooms as a single thermal zone to be kept at a roughly constant temperature. In my view, using a resistive heating approach (such as a Wills heater) as well as an ASHP can both work well. In this second case something like the 5kW Panasonic Aquarea ASHP would be a good fit as it uses a modulated inverter compressor so it can heat the slab directly without needing a buffer tank. The choice is a trade-off between running costs vs. installation costs. In our case, switching from a Willis to this type of ASHP would save me about £600 p.a, in electricity cost, so I would really need to do the install for a net £ 3-4K to make the investment case feasible. However I would like to defer this discussion to a separate thread because there are other issues that such an approach would need to address.
    13 points
  15. We moved into our new build mid-December 2017 in time to host an extended family Christmas. We are now over 4 years into living in our new home. We have lots of accumulated experience and made a few small tweaks. However, we are delighted about how the house has turned out, and we love living here. There were no material cock-ups, or regrets on design decisions, so we have probably fared a lot better than most new purchasers or self-builders. Maybe a general experiences post should be on the to do list, but what I want to focus on here, and a couple of follow-ups, is a general topic that others on the forum have asked about over the years: that is how our central heating system works in practice, and how I control it. The system as currently implemented is still largely the same as when I first commissioned it, that is a now 5 year-old RPi-based custom control system directly controlling the CH and DHW subsystems. This is a pretty minimal headless system running Node-RED, MySQL and MQTT client for control. The three material changes that I've made since moving in are: I have followed my son and son-in-law in using Home Assistant (HA) for general Home Automation. My server (an RPi4 in an Argon One case) uses an attached Zigbee gateway, and I have a lot of Zigbee devices around the house: switches, relays, light sensors, etc. and I do the typical home automation stuff with these. There are loads of YouTube videos and web articles covering how to implement HA, so please refer to these if you want to learn more. My HA installation includes an MQTT service for use as a connection hub for these IoT devices. I also have another RPi4 acting as an Internet-connected portal / Wireguard gateway/ file-server for caching video snippets from my PoE security cameras. Note that none of my IoT devices directly access the internet, and the only in-bound access into my LAN is via Wireguard tunnelled VPN, and my HTTPS-only blog. All other ports are blocked at the router. Before moving in, we assumed a target internal temperature of 20°C. In practice, we have found this too cold for our (fairly inactive OAP) preference and so we have settled on a minimum control threshold of 22.3°C. As you will see below, because we largely heat during the E7 off-peak window the actual room temperatures have a ~1°C cycle over the day, so the average temperature is about 22.8°C. This hike of 2.8°C increases the number of net heating days since my design heating calcs and the increased delta against external temperatures in turn increases our forecast heating requirement by roughly 18% over our initial 2017 heating estimate. Because our UFH is only in the ground-floor slab, we found that our upper floors were typically 1-2°C cooler than the ground floor in the winter months. We also need more than the 7 off-peak hours of heating in the coldest months, so I have added an electric oil-filled radiator on our 1st-floor landing; HA controls this through a Zigbee smart plug that also reports back on actual energy drawn during the on-time. HA uses MQTT to pass the actual daily energy draw back to the CH control system. This radiator provides enough upper-floor top-up heat, and does so using cheap rate electricity. Note that all servers are directly connected to my Ethernet switch, and the CH/DHW system has all of its critical sensors and output controls directly attached. It can continue to control the CH and DHW subsystems even if the HA system or Internet is offline. There is also no direct user interface to the system, with all logging data is exported to MQTT, and key CH/CHW set-points and configuration are imported likewise. This integration with MQTT, enables user interfacing to be done through the HA Lovelace interface. If there is sufficient interest I can do follow-up posts on some more of the "Boffins Corner" type details on these implementations, or if this turns out to be more of a discussion then it might be better to move this stuff to its own BC topic. However, for the rest of this post I want to focus on the algorithmic and control aspects of the heating system. In terms of inputs and outputs to the control system, these are: There are ~20 DS18B20 1-Wire attached digital thermometers used to instrument pretty much all aspects of the CH / DHW systems. Few are actively used in the control algorithms but were rather added for initial commission, design verification and health checking. Some are also used to monitor and to trip alarms; for example, there is a temperature sensor on the out and return feed for each UFH pipe loop. These were used to do the initial zone balancing. However, the average of the return feeds is used as a good estimate of the aggregate slab temperature. One of the temperature sensors is also embedded in the central hall stud wall to act as a measure of average internal house temperature. There are two flow sensors on the cold feed to my 2 SunAmp DHW storage units to monitor DHW use and to help automate during-day DHW boost. There are 4 240V/20A SSRs used to switch the power to my (2-off) SunAmps, my (1-off) Willis heater, and my (1-off) circulation pump. These and the rest of my 240V household system were wired up and Part P certified by my electrician. These SSRs are switched by a 5V 50mA digital input, and so can be driven from an RPi or similar. (I used a I²C attached MCP23008A multi-port driver to do this, as this can drive 5V 50mA digital inputs, but its input I²C side is compatible with RPi GPIO specs.) There are many ways to "skin this cat", but whichever you choose for your control implementation your system will need to control some 240V/12A devices and take some input temperature sensors. My preference was to directly attach all such critical sensors and outputs. My heating algorithm calculates a daily heating budget in kWh (each midnight) as a simple linear function of the delta between average local forecast temperature for the next 24 hrs and the average hall temperature for the previous 24 hrs. This budget is then adjusted by the following to give an overall daily target which is converted in minutes of Willis on time. heat input from the heater mentioned above. a simple linear function of the delta average hall temperature and the target set-point (currently 22.3°C). This is a feedback term to compensate for systematic over or under heating. I initially calculated the 4 coefficients of the two functions using my design heating calcs and an estimate of the thermal capacity of the interior house fabric within the warm space. After collecting the first year's actual day, I then did a regression fit based on logged actual data to replace the design estimates by empirical values. This was about a 10% adjustment, but to be quite honest the initial values gave quite stable control because of the feedback compensation. The control system runs in one of three modes: No heating is required. Up to 420 mins of heating is required. The start time is set so that heating ends at 7 AM, and the slab is continuously heated during this window. More than 420 mins of heating is required. 420 mins of heating is carried out in the off-peak window. On each hour from 8 AM to 10 PM, if the hall temperature is below the set-point (22.3°C), then an N-minute heating boost is applied, where N is calculated by dividing the surplus heating into the 1-hour heating slots remaining. Here are two history outputs from HA showing some of the logged results. The LH graph is the slab temperature over the last 7 days. The general saw-tooth is identical from my 3-D heat flow modelling discussed in my earlier topic, Modelling the "Chunk" Heating of a Passive Slab. The 7 hr off-peak heating raises overall slab temperature by ~4-5 °C; well within UFH design tolerances, and no need for any HW buffer tank: the slab is the buffer. The RH graph is the hall temperature. Note the days where on-hour boosts were needed. (Also note that the CH system only updates the MQTT temperature data half-hourly, hence the stepped curves.) So the approach is fairly simple, and the system works robustly. ? And here is a screenshot of my HA summary interface, which gives Jan the ability to control everything she needs from her mobile phone or tablet.
    13 points
  16. Since the basement was finished at the end of June things seem to have been dragging on for ages but we are finally out of the ground and ready for the timber frame. It has taken 13 weeks and we had delays with materials that held things up but when I look back at the photos from the basement being finished to where we are now it is amazing how much has been done and we’re very excited about the timber frame going up next week. When the groundworkers came back post-basement they started by insulating the basement walls externally with 200mm of EPS 100 and then backfilling with clean crushed as per the structural engineers specifications. Then they started digging the foundations for the ‘arms’ of the building as I call them and you’ll see why from some later photos as the main building looks like the body with 2 x arms coming off it. These are a garden room (that links to the kitchen/diner) and the utility room and garage. These are designed as insulated slabs with 300mm EPS underneath which you can see in the photos. Here we see I had to put some Perinsul blocks in, thank you to @ToughButterCup for getting them to me. While that was happening the brickie was also on-site building the internal walls for the basement. We have a 3m ceiling height in the basement so we had to get scaffolding in to build them safely which was another expense I hadn’t planned for (beginners naivety) but something that had to be done. It was around this time that I purchased a DJI Mini-2 drone. It is brilliant and has given us a whole new perspective on the build. Here are a few videos from before the slab pours (please excuse the auto-added cheesy music that DJI added). And some photos of the slab pours. I also put in some VCL between the basement and ground floor as a Tony tray. Once the slabs were poured we move on to the block and beam flooring. This caused the biggest issue with getting materials as the company the groundworkers were using moved their lead times from 15 days to 6 - 8 weeks which would’ve put us stupidly behind schedule. So I sourced some beams from a local builders merchant and paid the beamers to cut them to size on site rather than waiting for the correct sizes to be fabricated and delivered. It was pretty stressful to say the least. But what made it worse is that I decided a while ago to move from precast hollow core slabs to block and beam but no one along the way told me that the beams couldn’t take the load of the walls above like the hollow core could and, by chance, during my conversations with the block and beam company designing it I found out that I had to put supporting steels on top of the basement walls to take those load bearing walls from above ground. Back to the structural engineer to get those designed and then fabricated and installed. And then the beamers tell us that they won’t do the work without a complete fall arrest system across the entire basement 600mm down from the top of the basement walls. Back to the scaffolders to come and put that up at yet another expense (although the safety of the contractors is important to us so I didn’t grumble too much!) and we were finally ready for the block and beam to be installed. So what turned out to be the decision to save a few £k by moving to block and beam has in the end cost me a lot more due to the extra work involved. Oh well, you live and you learn. Anyway, the day came for the beamers to install it and they were a smash and grab outfit but that is, apparently, what all block and beamers are like. They just turn up and smash it out and leave without any due care and attention. To say they were miffed that they couldn’t do that on our build due to the steels on the basement wall is an understatement and comments like ‘if I’d known there were steels I wouldn’t have taken the job’ and ‘I’m losing money of this job’ really filled me with confidence. And if I ever do this again I will probably do the block and beam myself as, although hard work, it’s not complicated and I would’ve done a much better job. Anyway, it was done and they left and we could get on with laying the coursing blocks for the sole plates to sit on. This is where I insisted on precision and I spent a lot of time out there with the brickie assisting with setting out to make sure everything was spot on for the sole plates and checking that the levels throughout were within 5mm - 10mm across the building. It was time consuming but I think the accuracy will pay off in the end. While that was happening and with the timber frame imminent the scaffolders came and put up the required 2 lifts around the entire building and by 5pm the Friday before the frame was due it was all finished and we were ready……or so we thought. The timber frame ended up being delayed by 4 days due to the chippies testing positive for Covid-19 (the first time we have been directly impacted (not including the material shortage etc) by Covid) and during that 4 day delay the contract manager attended site and noticed that the garage (which is 120mm below the main house) had it’s coursing blocks below the main house. After a quick email exchange it was pointed out to me that I’d misread the plans and that those blocks, and the sole plates, need to be at the same level throughout so I needed to raise the coursing blocks by 120mm in the garage by the end of the following day. The groundworkers have moved on and I couldn’t get anyone to do it so I knocked up some pug, borrowed a disc cutter, bought myself a trowel and got laying. I’ve never laid blocks before but I did spend a lot of time watching and helping the brickie so I had a good idea as to what to do. I started after work on Wednesday (sole plates due to be fitted Friday) and finished half of it well after dark and then got up early the next day to finish the rest off. And it worked! Level and straight (ish) and still standing the next day. Phew! And this is where we’re at right now. Timber frame ground floor wall panels are due next Tuesday so we should really start to see things happening rapidly now and within 4 weeks our superstructure will be up. But that will be the subject of my next blog. Here’s a time-lapse video of this part of the build. I had to speed up the footage x10 and each day is about 4s long so things happen at quite a speed but it’s amazing to look back and see what has been done these last 13 weeks. Thanks again for reading and I hope you’re enjoying this journey as much as we are. Until next time…
    13 points
  17. I've finally got around to starting this blog. I'm hoping that it'll be easily updated and I'll provide lots of good pictures and info...we'll see how that goes. I'm at the point now where we have just taken our first big delivery, which is our insulated foundation system from Kore, this morning. So albeit, this process of building a house has been ongoing for some time, it has just become real that we are at the beginning of the build phase, which is very exciting. Some light background info - I've always wanted to build a house for the last 5-10 years, but it was a distant dream and wasn't quite sure how feasible it would be. I grew up in a rural house, my parents bought in 1983, modernised and updated over the years. It was a great childhood and spent many hours in the fields and in our garden, even just cutting the grass was fun (1 acre and a ride on mower). We sold that when I was 21 and ever since I've wanted to return to that life. I have two young kids of my own now and hence the want to return to the countryside to give them what I had was strong. I was always keen on building, swmbo, wasn't as such. So we searched and searched, but mostly the houses we could find that suited our needs were out of league (price!) and even if they were to be in our league there were things we would change or in the end it would be expensive to run. And hence that search helped my other half make the realisation that self build was our only option. My dad died in 2017 after a long illness with Dementia, a relief for him and for everyone else involved. We were very close and I took care of him day in and out, until he was in care. He was an engineer and had owned his own business since I was a child, albeit he lived a pretty simple life and was happy being at home in the garden he made and house he had renovated. Riding around on the ride on mower enjoying a quiet life...and now I guess that's exactly where I want to be. His passing left us with a little inheritance which has allowed this dream of self building to become a reality, I'm very thankful for this. I know it is something he would have been very excited to be part of and watch us do. So after messing around since 2017 and not being able to negotiate a plot or find one that was suitable (there's a lengthy thread on this!) I'd finally identified 4 acres in July 2019. It took a bit of time ( I had to confirm services and remove an Agricultural tie) but completed purchase in Jan 2020. I'll not cover the planning process in detail, but the plot had legacy planning permission which was 24 years old, but at that time the development had commenced and hence it was a straightforward change and submission of our designs. Building warrant was granted a week ago, with very little hassle really. I joined Buildhub in September 2019 or thereabouts. It's been a wealth of information that has helped me shape the design of the house and provided no end of guidance which I am very thankful for. It has allowed me to validate my opinions and approaches and learn from others to ensure i am following the right path. I started out prior to buildhub wanting a SIPS house, in fact googling that may have made me find my way here. Quickly I decided I wanted an insulated foundation too, I went around in circles a little bit with both of these decisions and reading others opinions on here. I even thought at one point they would both be too expensive for me , however I sit here writing this first post having taken delivery of my insulated foundation today and my SIPS kit is on order and due sometime in February. I don't actually need the insulated foundation till mid-late January but made a decision to get it in the country before Brexit issues occur and tariffs are possibly applied in January (rumoured at 6%). I'm very glad I made that decision as today our new strain of COVID has caused everyone to close the doors to us here in the UK, another couple of days and god knows when I would have gotten it. There is lots of other decisions and stuff has gone on in the background with planning and mortgages and budgets to get here, but that is mostly done and hence I feel this is the end of the beginning and now we can enter the start of the middle.... I'm very pleased and excited for the road ahead. I like pictures in blogs....here's a few of the Insulated foundation delivery today. Stored at a friends farm for the time being. It's being stored outside, has a few tractor tyres on it now to stop it blowing away and the main pallets are all strapped down. That's me standing on top.......
    13 points
  18. Overall it went swimmingly well, couple of minor issues but soon resolved and need to return to sort out a handle issue but John Knight Glass were, IMO really great and for final sign off we wait for contact over next couple weeks when someone else comes to site to check everything with us so enough time to raise any snagging issues hopefully. Despite some panic on the canal bridge when the trailer was about 8 inches off the floor, everyone held their breath when the glass got over successfully. The other option being discussed was asking CRT who were dredging at the time to transport them to us. Although that didn't happen, I'd of been quite pleased to see that ? The windows we picked were the aluclad UPVV studio KF320 windows and KS430 sliding door and we are more than happy with them. A couple from work in progress. It was nice as the sun was setting getting some pictures of the house today, finally with the windows.
    13 points
  19. First all my apologies as this blog entry is about about a year late given that we moved in August 2019, but better late than never as they say ! Moving on from finishing the shell, we moved onto completing the inside. We knew from previous experience this would be the most intensive part of the build and had tried to make as many decisions up front as we could regarding bathrooms, kitchens and flooring, nevertheless there were still a lot of decisions to make. Everything went broadly to plan with the electricians, plumber, carpenters and decorator all working well round each other and coordinated by the builder who had put up the shell. There was an awful lot of work ordering everything and making sure that material was on-site at the right time. There was the occasionally thing that didn't go to plan, most notably the kitchen where i had the bad luck to have my kitchen delivered with many missing and damaged components and a supplier who took 8 weeks to sort everything out. The trades were proactive and happy to suggest how we might achieve what we were looking for which was a great help, but by the end of the project we were both fit to drop. Self build is a very rewarding but exhausting business. Here are some pictures of the finished house. There is still a little bit of landscaping work, the fencing and some furniture to sort out and I guess at some stage we will sort out some blinds to replace the high-tech cardboard that is doing the job at the moment. Following the build, we sorted out the VAT refund - 500+ invoices and a £32,000 refund for VAT. I ordered just about everything and given the number of invoices I got someone to prepare the submission to HMRC this for me which was money well spent. The electrical certificate, certificate for the unvented cylinder, building certificate and warranty were sorted out and finally the last submission for the CIL exception was made. The Dog seems to like her new home ! Still a bit of work to do in the garden View from the study window
    13 points
  20. The kitchen has a 10.5 metre steel ridge which protrudes into the vaulted ceiling by 50cm. I also attached the ventilation 75mm pipework along the side of the steel to supply the living room at the opposite end. So a curved ceiling to run underneath the inside of the ridge. A simple explanation is imagining a skateboard halfpipe upside down. I built a frame out of ply with cutouts for batten to run the entire length of the ceiling. I then fitted a layer of 6mm red faced ply to create a curve. Then the final layer of 4mm birch plywood, glue and pinned and treated with Osmo oil. Well, it took a while. I know my building is not 100% square as one of the long kitchen walls was leaning out when we fitted the original rafters but overall the sheets all butted up square with only one sheet needing a little fillet added. I started in the middle of the room to allow any discrepancies to dealt with at either end. Then it was back to more plaster boarding and a novice bee keeper. More to follow.
    13 points
  21. One final push today saw all the furniture and curtains put in place- a big group effort with much input from the in-laws. I'm very fortunate to have a MiL who is an ace seamstress and who has a bit of a thing about Harris Tweed. To say I'm chuffed is a bit of an understatement. It's been over four years since the concept of this project first appeared, and three years since work began in earnest. Today we finally saw the culmination of all that effort as the building site was transformed into a home. It's exactly what I imagined: cosy, welcoming, stylish. We'll be listing it on the booking websites tomorrow (most likely a combination of AirBnB and Booking.com) so that will give me the impetus needed to tackle the lengthy snagging list and major outstanding jobs, most of which are on the outside. Some of the cladding details (corners and window reveals) aren't finished yet, the soffets need to be completed, and the biggest job of all is the decking. There's also the creature comforts of WiFi and TV to sort out. I know people come to Skye to get away from it all, but I bet the first thing they will ask for is a WiFi password Once again, huge thanks to everyone in the BuildHub community who has held my hand throughout this whole project. It's a lot smaller than many other builds, but it's been exceptionally hands on with me personally tackling almost every trade, from drafting the plans to building the kit; I even got an excuse to do some digger driving a couple of weeks ago.
    13 points
  22. Woke up this morning in our new home! Now sat on the sofa watching tv in my new home, waiting for a full day of rugby TV to start so I can sit and sip cold beers in my new home! Can you tell I’m pleased?! Facts and Figures 1 year, 1 month, 14 days (Breaking Ground to Moving in) 4 Double Bedrooms 3 Ensuite 1 Family Bathroom 1 WC Open plan lounge kitchen diner Utility Room Double Garage Workshop Land: £120k Build Cost: £200k Size: 300m2 Cost per m2: £666/m2 (This figure is slightly off as a large part of my ground floor is garage / workshop space so can’t really be counted as fully costed m2. However I’ve also got a £30k retaining wall in the ground floor section that wouldn’t usually form part of the cost per m2. Either way I think I can happily say I’ve built for approximately £800/m2 which I’m very pleased with) Photos below of all the finished areas. Garage and outside space an ongoing project!
    13 points
  23. Around 11 months ago, we started from a stripped site, the treatment plant was in and running the cabins / static so drainage just required connecting up. we had to wait for the warrant to be amended (change to the certificate of deign) this held us back ma month or so until the BCO just said "get on with it, we can sort that later"- top guy!! If we had waited for the amended certificate of design we would still be building, it took him 5 months to get it to us. I've documented most of the build in blogs on here, partly to have a refence to remember the process, partly as pay back to Buildhub for the inspiration and pointers in the planning / design stage. I'm so glad I spent hours looking at and reading others blogs that we made the switch to ICF. I'm convinced there is no way I would have achieved the efficiency I have for the money spent. Budget was always tight, so some decisions have been made due to Hobson's choice, leading to triple glazed UPVC windows and composite doors. The front door, south facing GRP Composite with low threshold and a slim glass panel leaks with 40mph winds, this leaks through the gazing cassette, and the low threshold. as I know we wont use this door much, we went for a slam lock, another mistake, it blows a gale through. To be fair the company are re making, I'm just not sure if there re-making the panel or the full door, I did ask, if they were remaking the full door to change to standard handle and lock, so it can be adjusted to minimise the drafts. we will see what happens, a full door replacement will mean taking off the reveals in side so a complete PITA, but worth it for no drafts. We had the airtightness test carried out, and they used the front door for the blower door to mitigate any issues with that door. I had put caps in the MVHR. so he just cracked on, the back door is not perfect again due to the low threshold. He didn't seal the blower door to the frame, not sure what the procedure is but seemed a little frustrating. We achieved 0.88 Air permeability, which I'm very happy with, budget wise we didn't spend hundreds on airtightness tape, just designed good solutions, and the doors leak a bit . Our As built EPC came back at A103 , with a possibility of A128.. the report say A105 if we install Thermal Solar EST saving of £40 pa , and A128 with a wind turbine EST saving of £1100 pa, so pretty much the best we could hit. To finish we need to sort out some paths outside, ramp, and the rain water pond, but other than the second bedroom need decorating the house is done. Next week we will hopefully get building control around to see what he 'needs' to get a completion cert. I'm hoping for some flexibility on the ramp and pond, . We need the VAT refund to pay for this stuff. We are working our way through the invoices, but we built for less the 90K and we still need the VAT refund. I've enjoyed it all, and we both agree we have a home. Good luck to all of you with your current builds.
    12 points
  24. It’s been over a year since we got our completion certification and we’re still mopping up tasks in the garden and generally cleaning up. It occurred to us that some aspects of the discovery process of the build may be off use to others on BuildHub. It’s too hot in here: Thermal modelling limitations. Our thermal modelling done as part of the design stage SAP suggested we had minimal thermal gain problems. However we suspected that thermal gain from our east facing windows would be a problem and indeed it has been. The first action we took was to put on a solar film on the outside of our east facing windows. After some research we opted for Johnson PD75 which claims to reduce thermal gain by 40%. It cost £1,170 so seemed like a good place to start. Well, it may have helped but by mid May it was clear it was not enough and we would need something more. We looked at air conditioning units and decided we would retrofit some. We hadn’t planned on this and the thought of messing up the clean lines of the build and the pristine plaster work did not appeal. Purely by chance it turned out that the false wall in our bathroom built at the request of my wife and much muttering from me (who needs somewhere to put a wine glass while your in the bath) was a saviour. It meant we had a service void from ground floor to second floor in which to route pipes to the internal units. We contacted Mr Harris and he kindly lent us the pump gear required for installation testing, so far so good. We identified the units with the best energy efficiency only to discover you are not allowed to purchase them without having confirmation the installation will be done by a certified F-gas installer. We wanted to do the main parts of the installation ourselves and just have the F-gas engineer do final test and connection. Sounds reasonable but we had a lot of difficulty finding anyone. Mr Harris came to the rescue again and recommended Artech Air who were unbelievably helpful. We ended up with two Midea Blanc units, a 2.5 kW for our bedroom and a 3.5kW for the open plan living area. Result – bliss, and a very reasonable bill for £1,800. In the long term they will add to the comfort of the house all year round. On a slightly different subject MVHR summer bypass. It sounds perfectly reasonable, don’t heat the incoming air form the outgoing air in once a set temperature threshold is reached. The incredible heat of the last month has made us completely rethink it’s use. If the air inside the house is colder than the outside air, then cool the incoming air ie you don’t want to bypass the heat exchange. Also when it very hot between 9:00 and say 20:00 don’t run the MVHV, there is plenty of air in the house and we certainly never felt stuffy. We set the MVHR scheduler to do this for us. Similarly in winter it goes off at 22:00 and back on at 07:00. PV We didn’t put any PV on when we built, the house should need such small inputs it simply didn’t make sense in carbon or cost terms, or so we thought. Two things changed our minds, the air conditioning and we bought an EV. Doing anything more than 4kW is a pain as it involves more certification and silly cost items like Southern Electricities £300 fee for observing testing on equipment that was already certified on the MCS database. Again we had not planned this in so it was a retrofit...grrrr. Very annoying as we were pretty smug about having thought through the whole build. Fortunately our standing seam roof made it as easy as it could be to fit panels and hide all the wires. With the panels added we are still in surplus on the air conditioning units, not cooling for free as we had to pay for the panels and inverter, but no additional utility cost. Bye the way this was done before some nameless psychopath started a war and energy prices rocketed. The house now sits at a very comfortable 23c while not drawing any energy from the grid. We even have enough surplus to charge the EV between 10:00 and 15:00 on sunny days at a very slow 6A. We also opted to put in battery storage which we ordered in February and has only just arrived, it should have been 8.2kWh but in the delay they manufacturer introduced a 9.5kWh version for not a lot of extra money. We’re not up and running with the battery as the manufacturers decided to change the inverter battery connection cables with the new model and there are no cables shipped with the battery. I must confess I found it very hard to see the funny side of this. House wiring We did this ourselves and got it tested and certified, but made no provision for an EV charger, inverter and PV. Fortunately we did put ‘Routabout’ access points into our floor intended to allow access should anything go wrong. We also have loose lay flooring which has made the four times the utility room floor has been up no drama. Providing access to fix and change is something definitely something that should be done early not as an afterthought, when we put the traps in we had no idea how useful they would be. Fixings and fastening Our build is ICF and while it’s great in may ways it does present some interesting challenges when it comes to mounting anything on the walls. The ICF system we used came from JUB and has a very tough vertical nylon strip every 150mm about 30mm from the internal surface. With a course thread screw you can hang things like TV’s but not heavy stuff cupboards. For heavy items it’s a case of drilling into the ICF concrete core 75mm internals and 170mm externally from the ICF surface. This makes for a significant cantilever, internally this is fine you just use big fastenings. Externally the problem is two fold, 1700mm cantilever and you don’t want any thermal bridging, this makes using big fastening as real no no. We ended up using four fastening types: Internally we used cheap and easy to use concrete frame fasteners for heavy stuff. For lighter stuff on plasterboard we used GripIt fastenings which do the job remarkably well. The largest size claims to be able to hold 70kg, but I wouldn’t trust it with anything like that. Externally we use Fischer ‘Thermofix’, expensive and not available in this country. Fischer say they don’t sell enough here to make it worth there while. It seemed lost on them that we were buying from Germany along with every other UK user of the fastening. For light external fixing we used pasta twirls supplied by JUB. Useless for anything heavier than a letter box. DIY cabinets We found we couldn’t always source ready made furniture that was the size we needed. Some friends run a bespoke kitchen business and pointed us a site “wood online” who make up panels to your specification complete with edging. Using a ‘Pocket hole’ jig and these panels allows you to create you own furniture simply and quickly at a fraction of the bespoke cost. We also found some very neat panel clips for panels that need to be removed for access. Garden We finally got round to sorting out the garden. It’s small, just 11m by 5m and like a lot of self builds it had been used as a storage area (dumping ground) during the build. As we’re getting on a bit we wanted to make it low maintenance and low water. Raised beds and a patio area seemed to fit the bill. As the house is a contemporary build and we wanted to the garden to complement the house which is white and two shades of grey. For the patio we have used 600 x 600 porcelain tiles for ease of handling and laying. Getting a patio right is not the easiest of jobs and I was not looking forward to. With the patio base prepared, materials were order, tiles on Tuesday followed three days later by 5000kg of limestone chippings. Of course it just happened to be one of the hottest weeks on record…returned the rapid set tile cement and bought standard set. This still went off at a frightening rate. Trying to get a large are flat and true is not as easy as it sounds even when you’ve done all the preparation. With the first slab set to the correct run-off the other tiles were laid using it as reference. Despite our best efforts to get it right, the first tile was just off and as a result by the tile the 8th tile in the row was reached we were using a significant amount of tile cement, about 10mm deep. The four 20kg bags of cement that should have done the whole job disappeared quickly and another 7 bags were required to complete the job. The hoop and wedge helped keep everything flush and the result is perfectly acceptable. Lesson learnt, do buy the expensive laser measuring and levelling gear at the start of the build, it’ll pay for itself many times over by the time you finish. I’ll know for the next build, however my wife may well threaten divorce if I mention the idea….
    12 points
  25. I'm pleased to say finally we are insulated and have render. Credit to our plasterer who has been brilliant and done an amazing job. The colour is Ecorend marble white so is a very clean white looking colour rather than the yellow/grey looking off whites we saw but we like it. The plasterer came in the early hours before the sun as it was blinding trying to apply it in direct sun over the past couple of weeks. Once we have the aggregate round the house and plants etc I don't think it will look too crazy. Waiting for the anthracite guttering to be fixed on and some of the plastic work and roof edging needs some TLC and if I hear the word 'mastic' again - which seems to be the answer to everything cladding and plastic related I'll strangle the builder. Also need fan covers attaching and our lights putting on which should be next week. Thought I'd share these pics. We have started to apply Bitumen paint on the bricks below DPC and this has smartened up the area where the bedroom/dressing room is where it is the split level inside with steps and rooms are higher than the rest of the house. We haven't finished all the way around yet. Loving the front door now with the render. Despite it being black in a silver frame and the anthracite windows we think it looks fine. This is the back of the house into our utility with the stable door. The hose pipe isn't on the render it's fixed onto a galvanised post. Of course we still have lots of garden work to do, no double garage and no dressing room etc but prices so high we have shelved things for now. Probably the most exciting non-house related news is we bought a boat which took a chunk out of the house budget!
    12 points
  26. Quickish update only because I seem to have run out of hours as now we are building, balancing family life and a full time demanding job. So after the last update, where the stone wasn't really getting solid. I ended up getting it dug out, it was bothering me too much and I was completely worried about it. It was no major issue the boys dug it out in an afternoon, then put dry type 1 back in there and compacted down and built the levels up no hassles. We had a full dry week so it made a massive difference and they were able to get along much much quicker. In between the stone drama I had the surveyor on site and we set up profile boards to set out the corners and main walls internally that I needed to reference off for ducts. I set my boards up so that the string lines lined up with the lower portion of the insulated foundation once I came to the stage of setting that out. Doing it that way worked well. They built the stone up to level, then we cut all the ducts and drains in. The groundworkers took my layout for the drains, then done what they wanted to do in instead, which worked better. They didn't fancy using the rest bends but I insisted in some places. They did prefer to use Tee's which seemed fine. I wasn't too bothered by this point. The ducts ae all mm precision hoefully along with the drains so they all pop up and I spent A LOT of time planning the plant room. Then we screeded with 50mm sand. I used steel pipes for this and we set them up with the laser. It worked well and we had it screeded with 50mm sand in an afternoon. I used concrete sand for this which was wet but worked fine. That's a picture of me in the bucket of the digger doing the bits out in the middle. None of us could deal with leaving a hole in the middle. I got straight on to the DPM after this. My system has the DPM placed under the Kore insulated foundation. I did this all myself and had worked out all the joins on CAD befroe hand. It's easy to lay that way, albeit I hadn't anticipated the PITA it is to not walk on the sand but lay the DPM and then not walk on the DPM is impossible as i want it to stay level. I used OSB boards to move about most of the time. Cutting round drains is a pisser with the DPM, alsowhere you have 4 ducts popping up next to one another in a bunch it is also a complete pain. I did big cuts to get it over and it took forever to patch. I used top hats where possible and taped them in but there was some dodgy joints around where multiple ducts come up in a bunch - Those have been foamed to death now the insulation is down. Things to note - the Visqueen DPM is good, their double sided tape is good. I actually kept it in a cooler with a hot water bottle to keep it malleable as it was pretty cold when I was doing it. Their single sided tape is absolutely shit, do not buy it. Toolstation single sided DPM tape is also shit! However the Screwfix DPM tape is mega, stick like mad no matter what. really impressed with it. here: So once DPM was done I got the insulate foundation down and got started. I took some advice from @LA3222 as albeit straightforward it's not bang on. I was expecting something more highly engineered and don't get me wrong it is of high quality but some bits are a little longer and few mm here and there and some cut slightly off the square which means a good bit of adjustment. But works fine. I set out the corners first, then loosely laid it with my profile board lines. I then ended up taking a middle section out each line to get it to the right lengths and adjusted from there. I checked the lengths and squareness and procrastinated about it, ovethought it and all sorts, I didn't trust my tape as I could stretch it however much i wanted. I then ended up moving it all about and doing all sorts, one thing was apparent was the internal diagonals KORE/tanners can get relied on exactly due to the manufacturing tolerances mentioned above. So you just need to get them square tothe same size and as long as it is ballpark it is fine. I set out again and used the outer lengths, then I bit the bullet and called the surveyor back. He took 250 off me....stayed for 45 mins. Only to confirm I was pretty much bang on. I was 0mm out in some corners (bare in mind i set up with tapes over 20m) and 3-7mm mostly. Two corners I was 20mm off but i knew that as a profile board got knocked. All in all gave me plenty confidence. I then proceeded to pin the edges and then I finished filling in the three internal layers last night. Took me two full days (sat and sun) and then three nights. I used the U pins, I found them good, i started with the PU foam but found it too hard for the edges and thought it woudl take a while. So I pinned it, then filled holes with PU foam.I used PU foam in all internal joints though as that was easier. Cutting through the EPS 300 is a PITA but planned well it's ok. I'd avoid drains in the out sections next time. If i get time I will put more effort at the insulated foundation installation details, but knackered tonight after the last 5 days at it and doing my normal work. I've been writing down things that I would change and I'll list them in each blog post to provide a hint for a step! Lots of pics attached as normal. Lessons learned: 1) It is is wet - buy the type 3 stone 2) Listen to your groundworks guys if you trust them - they wanted me to add big stone down the bottom to help it drain...I didn't want to. We should have. 3) Dont buy the visqueen DPM tape, waste of money. 4) Don't be cheap and by the pro nozzle for the foam gun, It's only 20 quid. I didn't that was a schoolboy error. 5) Don't buy the bahco £19 wavy 'insulation saw' it's crap and near impossible to use with the KORE stuff Ditch it and just a normal saw. It's messy but much much quicker. thanks for reading.
    12 points
  27. We’re getting there! flooring, kitchen and stairs, just bathrooms to go. It’s great to see it all taking shape as the finishing jobs get done. Not that it’s all gone to plan. The first job we tackled was to get the floor down. We wanted to get it done before installing the kitchen rather than having to work around the units. As the kitchen is part of the open plan living area on the first floor it meant doing the whole area some 70m2. It’s a lot of flooring and we needed something that was easy care and tough. After a fair bit of looking at the options, we opted for lose lay vinyl. There seem to be three vinyl options, adhesive plank, click and loose lay. I didn’t fancy sticking down such a large area and we have a couple of floor access panels that I wanted to keep access to. The click version is not dimensionally stable and requires an expansion gap and it’s not designed to have heavy objects such a kitchen units on it. Loose lay ticked the boxes, dimensionally stable, OK with heavy objects and as it turns out the simplest to lay. Karndean and Amtico both have loose lay options but they come in at £30-£40 per square metre. By lucky chance we found a commercial flooring supplier Quadrant who have a loose lay flooring system Salto with a spec pretty much identical to Amtico Access but at £22 per square meter. The planks get laid onto a three metre grid of tackifier, a non setting glue that just stops the tiles from sliding rather than actually gluing them down. If a plank gets damaged you can simply lift it out and replace it. Laying the floor could not have been simpler. In a couple of places we found that the tackifier was just not enough and we ended up fixing one or two end of row planks with a patch contact adhesive. With the floor down we could then start on the kitchen. With no stairs in place we used our electric winch to get the cabinets and appliances to the first floor. We bought the winch to get the 80kg MVHR unit onto the second floor and it has been invaluable in getting flooring, doors and many other heavy bits safely upstairs. With the units all upstairs we made a start putting the kitchen together. We had gone through a couple of design iterations and of course the one we settled on meant that the electrical sockets we put in when plaster boarding required moving to meet the 300mm minimum distance requirement. It’s easily fixed with a splash back so not a real problem. Our appliances are built in, a first for us. So we started out by getting the fridge freezer into its tall unit. There certainly is not much clearance, having carefully got the fridge correctly located I discovered I could not fit the hinges with the fridge in situ, so had to drag it out of the unit. Unit doors fitted and fridge shoe horned back into the unit. You then have to connect the fridge doors to the unit door, a bit fiddly but it all working nicely. Pushed the unit into place only to find the lead was a couple of centre metres short of the spur socket installed for it. Dragged the fridge out, made another hole in the carcase and re-routed the cabling, put fridge back in unit, push unit back into place only to remember the unit had not been secured to the wall after the second cable hole had been made…needless to say there was a bit of cursing as the fridge was dragged out again! A least if we ever have to fit another we’ll know how to set about it. The kitchen has a long set of linear units, which should have been a doddle to install against a nice straight wall. Unfortunately the wall they were getting installed against was the one that didn’t get braced properly on the final pour. Needless to say the units all required spacing out from the wall to form a line. A task not made simpler by the design which has two rows of bridging units over the hob. These are mounted on a wood frame constructed to fill the gap, which of course I cut before remembering the wall was not true. It didn’t take much work to re-jig it thank goodness. We also had to construct the shelving unit as this was a bespoke piece, to make the position of the boiler housing correct. With the linear section of the kitchen built, it was time to build the island. As it turned out this was a much more straight forward proposition as it didn’t involve and dodgy walls. It did involve cutting down a unit by half and cutting the composite worktop. We discounted doing an under-mount sink as we were cutting the worktop and any router chatter would ruin the worktop look. In any event the island went together nicely and the kitchen looks the part. One by-product of having the kitchen done was the completion of the electrical circuits. We duly called back in our electrician to do the final checks. With a couple of minor changes it was all passed. A significant mile stone to pass regarding building controls. Our electrician has been brilliant and supported our work through the build. Not something that all electricians are prepared to do and we were fortunate to find such a good one. It’s been cold and despite the high level of insulation in the house we were getting uncomfortably cool and decided it was time to get the gas boiler connected. We calculated our structure requires about 68w/degree input so very minimal heating should be required, making heat pumps not cost or energy efficient, hence the gas boiler. The boiler feeds two towel rails, no radiators. All the pipes had been put in place long ago before plastering and painting. A bit of a risk but we pressure tested everything before we put the plaster board up. When we finally got round to filling the system and pressurising it we found we had a leak and water was running down behind a radiator. Careful removal of plaster board revealed the cause, I had put a plaster board screw straight through the pipe! With the damaged pipe cut out and fixed, plasterboard and plaster re-done. I put the radiator back up and pressurised the system again only to find another leak. This one took a little longer to find. Again it turned out to be pipe damage, this time on the other radiator, and was one of the radiator mounting screws. Not impressive and something we’ll conveniently forget. At this point the system was holding pressure and all looked good, time to call in a gas safe man to commission the boiler. Called a couple of local gas fitters only to discover they were not prepared to commission a boiler they had not installed. Tried “check a trade” and one of the gas fitters replied saying he wanted to see the installation before taking the job on which is fair enough. Well, he turned up looked at the installation and said he was prepared to do the commissioning, he also pointed out that pipes within 1M of the boiler should be copper and not push fit fittings. We’ve been reciting building regs in our sleep since starting this project and had completely missed this requirement. We had done the gas pipe in copper of course, but why the water pipes? Still no point in arguing….so out comes the carefully installed kitchen cupboard and pipes replaced. Pressurised the system and guess what a leak, this time in a push fit with the new copper pipe. The pipe had caught the o-ring and cut it in two. Easily fixed but none the less annoying when you can’t see any benefit from changing the last meter of pipe to copper. All fixed time to call the gas man in, only to discover his colleague had a covid contact and they were all waiting on test results. Two weeks elapsed before he could come back and the boiler was commissioned at last. Bliss watching the room thermometer slowly creep from 9C to 18C. It certainly makes turning up on site a lot more welcoming. Last but not least we got our stairs in. We had bought the stairs from Fontanot last year and had agreed that the manufacturer would store them until we could take delivery. So they had been sitting in packing crates in Italy since last June and we didn’t get them delivered until October. They were well packed and all we did at the time was a superficial check of the contents, no damage, all present and correct. The stairs are modular and very minimalist, they give the impression of floating in air. Each stair tread support is connected to the next with an M20 bolt through the steel tread supports and spacing shims. It gets built from the top, so you start by installing the head bracket, then each tread until you get to the bottom step where another bracket secures the foot. On the ground floor this is fine, on the first to second floor it isn’t as the stairs don’t terminate on a horizontal floor. The manufactures representative had been on site so was well aware of this, the drawings also showed this but the stair kit shipped was identical to the lower stair. We contacted the supplier who was very responsive and would get back to me with a solution. Time ticked by with no word, so we contacted them again. They rather sheepishly admitted they had no “stock” solution and would have to make up a special bracket. Time ticked by again and we contacted them for progress. What they came back with was not elegant to say the least and would have spoilt the line of the stairs which are a feature of the build. We took a look at alternatives and realised that modifying one of the standard head brackets and mounting it inverted would provide a much better looking solution. New head bracket ordered from Italy along with a tread support. The tread support was modified to bolt directly to the head bracket. Progress at last. Modified bits arrived and unpacked, modifications just perfect, but they were the wrong colour...doh! So we are not out of the woods yet. It will get resolved just it is proving a rather painful process. Back to installing the ground floor stair. Working from the top, the steps adding one at a time using hand rails rods to maintain positioning. The bolts get torqued to 140nm, even so the stairs moved around rather worryingly. Every third step we put a wooden prop to support the construction. By the time you get the bottom step there is a LOT of weight in the structure and it did not feel at all firm. The bottom tread support bolts in to the floor. In our case this is an insulated concrete raft, which is fine as it is strong and plenty deep enough. However it does have a lot of re-enforcing rod, needless to say we found it on two of the four holes. Drilling through with a masonry drill should be possible, but we didn’t manage it and ended up ruining two good quality 12mm HSS bits to get through it. I’m sure there are better ways to do it, over an hour per hole. At last we could bolt down the bottom step. With all the steps secured we left the props in and installed the had rails and four stabiliser brackets. With some trepidation the supports were removed and a tentative test at climbing them was made. They were solid as a rock! Result.
    12 points
  28. It's 3 weeks since my last blog entry and, as usual, things have been moving at a pace. The difference with the most recent round of work, though, it that the building is starting to look like a liveable house rather than a construction site. This is largely due to the glory coats of plaster and paint, but far more than that has been keeping everyone busy. The boarding started in earnest before Christmas and so the plasterers were in bright and early in the new year. We've got through an astonishing amount of board of various types - I thought I'd calculated reasonably well and had a mahooosive delivery of the stuff a while back, but it all seemed to disappear and the building was hungry for more. I bought all the board from Sydenhams as I found their price to be competitive. I've used standard 12.5mm plasterboard on all external walls, 15mm acoustic on all ceilings and internal walls, moisture board for bath/wet rooms, and pink fire board for the garage walls and ceiling. The garage is attached and so building regs require a fire door (FD30, sourced from Enfield Doors, though I've since found cheaper suppliers when looking at other stuff) and fire board throughout the garage, but only a single layer as there is no habitable space above it. I've had a board lifter on hire as it really helps the team position the boards up onto the ceilings without dropping anything on themselves or damaging either themselves or the boards. Here is the board going up on the lounge/dining area towards the kitchen area. The orange frame is the plaster board lifter. The black thing outside the window is my sewage treatment plant tank, which will be installed in a couple of weeks(ish). Looking in the opposite direction towards the lounge area: There have been plenty of plasterboard offcuts and so we have followed @JSHarris's tip of stuffing as much of this into the stud walls before boarding over. Double bubble - increasing the heat retaining ability of the house and no paying expensive disposal fees on waste plasterboard. As well as the boarding and plastering, first fix is underway, getting all the wiring, sockets and switch positions in and running vast amounts of cable through the building for all sorts of stuff. It's not just a case of chucking the cable in, he's done a great job of working out the flow of the building and the people in it, and how the building's circuitry should function best to suit them. It's a pity that it isn't more visual, but suffice it to say that at the last count, something like 2.9km of cable has gone into the building. It's in there somewhere! The room that forms the greater part of the ground floor is the kitchen/dining/lounge area and it's a very large space. From the outset, I've wanted to achieve some form of visual separation of the living area but without putting physical barriers in the way. It seems a waste to have gone to such great effort to create a lovely large space like that to then chop it up and close it in. I had inspiration for the solution from a couple of sources, the first of which is a tiny, crappy image on Pinterest when I was browsing cinema rooms. The second came about from chatting to another BH member, @Dreadnaught and a suggestion someone made to him to vary the heights of the ceiling throughout his proposed build. From this, I decided that I wanted a dropped section, like a frame, on the ceiling above the lounge area, with lighting recessed into the inner lip of the dropped section. Everyone pulled together really well to meet the challenge, and worked out what was needed from the carpentry, boarding, plastering and electrics contingents. The full ceiling was boarded out first, then the studwork frame put over it. The electrics were run through, then the frame was boarded and eventually plastered. Here's the completed framework and the first of the plasterboard going up. They're a cheerful bunch in their work! One thing I haven't skimped on is hire equipment to make the job of the plasterers and others easier. I figure it's a false economy to not get equipment like platforms and board lifters in as it will just cost me extra labour as the guys won't be able to work efficiently and possibly, not as well either. We had scaffold towers upstairs in the bedrooms for plastering and downstairs, we had a really big platform. I wouldn't do it any other way as the quality of the boarding and plastering is second to none. Once the studwork was boarded out, the inner ceiling section was plastered. The inner lip of the frame had an upstand added to it to make it appear more substantial and to hide the rows of LED lights behind them. We're going for a range of lighting intensity here, achieved by increasing amounts of lights, rather than dimmers. There will be 3 rows of LED lights hidden up there and we've used a car headlight analogy for want of better descriptions - the selection is dipped lights, main beam and rally lights. These are the only ceiling lights in this area as we plan to have floor lamps for specific task or reading lighting. Once the inner ceiling was plastered, the framework itself was done the following day. This photo is some way on from that, as you can see. By this stage, the whole of the downstairs main room has been done and recesses formed for the spotlights at the other end of the room. Not too long after this, the kitchen arrived from DIY Kitchens. Lovely quality units and everything is going together well. It did mean, though, that I had to get on with the painting up the kitchen end so that a start could be made on installation. A paragraph or two on painting is appropriate here. I put a brief post into the main decorating section here on BH regarding spray painting, but it deserves repetition. I've planned from the outset to do the painting myself. I'm competent and it's nice to get some hands on involvement in the build. But, and it really is a big one, there is a vast surface area to cover in this house, and the vaulted ceilings upstairs are really quite intimidating for a vertically challenged person such as myself. Mind you, I think a vault of 4.7m would make most people ponder their method of attack. I decided that by far the most effective approach for me was to spray the mist coats to seal the plaster and continue with white for the ceilings. I wasn't sure at that stage whether I would also apply the colour coats by spraying, so adopted a 'wait and see' approach. First off, masking takes ages, even with a relatively empty house, as that spray will get everywhere and anywhere. Once the masking is done and you've familiarised yourself with the sprayer itself, though, the speed of coverage is astonishing. I was able to comfortably do one large room per day - both mist coats and a couple of extra ones on the ceiling to get it opaque and full white. It was messy. Really messy! Especially as when I first got going I had the spray pressure a little too high, the mad angles of the vaulted ceilings meant that my nozzle was never going to be held at a constant 90 degrees to the surface, and it's just a messy process regardless. In addition, there is a vast amount of moisture in the air, particularly as we had plaster drying at the same time. I hired a commercial dehumidifier for a couple of weeks to help with this and it was very effective. I bought all my paint from Brewer's Decorator Centre, who are mainly based along the south coast of England. I opened a trade account with them and got 20% off the entirety of my first order, so I put everything I could think of onto that, including my antinox floor protection mats. Very useful they were, too. I used their contract matt white for the mist coat and ceilings. It's white, but not brilliant white and it's lovely. Very chalky, easy to sand and gives a nice highly matt finish. Also cheap as chips. Here's one of the bedrooms, masked up and sprayed. Here's another bedroom with that ceiling. My scaffold tower came into its own for reaching up to those heights. Then, finally, the kitchen area with its mist coat. The sprayer is the little beastie sitting on the plasterboard. I popped over on a weekend to also put the first colour coat on over at the kitchen area, whilst I could still get in easily before the kitchen started going in. I'm having splashbacks between the wall and base units, hence the odd looking finish level with the paint. These were all the kitchen units as they arrived, prior to painting. Everything was really well packaged and came with the doors on and drawers in. The delivery crew were pleasant and efficient, so all in all, a good experience. Moving away from painting and plastering, the ceiling plan for the lights was marked up on the floor, along with speakers and smoke detectors before the boards went on so that there was no guesswork involved in what was running where. Here's the marking plan: This is what the kitchen units look like at the moment. I made a cock up in ordering, purely out of ignorance, and I'm waiting for a few end deco panels to arrive. These didn't even occur to me as they will go between units and appliances to give a better appearance from face on. It made perfect sense when it was pointed out to me, so things have halted temporarily until those and my worktops arrive shortly. In the meantime, it's looking good: We also now have spotlights in place: Finally, for the curious, this is what karndean flooring looks like. It has been laid upstairs and the downstairs will be finished in a couple of weeks. Upstairs, it was all laid on ply that was feathered in at the edges and downstairs will have a latex feathering coat to level the floor and provide an even base. Next up is more of the same. The final session of boarding and plastering, lots more painting, the end of first fix and moving onto second fix. Outside, we need to get cracking on the rainwater goods, perimeter drain and exterior cladding. The cladding is due to arrive next week, so it will be interesting to see that and figure out the system. I hope to be able to report back on over height doors soon, as well, and my endeavours to find these at a reasonable price, but that's all for now. There's painting to be done.
    12 points
  29. Scaffold down and windows in...big dose of euphoria....feels like a real milestone. We can now get a sense of the completed project. With the scaffold removed the house now looks far more suited to the plot and we hope our neighbours will be as relieved as we are. The window install went well. Our windows are Velfac and we opted to use an approved installer as it extended the warrantee to six years. It cost a bit more but the standard of install was good with great care being taken. A few grubby hand prints on the render but nothing we could not clean of with soapy water. One aspect of doing your own build that we had not considered, is the fact you start out with something perfect and new. It will slowly age and degrade. It’s akin to the feeling of the first mark on a new car. Pat and I have restored a couple of cars in the past and avoided going the whole hog of a concourse restore as it can spoil your willingness to use and enjoy the car. We just need to keep the same mind set with the build. With a house we can lock, our intention is to let the dust settle. We’ll come back to the project with fresh enthusiasm in October.
    12 points
  30. Like all Self builders we found we had a limited number of options for living accommodation during the build, given that we needed to demolish the bungalow to clear the plot for the build. The options were, rent locally or a caravan on site. Renting locally wasn’t an option due to the high rental costs, so we looked at the caravan option. The main problem was access, an 8 feet wide drive with a hairpin bend half way up, a dry stone wall, 80 feet tall trees and limestone outcrop put paid to that idea. A local crane company visited the site to look at the feasibility of craning the caravan over the trees, the narrowness of the road, a road closure and 4 mile diversionary routes for vehicles, a licence from the local authority soon put paid to that idea. Then a brief conversation with a neighbour and a lightbulb moment, we can up with the idea of a timber framed tiny house built in an orchard that formed part of the plot. The day before submission of the planning application a sketch of a small 7 x 5m cabin was added to one of the drawings. Thankfully we got planning approval. The construction of the cabin allowed us to practice our woodworking, insulation and other construction and trade skills. This is where we currently live. This what it looks like on a wet autumn day. Not the power cable over sailing the cabin. Happily the DNO installed taller poles to increase the clearance.
    12 points
  31. The Timber Frame company arrived on site on a very wet mid-January morning. Very quickly wagon loads of components started to arrive and before long every space around the slab and up the drive was dotted with Ikea style flat packs, assorted timber and steelwork. The first job was to floor out over the basement to form a flat working platform for the main house erection. The original specification called for pre-stressed concrete floor panels, these were changed to Posi-joist, as this gave us space within the joist to locate services, ducting, electrics and waste etc. With the basement floor in place, the sole plate was positioned, levelled and fixed ready to attach the wall panels. With every panel, piece of timber, beam and noggin precut in the factory and numbered and with a full set of drawings, the house started to take shape quickly. Four weeks later and the roof timbers were in place and the next job is to fit the roof.
    12 points
  32. When the sun is below the horizon and 450 divided by 2 = 250 it is time to quit for the day. My assistant setting-out surveyor and I had a minor domestic incident in the gathering gloom at a foundation profile where our joint mathematical error became apparent. The gloom was both visible and mental. We had no choice but to soldier on marking out the foundations because although it was 9:30pm, tomorrow was dig-day and the JCB would be onsite at 7:30am. I had seriously underestimated the time needed to set out the foundation plan for a main house and garage comprised of 5 interlocking rectangles and 4 internal supporting walls. As the clock counted down to dig-day some fag packet maths revealed I needed 35 profiles, 70 stakes for the profiles, the rock hard ground required that all profile stakes needed a pointed entry = 140 cuts with a saw and oh don’t forget the 140 screws. The elastic sail measuring tape in my toolbox had thrown out my initial schedule and meant the first setting out attempt was scrubbed because I could not get stable diagonals. A new 30 meter long £35 steel tape from Screwfix was the answer when paired with my proper surveyors grp tape. Three days after that trip to screwfix and after 3 days of punishing heat, we drove home defeated with an incomplete set of walls marked out. At 1am my mind was churning, should I cancel the dig and be branded in the locality as the hapless self builder who messed around the pro’s. Could we live with a trapezoid kitchen 25mm out of true, yes, but what about the stairs condemned by my arithmetic error to run up the supporting wall 25mm out. The alarm woke me at 3:15am, I was back onsite for sun rise and even the vocal sheep in the adjoining field seemed to be mocking me. Before Swmbo turned up at 5:30am dressed for the office I banged in the remaining profiles and we then marked out the missing walls in a new colour (those line marking paint cans gunge up quickly). The JCB arrived 40 minutes late which allowed me to walk the foundation plan with a superficial air of confidence that masked my inner fatigue. Mr Digger was not phased by the erroneous foundation line, he just rubbed out the bad line with his foot and said he would align the bucket edge to the good one. The sun was up, the sheep had shut up and it was a relief to hand over to the pro’s. The day just go better. Building Control arrived at 11am and decreed 1m trenches would suffice because ground conditions we so good, the clay looking stuff was actually silt. We could have got away with 225mm of concrete but I had ordered enough for 600mm foundations. Mr BC was in such a good mood he gave the assembled crew a quick lesson on how to distinguish nice silt from evil clay. Many visitors passed by and declared I had the best looking trenches seen in Lincolnshire for years.
    12 points
  33. So, I know I promised tales of cladding and roofing in the last instalment, but I have reviewed my photo stream and in fact realised that the window install was the next thing. At the end of November (as we all know, winter is prime building time), we finally retrieved our bargain basement windows from storage and brought them to site. Ah, the bargain basement windows, a tale of joy, horror, stress, fury, confusion and eventual revenge all in one. I should explain. When we had secured the plot and had initial drawings from the architect and were waiting for engineering/calcs/building control drawings/services/everything else, we passed the time by getting hilariously large quotes for every aspect of the design. It kept us amused. So, after reading a lot on fabric first design and passive homes, off we trotted to our local Internorm dealer. Lovely showroom, excellent coffee, charming, if slightly oily salesperson. There was much discussion about our options - I asked about passive standard 3G timber aluclad. After a while, a large figure was mentioned. A very large figure. So large, in fact, that I actually was convinced that the salesperson was having a little joke with me. He wasn't. No further coffee was offered. We gathered our coats, emptied the complimentary biscuits into my handbag and prepared to leave shamefacedly, and preferably without admitting that we were FAR TOO POOR to afford these lovely windows. On the way out, the salesman commented off handedly and rather insincerely "Sorry we couldn't help you today. Unless you want to buy the ones in the basement, ha ha ha." Reader, I have little-to-no shame when it comes to sniffing out a bargain. I cannot be humiliated. So, I was accompanied to the basement of the showroom, whereupon I was greeted with a £100,000 wonderland of window-related (expletive deleted)-ups. Results of inaccurate measuring, bankruptcy of developers, incorrect specifying, just general inefficiency. Of absolutely (expletive deleted)-all use to anyone, of course. Apart from someone who had not fully finalised their house plans. And a salesperson who is uncommonly keen on crystallising some value from said (expletive deleted)-ups. It was a partnership written in the stars. Details of hard-nosed negotiating aside (and there was someone in the room close to tears, and it wasn't me), we came away with 15 brand new windows (including 3 large sliders), a fully biometric ex display front door with side lights, a utility door, and a large panel of glass. All pretty much passive standard, some with built in blinds, some alu-clad timber, some Alu clad UPVC. For not much money. At all. A very satisfyingly small amount of money. The architect was somewhat perturbed by this moderately unconventional approach of designing the house around already purchased windows, to say the least. For a while, I had a Quooker tap and approx £80,000 of windows as my only purchases for the house. However, he came up trumps and designed the house in such a way as you would never know that he had any design restrictions at all. The man is a quiet genius. We had cherry picked the best stuff - so all our sliders for the bedrooms are approximately (but not quite) the same size, they vary by about 30mm here and there, but they are all on different elevations of the house so you never see them right next to each other. We wanted to use one particular window in the bathroom as it had built in blinds, but it was a little too big, so we sank the bath into the floor to allow the window to have opening clearance. It looks amazing and like an intended "design feature". So, we purchased the bargain basement windows, and following our cynical, but realistic architects advice - we got a trailer and got them the hell out of that warehouse. They stayed wrapped up and palletised for approx 2 years until that fateful day in November. Now, what we should have done was quit while we were ahead, taken note of the surpassingly large number of (expletive deleted)-ups and run like the wind away from that warehouse. You will not be surprised to learn that this did not happen. We still needed our large feature window - a 5m wide, 2.7m high alu clad timber lift and slide window and matching fixed panels above. This was not cheap. Very very not cheap. But it was lovely. We decided that as we'd saved so much money with the rest of the windows, we could justify this lovely thing. We got a good, although still bloody expensive price on it, paid a 50% deposit, and were instructed to let them know when we were ready to have the window produced - as we hadn't been through building control fully yet, so didn't want to press "Go" just then. So, all well. We got on with what we needed to do, engineering, building control, life etc and gave no more thought to it. We get our building warrant. We phone up the showroom to say "yay! please make our very highly priced window!". Only, there's a disconnected tone. Odd, we think - must have misdialled. We try again, same thing. We google. Website down, emails bounce. A light sweat breaks out. The insufferable shits went bust. No one told us. It may or may not be directly related to the basement of (expletive deleted)-ups. Internorm had never heard of our order and had not received our deposit, so couldn't help. Now, thank christ that I am naturally untrusting of salespeople and INSISTED on paying £101 of the VERY LARGE deposit on a credit card. Section 75, how I love thee. We got the whole lot back. Eventually. After a lot of paperwork and phonecalls. But now we have a load of second hand windows, some with bits missing and no-one to fit them. And no-one to order our lovely slider from Help was on the way from an unexpected quarter though. Our house build is being filmed for TV, and we happened to have a filming day a couple of weeks later. Someone on the crew gave us the details of a helpful person within Internorm, who passed us on to another dealer who honoured the original price for the sliders, came up from England to fit the windows, supplied all our missing bits and were generally wonderful. So, we come to November. There are two access points to our site - one at the rear, which we can just about fit an articulated lorry up, and one at the front, on the extremely busy main street, that is cobbled and 2cm narrower than a transit with the wing mirrors folded, and only just as tall. The Internorm dealer had already made a site visit to review the access and made many sucky-teeth noises, but said "it's ok, we'll get a robot handler up from Leeds that can hold the window at 45 degrees while we drive it up." "Ooooh", we think, "A robot! Technology will save this whole scenario". The day started relatively badly when it transpired that the artic driver, instead of turning right when he should have, so he could drive straight down the street and have the windows on the correct side for unloading, had in fact, turned left and was now in the middle of fully reversing down a medieval street so long that it takes approx 8 minutes to walk from one end to the other. At 9am. Also, he was (I think) Romanian, with no English, and there were no Romanian speakers amongst the installation crew. So, when he finally arrived, after monumentally pissing off approximately 14 million local residents, the windows were on the wrong side and no room to turn. So we had to unload the rest of his lorry, stack it up on the street, taking up virtually every parking space in the place and drive the telehandler across the street, blocking all the traffic to get the window off. It is massive. Securing it on the tele handler is not a quick process. There was a lot of shouting. Also, did I mention I'm 6 months pregnant at this point? So, once unloaded, we look around eagerly for the promised technology laden robot. Looking a bit sheepish, the install crew confessed that it hadn't been available, but "don't worry, we brought something else". Great, I think! No problemo. The "something else" appeared, to my untrained eye, to be a couple of skateboards. So, we ended up with our massive window being rolled up the close on a couple of skateboards, being held at 45 degrees by a telehandler and 10 or so guys not all of whom shared a common language. To be honest, it went better than it should have done. The only hairy moment was when the tyre of the telehandler hit a drainpipe and it cracked with a noise EXACTLY like breaking glass. I was at the street end and couldn't see the window, just heard the cracking noise and a lot of a shouting. I was pretty convinced I was about to HAVE the baby. Terrifying. But, all in all ... TADAHHH! Over the next couple of days, all the windows were fitted and we were (nearly) watertight. Exciting progress.
    11 points
  34. Well we are on the way now and no going back. The groundworks guy started last week, he is putting in the road and hardstanding and will do the insulated foundation under my guidance and I will assist. It's a good relationship and he comes when its not raining and is well experienced in groundworks. He is actually building his own home just now too (we are similar ages). The night before he came on site...I was hurriedly arranging site insurance (horrific cost of over £2k - but it is for 24 months) that was sorted, then in the dark I went up and attached the cursory health and safety signs at the entrance. I also put a sign facing out into the surrounding fields (see pic below) as we have people who walk by and I haven't heras fenced the site hence if someone crosses the fence they should be aware there might be big holes in the ground. The digger came the next morning and we have nearly finished the access going in to the house, around 400 Tonne of 3" crusher run has got us up to the house location. Which is pretty damn close to what I calculated, we were put off my rain somewhat this week which suited us both as I was stowed with my normal job, I did have holidays booked but couldnt get off as I had too much on. However come Monday..I will be off for a week.... I 've been busy at night over thinking, over engineering and done far too much detailed planning around drainage and ducts. But I'm nearly ready. The Kore Insulated foundation system came in December....I can tell you how glad I was that i brought it in before Brexit. I'm hearing stories that it is completely problematic now. I was missing some EPS for a thermal break between man slab and integral garage but steven from Kore sorted it and should be here next week just in time. I'm spending my night tonight comparing prices of drainage which I'll bring on site on Tuesday. The groundworkers will be back Monday and we expect a big week full speed ahead, we will scrape the foundation out (the footprint top soil is removed) get it level, then fill with Type 1. Then surveyor here on Wednesday to set out profile boards with, I done all the ACAD drawings for him to place it all and do the ducts and drains and insulated foundation corners etc, He's also been really helpful and proactive. The final UFH design is done, I'll order the pipe on Wednesday too and they can get it next day, so that's fine. Next week is a big week and I'm excited...I've planned some bits to death, but in reality we will just see how it goes. Some pictures attached because that's what a blog is all about Jude was thoroughly enjoying the water and mud!....wish us luck! 20210115_154740.mp4
    11 points
  35. it's been a bit quiet on our blog so I thought I should update it. While we've been waiting for the groundworks to start we've been busy getting the site ready. This has included getting the new entrance to the plot created, getting the sub-base for the driveway in place and then topping it off with a layer of 6F5 as a hardstanding for the construction vehicles (after the build I can then remove the top layer to reveal the, hopefully, still in good condition sub-base to put the final layer on top of. well that's the plan at least!) and putting up the site toilet. Obviously the last job was the most important. Our new entrance to the plot is over a culvert and as it's connecting to an adopted road it had to be done by an insured contractor and so I had to fork out the cash to get it done. but they did a very good job and we're very happy with it. the culvert in situ with enough concrete on top to take the lorries and cranes for the build a nice base layer of tarmac finished, which will see us through the build when they will come back and put a nicely finished top layer on. nice sand-bagging. ? once, they'd finished the entrance we moved on to the driveway and hardstanding but, first, an observation....it's funny how things don't look as big on paper as they do in real life. that's exactly the conclusion I came to after I looked at the plans and thought "that driveway isn't that big I'll just dig it out myself and save myself a fair chunk of cash" and then went on to dig it out. it was only after I'd finished the 120m2 area did I realise how big the driveway is going to be (I swear it doesn't look that big on paper!). oh well, it's done now, at least we'll have plenty of parking. maybe I can rent it out and do a 'Park and Ride' in to the local town to recoup some of the costs. ? a big hole dug and covered in Terram (or an equivalent to be exact) 100 tonnes of beautiful primary Type-3 granite aggregate all compacted by that beast of a roller. Don't really care what everyone else thinks but I think I did a darn good job for my first driveway sub-base. Sadly it all got covered by another layer of Terram and then a load of 6F5 got dumped on top and it now looks like a building site hardstanding area (which is what it is!). here's a photo of the lovely lady of the house helping out on the roller. it was a bit cold out that day. And finally we get to the most important job, the building of the site toilet. Friends of ours got it from a local freebie site and used it for their self-build, we then dismantled it, transported it to our site, erected it, put a new roof on it and plumbed in the toilet and sink to our existing STP. we think it's a very luxurious WC for site use. it's even got a couple of windows so you can watch the work progress while you're doing your business. and that's it for this blog post. we are extremely excited as tomorrow is the day we've been waiting for and the groundworks starts in earnest. They'll be on site to set up and start digging out the big hole for the basement as the basement contractors are due to start on the 3rd May so we should start to see some real progress now! finally!! thanks for reading. ?
    11 points
  36. So finally got round to finishing all the decorating over the Christmas break! The front window will be getting swapped for triple glazing at some point, but other than that and a tiny bit of skirting board its complete.
    11 points
  37. After demolition was completed in March, nothing happened again until late June. If you want a good worker, you have to wait. And that's my friend of 10 year plus, Noel. So I was happy to wait a few months to get him to do the extensive ground works, an experienced plant operator with a team of solid workers at his disposal. As we're building a basement, we knew excavation would be extensive. Once we'd leveled the site, dug out the founds, the drainage and main basement excavation works could start. As you can see, we've ended up with a rather large pile of bricks... A sense of scale, this is 1/2 depth of 1/2 of the main building footprint... the clay was already building up at this point! We knew then we'd have to shift a few loads away as there wouldn't be room on site. All started well... until, well, I got a knock on the office door and was greeted to Noel looking in with a strange, perplexed, half smile reminiscent of a child that's done something wrong and is straining to hide their obvious pride in their achievement. "Conor, I've found a well" "What do you mean, a well?" "A well". A few moments of silence passed. Then he showed me this: Somebody, back in 1920 or so, in their unfathomable wisdom, decided to build their house directly over a 5m deep, sandstone walled well. DONT PANIC!!! A few phone calls and a bit of head scratching later, we found a solution. 5m3 of lean mix concrete was quickly ordered! The well was pretty much at the back inner corner of the house so had to be dealt with. Luckily, the well was dry (apart from a little sludge at the bottom) and not apparently hydraulically linked to anything of importance... so engineer said fill it up! A shame, but a relatively cheap outcome for what could have been a disaster. We kept going, the clay started to be trucked away at a painful £150 a load. I lost count after a week. Another 'sitting at my office chair' moment happened just as we were seeing the end of the dig. What's the smell? Don't tell me Noel's spilled a load of diesel!!! Nope, we'd hit a large patch of soil contaminated with home heating oil. It was flagged as an issue when buying the house, but the survey indicated that it was localised and not at toxic levels. OK. So, it would appear that the oil had seeped down from the oil tank to about 2m deep in to a slight gravel strata and stuck there. The smell was incredible. Another panicked phone call to the oil contamination expert. Came out a few days later and took samples. We carefully stockpiled the contaminated soil to another part of the site on a sheet of polythene. Good job too, came back as hazardous and we would have been in trouble if we'd taken it to landfill. It's still there. And will be there for a long time in the hope that nature will take it's course and clean it.... In the end, we finished after almost three weeks (up from the one week estimate) and trucked out 51 loads of soil (816 tonnes) and imported 225 tonnes of stone. Bonus tho, we now had somewhere to put our "day" caravan and awning and finally have a spot to have a BBQ and beer after work.... and quality time with family. Ended up 50% over budget.... well, at least we're out of the ground now....
    11 points
  38. Things seem to be happening very quickly and progress has gone really well. The block and beam of the huge extension is coming together now and the focus has been outside, although with the occasional downpour the inside is now half empty with our 1970s bathroom suite finally gone. In the interim I've sold everything inside, the kitchen, boiler, naff internal doors and even the crappy floor tiles we took off. All copper and rads ready for my dad to weigh in. Have now run out of stuff to sell! Here are a couple of pics from this week. The final pic, the bank you can see and the path runs 90 metres from the entrance to the end of our garden from one old railway bridge to the other old railway bridge the other end which is over the canal. The railway at the top of the embankment is no more. It was the line that ran from Whitchurch to Chester and we can clamber up to the top of the embankment which is now an overgrown mess of bramble and ivy, no track any longer. We cleared some of the ivy and when we were clearing the garden of shrubs, bulbs and plants that we knew would get disturbed I literally moved every one by hand and planted it on the bank and we have been lucky that the majority of the plants have taken and had daffs, bluebells and lots of other things flower so it looks quite nice, even the foxgloves that seem to have gone crazy. We do need to sort out some sort of wall or something to replace the rockery' bit which was already there. I dread to think of the cost for such a long length. It's not as high in some places and levels off.
    11 points
  39. It has been 3 weeks since the last Blog post and in some ways it feel an eternity and in others it seems only yesterday since Plot 1 TF was done - which is where we left the story. So lots and lots has happened since then so this entry will cover 'lots of stuff' in one go. Our main aim is to get both shell buildings up and then get them wind and watertight as soon as possible. The heavy rain we had just after Plot 1 was finished showed that the MBC OSB roof is not in any way watertight as water poured in through the roof and down the stairs - so we tarpaulined this one and then it hasn't rained since - typical. Anyway a huge push to get to a point where we can (hopefully) draw breath in two watertight houses - hence LOTS OF STUFF (good, bad and ugly!) PLOT 2 Timber Frame So MBC finished Plot 1 and moved over to Plot 2 - another big crane day and the lower floor went up in one day and the joist went on the next and then the boys left us for a long weekend back to Ireland as we fitted the UFH pipes. Having done it once already the UFH pipes went in just fine and this time we didn't have to cut all the metal plates so it was a bit easier. Then the MBC team came back and fitted the floor deck and the sole plate for the top floor and then the crane came back for the top floor walls and roof. The wind came up and so we had to have the crane back the next day to finish off as wind is not your friend when you have to lift big panels up and over a three story building! The boys cracked on and decided to work the Bank Holiday weekend and try to finish by the Sunday. We had already had some comments on the noise and weekend working and had talked to our BCO so we posted a polite notice to say because of CV19 guidance we were trying to reduce travel of our contractors so they would be working through. A couple of neighbours were supportive and sympathetic and one of them even invited the boys for a socially distanced beer after work. We had them stop work for 2 minutes at 11:00 on VE day so exactly at that point one of the neighbours switched on his pressure washer - you cant make this stuff up!. Everything pretty much went to plan and after a heroic effort the MBC crew finished on the Sunday evening as promised and both houses finished to shell level in under 5 weeks - and they look amazing. We did our best to look after the MBC crew as they were in local B&B without the Breakfast (or any food component) - its never ceases to amaze us how well simply treating contractors like human beings goes down. We guess that some of their clients must treat them badly - but why on earth would you want to? After MBC left we had a call from Environmental Health and it seems that some noise complaints had been received - it seems that the latest Government edict on allowing longer working hours on construction to get the economy moving only apply to Planning and not Environmental Health so we were suitably humble and promised to be good in the face of some very vague guidance. Given that we have been working on site since August and these are the first noise complaints its obviously not a serious problem, and as we are self building under loads of pressure we will continue to do DIY at weekends - though as quietly as possible. Yet again we find we really do have one or two vile neighbours. Roofing As we have a flat roof to keep the roof height at the same level as the original bungalow it has an EPDM (plastic / rubber single ply) membrane roof. This sits on a 24mm plywood deck on top of the MBC flat 12mm OSB roof and the MBC firring strips - which slope the roof slightly to get the water to run off. Sounds pretty simple but as with all these things its not so simple. First you need airflow in the gap between the two deck layers so there is no condensation to rot the timber - for this you need plastic soffit vents around the edge to stop the bugs and birds getting in so Joe and Chris fitted all these. Then you need to think how you get over 4 tonnes of plywood 9m up and onto the roof (plus all the rolls of membrane etc) and our roofers said they would do the roofing but not the lifting. Simple solution here was a tele-handler which is a huge forklift that makes short work of this kind of thing - just hire one - simple. But then you need a driver - again simple: one of Joe's colleagues Andy drives one all the time on musical festival sites and is qualified and was happy to come over to help out. So Andy and the roofers turned up and after a bit of delay the first pallet of ply was lifted onto the roof and they were away. Again a good crew who worked really hard and seem to be doing a great job. They have spent a week and plyed and membraned the main part of both roofs so we almost have a dry roof. It was really hot on the roof with no shade so ice-cream went down really well (and for us as we were up there working as well). They still need to do all the fiddly bits like rooflights and soil stack, plus all of the top of the oversail roof but the bulk is done. One wrinkle here is that the rear bay on Plot 2 has the same oversail detail and MBC couldn't fit this because the scaffolding is in the way, but we couldn't take down the scaffolding because we needed it for roofing the main roof on the floor above. So when the main roof is done we will have the scaffolders back to take down the back corner and then MBC will fit the roof and then the roofers will come back and fit that section of membrane roof. Oh how it all gets really convoluted and complex really quickly. Finally to add to the simple / complex plan we had the roofers and the window fitters start on the same day - what could possibly go wrong! Windows The EcoHaus Internorm surveyor came out and lasered around and said that the rear bay window on Plot 1 was 30mm too low and the three windows wouldn't fit. Some checking and it was an MBC error that they happily agreed to fix and Brendan popped over and spent a morning cutting 30mm off the underside of the 3 sided glulam frame in situ and in mid air with a skill saw. We were apprehensive about the sort of job he would do but skill saw is an understatement when it comes to Brendan: two saw cuts one from each side that met perfectly in the middle - truly fantastic work. So one week after MBC had finished EcoHaus Internorm arrived to fit the windows (same day as the roofers - but the windows arrived first!). Their plan was to fit all of Plot 1 windows and then move to Plot 2 - but they were all over the place fitting windows at what seemed like random. We had some of the scaffold moved to make space for them and they seemed happy - and we said if they needed anything at all just to ask. So we were working around the back of the house when we heard an almighty crash and ran to see what had happened. They had asked Andy to lift a huge pallet of windows up above the garage level (about 2m) so they could load them through the window opening. During the unload one of the fitters stepped off the scaffold onto the pallet. The load slipped and the windows fell. Included in this fall was the fitter who had stepped onto the pallet. Ongoing discussions with EcoHaus preclude us from saying much more about this except to say that mercifully the fitter was only bruised and a load of windows were damaged (no glass broken though) and will need replacing - it could have been much much worse. They carried on and then discovered than one of the huge panes of glass for Plot 1's rear slider was cracked in transit from Austria, and also that there were no bolts to fit Plot 2's Juliet balcony. Finally, and this is my fault; the front door for Plot 2 is handed wrong and will need a new frame. So they finished fitting what they could but we have three gaping holes awaiting replacements and a bunch of other stuff that needs rectifying. We have to say that the quality of the actual windows is fantastic, but the experience has not been good so far. Just to contrast this with another MBC issue: we discovered that the kitchen window on Plot 1 didn't fit and there was a 300mm gap above the head of the window (window surveyor didn't spot this one). Well after MBC had left site we discovered a 300mm panel that didn't seem to have a home! Quick call to MBC and yes this was the missing piece, they apologised and Mike came over the next day, apologised some more, fitted the panel and problem solved. If only all the people we deal with had the same attitude then it might all be simple! Rooflights, gutter, soffits and facia Since we have been on a cost cutting mission we have taken on much more of the 'doing' ourselves and keep trying to cut costs where we can. One of these is the guttering etc. the original plan was powder coated aluminium. However this would have been about 3x the cost of plastic, and given the really complex oversail roof detail this would have been really expensive to have fitted. So, and with some real reluctance, we have gone for plastic gutter and soffits and facia. We would be the first to admit it doesn't look as good and will not last as well as aluminium but it is 9m in the air and nobody will examine it in detail. Its likely we will compromise and fit metal gutter to the rear bay (when its finished) as this will be almost at eye height and will look much better. So a mad rush as the three of us have been busy fitting all this and trying to keep half a step in front of the roofers who need the gutter fitted before they can membrane the oversail roof. The reality is that the plastic looks really OK - though we are somewhat mystified by the physics of fitting a flat gutter all the way round the roof - anyone done this? We had to call a stop on Saturday as the wind was really strong and the plastic panels wanted to take off and it really wasn't safe. Also as part of the roofworks we have 4 rooflights on the roof :- 3 fixed pyramid lanterns, 1 on Plot 1 over the stairs and 2 over stairs and landing on Plot 2, plus one flat sliding opening rooflight over the en-suite on Plot 2. The fixed lanterns were flat pack so we have just brought all the parts up onto the roof and built them in-situ ready for the roofers to flash the membrane roof around them. The sliding light was ready built and is really heavy and a 4-man lift so MBC helped unload it and store it and the roofers moved it to the tele-handler and we hoisted it up to the roof and they moved it to a point where its a really simple install. We have had to build the upstand / kerbs for all of these so they fit exactly into place - and we were able to test this with the empty frames. We have just placed the completed unit above the landing and it really looks great - the one above the stairs will look great but at the moment the hole is covered with ply as there is a 9m drop below it and we dont want to leave that open for obvious reasons! MVHR Joe decided he was going to fit his own MVHR system as its not too big and complex and he is desperate to save every penny as he doesn't imagine he will be back on live music lighting until next year so has no income and a lot of time. We have all worked on this install and its not too hard, but the sheer volume of ventilation pipework is mind boggling and routing it is a real challenge. Plot 2 is more complex and since we no longer have an M&E person will get CVC in to install and commission - though having done one we could probably do this one as well! As you can see a lot of stuff in the last few weeks - and a real mix of good, bad and ugly! And still not wind and watertight as planned, but certainly a lot drier! Next steps will be to sort the insulation (Plot 2 is really complex) and screed - which needs doing before MBC can test for air tightness and we can start first fix, and also to get the render done so we can get the scaffold down and finally see the houses for the scaffold. On the insulation and screed front we has planned on 150mm of PIR insulation and 100mm of screed, the thick screed to get some thermal mass and delay into the heating/cooling system. In the interests of cost reduction it looks like 100mm EPS + 90mm PIR + 60mm pumped screed will be much cheaper and have similar U value but lower thermal mass - any thoughts on this plan? Or even 200mm EPS + 50mm screed - which has slightly worse performance but lower cost? One nice moment last week was when we were up on the scaffold and a couple walked past, stopped, looked at the build and said 'wow that looks amazing!' . So nice to hear that others agree with us; it really is starting to look amazing!!!!
    11 points
  40. In my last blog entry we had done the majority of first fix and were about to tackle the lighting circuits. We had intended to do this in the conventional ring and switch runs. Reading up on our options it soon became obvious this was not the best option and that running radial circuits made much more sense. A radial approach will let us install led drivers and any automation in a central area for ease of maintenance and to allow us too upgrade with wi-fi switches at some point in the future. Initially we are installing RF controlled relays with switches that look like fairly conventional switches stuck on the walls at appropriate places. There are a couple of of lighting circuits where having Shelly controlled switches will be beneficial as we can programme them to come on at sunset for a couple of hours. All has gone reasonably well, our council building controls visited and gave us a clean bill of health and said they didn’t need to come back before completion. They’ve been really good to us drawing our attention to possible problems, so getting the news was a nice vote of confidence. It’s been hard work and we’ve been on site most days, so when it came to the 14th I did little to help my cause by buying Pat a new set of overalls ? … we both had a laugh about it. Our plans were to get the plaster-boarding done by mid March, which is when the plasterer was scheduled to finish a large job. This schedule gave us plenty of time to fit service battens on the vaulted ceiling and get everything as true as we can to give us a nice flat ceiling. Not having plaster-boarded before we decided it was prudent to call in the plasterer to take a look at what we had done and point out anything we needed to do differently. So when Shaun our plasterer came on Tuesday last week and told us it all looked good and the big job he had been due to start had been delayed as the electricians had failed to come on site. Quick discussion and we decided to break our plastering into two pieces of work and start on the 25th a full three weeks before we had planned. It was an all hands to the pumps week to meet the schedule. Our house has a two story stair case in a 1.8M by 2.4M void so when working on the ceiling over the void it looks like a very long drop...a good 8 meters. The boarding above the void is in full view, so we wanted to get a nice straight line on the intersection on the apex. We set up staging in the void on the second floor. Well supported but still knee quaking. Getting the board lifter into the work area was also a problem. Just to help the wall on one side of the area was not true so getting a 2.4M board lined up and fixed true proved a bit of a mission. In the end it took four attempts and some use of packing shims to get it right. Not a good start as it had taken the best part of a day to do a comparatively small area. Our kitchen ceiling is vaulted and we had bought a board lifter and an extension arm to allow us to do it. This extension arm allows the boards to be raised to 4.6M plenty we thought. It turned out to be just 800mm less than we needed so we ended up putting the lifter on blocks to get the additional height. In the end it worked out fairly well with minimal trauma. Can’t imagine how people do it without a lifter. Progress picked up well from this point and we put up the last few sheets with a little time to spare. Plasterer arrived on schedule and got to work fast. Such a transformation.
    11 points
  41. Yesterday was air tightness test day and MBC's final day on site getting everything prepped for the final test and then finishing off a few details. For those not so familiar with this kind of thing, a few details of the process follow. Our house isn't a passive house as it hasn't been designed with that in mind - it was the design first and then build to passive standards, so no accreditation or anything like that. That said, I wanted a low energy house and hence the choice of the passive system offered by MBC. Part of this system is that as well as the building and foundation being highly insulated, it also leaks very little air, as this is one of the major sources of heat loss in buildings and houses. The leakiness of a house is measured in terms of the number of times the volume of air contained by the building passes out of all the various gaps in one hour. As mentioned on this forum elsewhere, a modern well-built house without any special air tight measures would probably change its volume of air between 3 and 5 times per hour. The final part of MBC's construction method is to tape over anywhere there is likely to be a gap and make the building as air tight as possible; the target is to have 0.6 or less air changes per hour. One exterior door into the house is chosen as the point of measurement and this is where all the kit goes. Note that the air tight test is testing the quality of MBC's work and whilst it will highlight gaps elsewhere, it's not MBC's remit to correct leaks caused by others, only themselves. The point of measurement for my house is the door between the garage and the utility room, where the FD30 rated door was recently installed. The door is sealed up with a membrane that's supported and held in place by an adjustable frame: The hands are those of Steve, of Melin Consultants, who carry out most of MBC's air tests. This is the frame/shield being put in place in the doorway. I really did try and get a photo without builder's/air tester's bum, but to no avail. Those with delicate sensibilities should look away now and skip the next photo. After the frame, the fan is put into the hole in the shield, drawn tight and any gaps between the frame and door frame are temporarily sealed up. The rate of air flow into and out of the building is altered by both the speed of the fan and the number of vents that are opened up on the fan. The building is de-pressurised first, then re-pressurised and the readings taken. Because of environmental factors such as wind, this is done 10 times to get a data set and the average is taken for the final result. When this test was done yesterday, it was a windy day with the wind coming from the north east, the direction that the garage door faces. As the test progressed, it became clear that the house is well sealed and so it needed a smaller fan. The red shield was swapped over and the smaller fan put in place. The rest of the readings were taken and we got our final reading. Darren and his MBC crew aced it - with a target of 0.6 ac/h it came in at 0.25. Brilliant. Darren is a calm chap under all sorts of pressures but the air test was about the only time I've seen him display (slight) signs of nerves. He was equally understated in his satisfaction with the result even though it turns out that this is one of the lowest numbers they've had in 7 years. Well done, Darren and crew. If you're wondering what all that foam is doing on the floor, that's left over from work on the foul wastes over the weekend and foaming them in before putting air tight tape around them to make sure it wasn't detrimental to the air test result. We have a few very minor leaks, mostly gaps between the panels in the windows that have several sections. No surprise and these are due to be siliconed once we've finished most of the pretty stuff. There is also a bit of air flow through the keyholes but I've been advised that a good coating of vaseline on the key and in and out of the lock a few times should seal it up well enough. I daresay that would seal most things. The gaps were temporarily sealed up with a bit of low tack plastic for the air test, so the result assumes this has been done. All the battens are in now and the downstairs was finished off yesterday, and concrete was put into the remaining recess that had been formed for the lift and slide doors to get a level threshold. I am, of course, delighted with the air tight result and really pleased for MBC as well, as they have worked really hard and whenever there has been a problem, come up with solutions. I know that others have had varied experiences but for my own, I have found MBC to be a pleasure to work with right from the start. At the design stage, David worked his socks off liaising with my architect to get all the details right and to work out how to build the design using their system, and this has been the case with any third parties I've asked them to speak with directly. The communication from Trish has been great - I've always know what was going to happen and when and been kept informed when timings have had to change. The guys on the ground have worked like machines; I'm astonished at how hard they work, to be frank, and throughout the whole time I've never heard any rows or arguments. That's not to say that there haven't been any, but if there have, they didn't take place in front of me. For me, this has been a really good experience. What next? There's still plenty to do but the next main contractor is largely doing all of the internal systems, plumbing and wiring (note - I'm no longer giving details of this as I can't recommend due to unfinished work). The MVHR ducting and manifolds have been worked on but will kick off in earnest on 3rd December once the cellulose has been blown in upstairs. The cellulose is arriving on Friday 30th, along with Gordon, who will put it into the walls and ceiling. All 520 bags of it! Before then, my Ryterna garage door is due to be installed next week so I'll report back on that. That's being supplied and installed by Joe from Dorset Garage Doors Ltd, just up the road from me in Lydlinch. There's a lot of work to be done outside, too, but I'll be thinking through that today and get my plan of action together. Whatever else happens, some gentle heat will be put into the slab this week, using a couple of Willis heaters. It's getting pretty chilly on site now and it will be nice to get the house drying out properly and check that side of things is working properly. A good week and, hopefully, more to come.
    11 points
  42. Hello, Another post and another year of self building. Since my last entry we have made some progress in a few areas. I previously mentioned some trouble that I had with the treatment tank. We choose a Tricel model as it is widely installed on Skye and the local merchants all suggested it. The alternative was a rotating one with moving parts which I was keen to avoid. Other models were getting costly to be delivered and would require some form of mechanical unloading at my end. After my post I had a fair bit of communication with the manufacturer and the merchant. I didn’t back down and didn’t pay, in the end they backed down and sent a replacement. This went via Inverness and the merchant wanted to inspect before delivering to Skye, guess what they found? Three tanks later and it’s now in the ground. Discharge will be to a ditch, which at this time of year is wet but for most of the year is usually dry, this runs off to a wooded area at the bottom of the croft. Our original warrant and SEPA approval was for a traditional septic tank and soakaway (amended installation was agreed with both parties). After some posts on BH it was clear that a treatment tank would be the better option all around. I should say that a traditional septic tank and soakway is still quite popular in the Hebrides, two recent self builds both installed this set-up. Whilst the digger was here, we decided to get some further work done. A gravel drain was put around the back and is working well. Rotten rock which was at the front of the house was used to bring up the level around the house. A big pile of clay and top soil (or mud mountain as some called it ?) from works back in 2015 was then landscaped around the site. We are pleased with how the house sits in its surroundings. Finally, here is one from the Broch. People have been self building here since the Iron Age! Although this one is down to foundation level with the rock reused multiple times in various self builds during the last two thousand years. We now need to put the fence back up around the site to allow our sheep to come back on the croft. Today’s job has been digging and fitting four posts. The electricity connection was moved from the temporary supply box into the house. The cost for this work was cheap at around £200 and done by two very tidy and polite SSE workers. This simple homemade box was constructed from scraps and has lasted four long Hebridean winters but will now be recycled for another purpose. Talking of recycling, I don’t have a skip on site and everything apart from dust is stored and will be used for another job. Internally all our efforts have been on the upstairs of the house. Upstairs is an easy win to get completed as it’s just our two children’s bedrooms and an upstairs living area. A bit of time has been spent with our MDF skirtings, architraves and cills. We used real wood in our last build project and it has moved slightly over the years, MDF won’t do this and is cheap, but requires work in sanding and painting. Carpets are due to be fitted at the start of January and once these are down it will just be electrical sockets, lights etc to finish the rooms. Internal decorating can then commence downstairs. That’s about it, the kitchen has been fitted and downstairs flooring is done but both are covered by copious amounts of cardboard and I’ll upload some photos once this is removed. Thanks for reading. This will be the last post for 2019, hope everybody has a great Christmas and best wishes for your projects in the New Year!
    11 points
  43. Well, it’s been a month since my last blog update. We've witnessed out first concrete pour and now have floor joists so we are all set to build the next floor. The bracing plan we have from JUB looks like we have the potential to pour the second floor and gables in a single pour. This is a decision I'm only too happy to leave to the builders who continue to impress us with their ability to get on with a job regardless. In my last blog we had got on really quickly and had the ground floor pretty much ready for a concrete pour. We needed to wait as there was no rebar on site for the cantilever lintels for the first floor. Our structural engineers had provided a revised structural plan toward the end of February, but it did not have a bar schedule. One was requested and sent through quickly. So far so good, we had the second lot of blocks scheduled for delivery on the 24th March. The original schedule allowed the pour and joists to be in place prior to the block delivery. At the same time as this was progressing the pricing for the next phase was finalised and we gave agreement to proceed. A hiccup with the joist delivery delayed work on site. On a small site the second block delivery pretty much took up all the available space. ICF blocks and a cramped working site are not good news. The ICF is pretty dense but it’s easily damaged when it gets in the way. We ended up playing shuffle the blocks to get the remaining work done and for the first pour. Our builders did a splendid job and just took it all in their stride they were careful with the blocks and didn't complain about the site restrictions once. We had been warned that pours are not for the feint hearted, thankfully in the end ours went pretty well. The only real surprise was the bottom courses of blocks on one side of the build started to move outward on the raft. Fortunately it was spotted and the pour was suspended while Mike and the other lads added some more shuttering. With the new shuttering in place the pour continued and was completed without incident. Apparently it's unusual for the bottom row of blocks to move, but given they are not keyed into the raft and are subject to the greatest concrete pressure it's not entirely surprising. The blocks on the second floor will be keyed into the existing blocks so they should not suffer. With the pour done it was time to get the ledger beams in place to take the first floor joists. Our structural plans had the ledger beams fixed by bolts at 500 centres with the joists at 400 centres. Sounds OK but in practice it’s not ideal as it means you get clashes of beams and bolts, so the plan was revised and the bolts put in at 400 centres so they would not clash with the joist. Ledger beams in place the joist went in pretty quickly, transforming the house. Once you get past the ground floor you need to get scaffold in place for an ICF, not to build from but to prevent possible accidents if someone were to fall through the blocks from the inside. Our builder wanted us to arrange the scaffold, not sure if this is the norm, I suspect it’s liability related. We have used a local firm ROM Scaffold. Their guys arrived on Wednesday and pretty much had completed their work on the Thursday. The scaffold will also allow for our window installation and rendering. Looking forward to getting the next floor up and starting work on the roof.
    11 points
  44. With the 2019 season now here, I've spent the last couple of weekends doing a bit of tarting up around the outside of the wee house. Little things that you don't think really matter, but the end result looks far more 'finished'. I was never very sure how to complete the gable ends of the house- whether to box them in or not- but eventually decided to kill two birds with one stone and use the space for a log store. I think it looks pretty good, and it's tempting to do the same on every side of the house, although those elevations do see a lot more wind and rain. My current obsession with processing my log pile is all down to a fantastic book I was given: 'Norwegian Wood- chopping, stacking, and drying wood the Scandinavian way'. Highly recommended, and an absorbing read even if you never intend to ever light a fire. The other bit of work has been to create a gravel path around the side of the house, and so properly edge the gravel area underneath the house. The only downside of all this work is that it makes the lumpy lawn look even worse than it did before
    11 points
  45. Moving on to day 2 of the timber frame erection, I make no apologies for this photo-heavy post as the pictures speak far more eloquently than I can on the subject matter. Especially as I don't know the right words for much of it. It rained overnight here in Dorset, but nothing disastrous and it was all gone by a couple of hours into the morning. Here's how I left the team yesterday evening: This morning, another day, another crane. This one, I think, was even bigger, but it hurt my neck to keep looking that high, so I can't swear to it. Along with the crane was the next lot of timber frame components, but also the steels for the ground floor ceiling/first floor. There's a lot of steel in my building and whilst being very good for the structural integrity of the building, it's pretty rubbish if you want to stick an MVHR duct through it. At the production stage, my MVHR guy liaised with MBC to request penetrations through the steels for the ducting so that we didn't have to try and deal with this after the event. Here's one such steel with the right holes in the right places. Again, the crane did its thing and shifted all the posi joists into the interior the building and helped position the internal stud walls. All the steels were craned into position as well. The posi joists were man-handled up onto the steels: This is the run of the posi joists, looking from the eastwards from the west facing window. This is looking from the end of the living/dining area towards the kitchen and utility. This is looking back towards the building from the field. The silver box is the attached garage which will not be part of the thermal envelope; we haven't yet decided whether to put any insulation into this, but that can come later. The interior of the garage looking out to the field: A shot taken from the scaffolding. I'm standing at the west side of the living room (where the field is) looking over the lane and the fields beyond. For those of you who know north Dorset, that's Hambledon Hill near Blandford Forum in the distance. And finally, this was resting on the joists upstairs. It pleases me greatly.
    11 points
  46. We have our building warrant, FINALLY. I have a new job. The small one has started school. MBC are here. The glorious day of the 29th August arrived, and so did the vans, carrying Brendan's crew. The sun was shining, tonnes of sand were delivered and painstakingly spread out. It's amazing how much time the MBC boys took to make sure everything was exactly level before carrying on, I found the level of care that was taken very reassuring, and of course Sean was on hand with a terrible joke whenever required. Sometimes, also when not required. Our months of waiting for the building warrant were not completely unproductive as we now have a pimped out site office, including a cast-off white leather sofa (practical colour choice for a building site), high speed wifi, a gopro to capture the build, a desk (with executive chair), first aid point, filing cabinet, H&S kit storage, many many many copies of all the plans, and most importantly of all, a tea/coffee point with fully stocked biscuit drawer. "Luxury!", as the MBC boys proclaimed. Drainage channels were hand dug the next day - a nervewracking time with measuring and re-measuring. The brand-new-just-out-of-the-box Bosch laser measurer was ceremonially launched from the top of the rubble pile by the small one, landing with an ominous crunching noise. "That will hardly have affected the accuracy at all", we thought. Still, at least we know who to blame if all the drains are in the wrong place. Over the months/years we have had various thoughts about where the kitchen island should go, but now we come to decision time. The drains and conduit must go in, today, and they are non-changeable. The island will be all our workspace (the rest is floor to ceiling units) so needs an electrical feed and hot/cold water as well as a drain for the sink, waste disposal and dishwasher. So, instead of making a decision that will inevitably be wrong, we decide to put in the two final options. 1: The architect's recommended positioning that we think is too far away from the sunny spot 2: Our preferred option, closer to the large sliding doors We try and position the pop ups in such a way that the unused one will be under a sofa or table and hopefully not too noticeable. It is almost guaranteed that the architect will be right in the end, as he always is, but it's a struggle to commit at such an early stage. The unused one will be cut off, and topped with an official plaque set into the floor, engraved with "always listen to the architect". We're justifying it as a feature. The next day was the delivery of the EPS on a very large lorry. Our site is right in the middle of town and the access is surrounded by garages and illicit parking. This time of year, there are no students around, so although the lorry is a tight fit, there are no hastily abandoned cars in the way. Next month though.... The EPS ring beam is fitted and the footprint of the house becomes rapidly visible. Although pre-warned by our architect that the space would look small with no walls up, we are both thoroughly freaked out and convinced that the rooms are all too small. There is measuring, re-measuring. comparing against plans... but nothing we can do. Thankfully, on our way back to the rented place, we drive past a new build estate that is also just at foundation level. We slowly realise that the footprint for those homes contains a 3-bedroom house AND garage. Ours is generously sized in comparison, to say the least. The next few days are taken up with making steel reinforcing cages, laying UFH pipe and checking the drainage (again). My time is spent at work, obsessively checking the weather forecast. We have, against all sensible and knowledgeable advice, decided to attempt a smooth concrete finished slab. No tiles, carpet, wood, screed, diamond polish … nothing. Trying to explain this concept to the many people involved has not been easy. Reactions have varied between trying to convince us that diamond polishing to a mirror finish is hideously expensive (we don’t want a mirror finish – there are deliberately no shiny surfaces in the whole house, as I am obsessed with matt finish and hate polishing) to “but it’ll look like a B&Q warehouse!” (my dad). MBC are also not keen AT ALL, due to a problem they had with a previous job where the finish didn’t work and all the window/door thresholds had to be redone to allow to an additional screed to go on top. Showing people a photo of a farm shed floor that had been done by a friend by just powerfloating the surface for longer than normal did not help. The conversation went along the lines of the following: “This is the finish we’d ideally like, it’s a farm shed.” “…..? A farm shed? For cows?” “Yes” “But, polished to expose the aggregate? What kind of aggregate do you want?”. “No, no aggregate. Not polished. Just powerfloated.” “But it won’t be shiny, and that needs specialist tools.” “We don’t want it to be shiny. Just smooth. Like the IKEA warehouse. Or B&Q”. “………….really?” “Yes” “hmmmm.” (sucky teeth noises follow..) The process was somewhat wearing, but we rode confidently over everyone’s objections and doubts anyway and carried on. One thing we did know (from our farm shed creating friend) was that rain during or shortly after the pour would be bad. Very bad. It’s September, in Scotland. Could have been worse. Two week ahead forecasts are notoriously inaccurate. Right? Right? I had seven different weather apps on my phone at one point, all saying the same. Thunderstorms. A 14 day forecast went to a 10 day one, then a 7 day one .. rain all week, particularly heavy on the day of the pour. Just to put the cherry on top. The day before we poured the floor, it tipped down all day. Not 5 minutes passed without freezing rain. The next day, I left for work, having deleted all the weather apps and given up all hope of a polished floor. At the site – not a cloud in the sky. Brilliant blue skies, sunshine, tonnes too much concrete. The MBC crew powerfloated the slab for much longer than they normally would, and by the time I saw it at 8pm that night, it was as smooth as we could have wished for, and a beautiful mottled grey. If I wasn’t a rabid atheist, I would have sworn I heard a troop of celestial trumpets playing. So, a perfect end to a brilliant first stage of the build.
    11 points
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