BUILDING PROJECT

GARDEN ROOM DEMOLITION

May 2008
To make room for the new extension, the 1970s single-brick wall lean-to 'garden room' had to be demolished. This also involved removal of the heating system and old oil tank.
Despite a 14 inch thick concrete sub-floor that had to be broken up and removed, this project was achieved on a single Saturday.

FOUNDATIONS

May 2008
The main foundations were dug using a 1970s Whitlock digger. The old'uns are still good'uns. Supplementary excavation for the internal wall foundations was made with a JCB 8014 1.5 ton mini-digger hired from Jewson's - cheers Kevin!
A few surprises lurked beneath the surface - such as having to go down nearly 2 metres in some places to clear old Norfolk Red bricks, presumably from earlier buildings on the site.

HOGGIN INFILL AND OVERSITE CONCRETE

Early June 2008
The extra depth in critical parts of the foundations meant that almost 12 cubic metres of concrete were needed before the trench blocks could go down. The slope of the site demanded extra type1 hoggin at the East end but 40 tonnes eventually brought us up to damp membrane level.
Just 10 more cubic metres of concrete and the oversite slab was in...

BRICKWORK STARTS

THE FIRST BRICKS ARE LAID

The bricks are Maldon Antiques from Hoskins Bricks. These are manufactured to look like reclaimed bricks and come in a variety of shades and 'conditions' - but unlike actual reclaims they meet all the modern standards and you don't have to end up chucking half of them straight in the skip!
Our main man, Tony, is using a lime-based mortar for it's texture, workability and downright loveliness. And the sun just keeps on shining...

LAYING THE DRAINS

June 2008
A couple of days away from the office, ideal opportunity to get the drains in! We've got to install a sewage treatment plant since the ground conditions in the rear garden (lots of heavy clay from about 18 inches down) won't allow a normal septic tank.
That'll come later, for now its digging out, installing 3 inspection chambers and connecting up all the outlets with underground pipe work.

SCAFFOLDING 'FIRST LIFT'

June 2008
Everything's taking shape now and its time for the first lift of scaffolding so that Tony doesn't have to stand on tiptoes to reach the top of the walls any more.

INTERNAL BLOCKWORK

June 2008
The internal layout begins to take shape as the block work goes down

GROUND FLOOR LINTELS

July 2008
The various Catnic lintels are put into place over the window openings.

EXCAVATIONS FOR THE WASTE TREATMENT PLANT

July 2008
The rear of the site consists mainly of clay from about a foot down. Clay doesn't drain efficiently so the Environment Agency requires that we use a Waste Treatment Plant instead of a traditional septic tank. We'll pump the treated effluent directly to the surface.
The plant requires a hole to be excavated 2.4m square and 3m deep. Inlet invert is at 1.5m.
Anybody want 8 tonnes of clay?

INSTALLING THE WASTE TREATMENT PLANT

July 2008
The Titan treatment plant weighs a third of a ton but is somewhat fragile, so it's a gentle operation to lower it accurately into the hole in the ground.
It also has to align perfectly with the end of the underground drain. After a little bit of pushing and shoving everything slips into place - Success!

STEEL BEAMS FOR THE FIRST FLOOR

July 2008
A network of 25 steel beams are needed to support the upper floor and roof.
The first batch, including the 3 largest at a third of a ton each, are manhandled into the structure then carefully hoisted into position with a combination of the Genie Lift and manual persuasion.

FLAT ROOF REMOVAL

July 2008
The leaky flat-roofed bathroom needed to be incorporated into a continuous pitched roofline. Ply boarding was applied to the new rafters below the roofing membrane due to the low pitch.
This job needed to flow smoothly into the next section - the replacement of the utility area roof.

KITCHEN/UTILITY ROOF REPLACEMENT

July 2008
Following on from the previous day's work lowering the roofline of the flat-roofed bathroom, now its the job to replace and raise the roofline of the existing kitchen, which will become the new utility room - eventually!

FIRST FLOOR CEILING JOISTS

July 2008
A ridiculous number of 200mmx50mm joists were laced into the inner walls and set on hangers within the steel substructure.
Whilst this was taking place the second stage scaffolding was erected, ready to make a start on the first floor brickworks

ROOF LEVEL BRICKWORK AND WALL PLATES

August 2008
First floor brickwork and internal block work is completed, and the timber wall plates installed ready for the roof construction

STEEL ROOF PURLINS

August 2008
The roof is a traditional 'cut' roof using steel purlins and ridge beam instead of timber trusses.
Trusses would prove impractical due to the relatively low roof height combined with the 6m span.
Careful design and appropriate brick pads and supports mean that the purlin beams - each in 3 sections - can be manually lifted into place and bolted together

ROOF RIDGE AND RAFTERS

September 2008
The last of the steelwork is lowered into position mechanically, perched seemingly precariously upon the block work and engineering brick pads.
The rafters are positioned and we're ready to begin the final building phase!

ROOF STRUCTURE COMPLETE AND WATERTIGHT

September 2008
Timber ceiling joists bolted across the rafters complete the roof structure. Cast iron wall ties, although not structurally necessary, are fixed through the gable brickwork to add visual interest.
Finally the waterproof membrane and tile battens are fixed, making the roof watertight.

FLOORBOARDS

September 2008
Tongue-and groove timber floorboards are laid to make the floors for the bedrooms and landing, and marine grade ply to the bathrooms.
A Paslode frame nailer makes short work of nailing the timbers to the joists, so the weekend team completes the task with half a day to spare...

FIRST FLOOR STUDWORK

September 2008
There are only a few timber stud walls - mainly for the en-suite bathrooms - so these are quickly constructed.

GROUND FLOOR SCREED

September 2008
The 'Jablite' polystyrene insulation is placed around the heating pipes throughout the ground floor, the floor screed is pumped in and hand finished.

LOUNGE EXTENSION ROOF

October 2008
Despite the inclement weather, the roofing work progresses.
Having tiled the rear section of the main building, the roof to the rear of the lounge is constructed and tiled.

OAK BEAMS

October 2008
Large beams in American white oak are prepared, routed, sanded and eased into the block work across the width of the two largest rooms - the lounge and kitchen.

MAIN SCAFFOLD DOWN

October 2008
The main build is complete, and the scaffold can now be removed. There is still plenty of scaffold around the front of the original property, where work will now start to join the new roof to the existing one.

WINDOW INSTALLATION

October 2008
As the days grow colder it's a relief to get the windows installed. Now the building is more or less watertight the internal works can progress...

FIRST FLOOR DRY LINING

November 2008
The first floor dry lining has been taking place gradually during October, and now the main building is watertight the plasterboards can be completed and the scrimming gets underway.
There are two Velux 'sun tunnels' installed over the stairwell which give a dramatic effect as the sun moves from East to West during the day.

ROOF COMPLETION AND SCAFFOLD REMOVAL

November 2008
The most complex part of the project was always likely to be the joining of the existing roof sections on the original cottage to the new ones; but with meticulous planning, perseverance and skill - and despite the non-stop rain - the old now blends perfectly with the new.
The West side, with 3 different pitches to combine into a single valley, was a real challenge.
With the dark nights now upon us and the bulk of the build complete we say a fond farewell to Peter, who has been Toni's right-hand man from the start of the project.

BATHROOM TILING

November 2008
The bathroom and toilet walls are half-tiled in travertine, the floors in slate. The lack of uniformity in these natural materials makes the tiling a process of selection as much as one of merely fixing.
This is clearly going to be a long job!

CEILINGS AND WALLS

December 2008
The ceilings are smooth-skimmed using Aertex instead of traditional plaster - this is designed to minimise the inevitable cracks that usually appear once the building is subject to the everyday heat and humidity of occupation.
The wallboards are scrimmed and filled ready to be sanded smooth for painting.

INSTALLING THE OAK STAIRCASE

December 2008
The staircase has been hand crafted in American Oak by local company Stalham Joinery. At last the old pole ladder can be removed and the flight, newels and balustrades installed.
As soon as the stairs are ready the adjoining walls are quickly boarded and prepared; the transformation of the last remaining 'heavy' section is complete.

KITCHEN

December 2008
The kitchen units and worktops are positioned according to plan and the various appliances are installed. As is often the case with kitchens, there is much to-ing and fro-ing due to incorrect and incomplete cabinets but at least now we're only the one door missing.
As we approach the end of the year most sections of the project are nearing completion.
The finishing deadline is February half-term holiday.

FLOORING COVERINGS

January 2008
The various flooring coverings include oak boards in the hall and landings, slate in the bathrooms, ceramic in the kitchen and carpet in the living rooms and bedrooms.
Some hasty rescheduling is arranged so the decorating works keep just ahead of the floor covering work - well almost.

BATHROOM FITTINGS

BATHROOM FITTINGS AND EN-SUITES

The fittings for the bathroom and en-suites are installed - everything lines up with the pipe work laid some months ago

LOUNGE

February 2008
The lounge area has been used as a store and workshop for some months, but finally it's cleared out and turned into a proper room!