Extension Oversite Concrete

Before Andrew the blockwork guru can carry on, we have to sort out the oversite concrete.  The

The first job was to bail the moat out which took 2.5 hours

Then we filled the gap between the blockwork- that took about 5 hours with the concrete mixer going all the time. We used 7:1 lean mix. 

We tamped the concrete and James had a novel technique for finishing off the top.

Job done

Filling the inside

Services entry

 Nearly done

 Just to tidy up final level and sand blinding

 

Getting the level for the Gable Frame

The steel gable frame will form the entrance for the barn, getting the level right is important.
We had to dig the trench which was really hard work- about 5 hours, for the frame to sit on and for the dwarf retaining wall.
Good job we could use the laser level to sort out the levels.

The builder lasted an hour and I lasted 5 hours

Pretty messy boulder clay

The laser was great at getting the level we needed

 All of the earth outside is to be lowered later 

The challenge was to try to get the level of the front and back room sorted out in the end we went up 100mm 

Roofing Joiners

On Tuesday 22 September the Roofing Joiners arrived from Amlwch - there had been quite a lot of faff over the joists which were supposed to be 175 x 50 however they couldn't get the long lengths 6 metres for the back side of the roof in 175 x 50, so we moved to 200x50 for the lot which meant that all of the insulation could go in between the rafters well 175mm of it at least with 37.5 insulated plasterboard on the inside.

Preparing the rafters

Setting out

Each rafter was birdsmouthed on the ridge and the wall plate- they were very accurate 

The yard side was easier as it was fairly square but the backside which was much longer took much more thinking power.

 The velux's all 5 of them have doubled up rafters.   

The two sides of the roof are at different angles, the ridge is still to be trimmed.

The gable ends are to be filled to support the gable ladders.  

Ridge Beams

We ordered the steel ridge beams and they were delivered about a week later. Each one was about 6 metres long - 203x133 and weighed about 180kg.
We made an arrangement for a HIAB to lift them onto the ridge, but the following morning the builders merchant arrived with an order and lifted them on with his HIAB for us.

 This one went on then I realised it was the wrong side so we had to start all over again - each one was a slightly different length!

Job done and wall plate fitted ready for the rafters

Making the Crog Loft Doorway

There is a small window between the two halves of the barn, this needed to be transformed into a doorway to the crogloft.
We had to remove the top of the wall and then open up the doorway. James helped me with this, then we rebuilt the top of the wall and laid new lintels- 140cm x100cm which were heavy to lift. Then we used about 20 blocks to rebuild the  top of the wall to take the padstones for the new steel ridges.

Concrete Foundations

Concrete Foundations to the Extension and Some Blockwork

The next job on the list was to lay the concrete foundations- 900mm wide and 300mm deep- 4cubic metres of concrete. We used wooden pegs to mark the height of the concrete.
It rained all morning right upto an hour or so before the concrete lorry arrived.
We needed to step up the foundations to the underside of the existing stone wall. We did this in two steps using shuttering plywood.  It was all good apart from some concrete oozing out under a step which meant that instead of a perfectly flat base there was a small slope and it was about 25mm out- which Andrew the block worker said not to worry about as he would make it disappear!

 

 Setting out the Blockwork

Making sure all is square

Laying the first blocks

The first 3 courses in place- the next job is to bail the moat out and then infill and oversite concrete the floor before Andrew completes the  blockwork.
  

Removing the old Extensions and Digging the Foundations

The past couple of months have been busy at Cae Helygen.

Problem with the gable end pointing
We had  re - rendered the  gable end above the kitchen but unfortunately there were still some damp patches on the inside wall, so we used the kango to take out all of the pointing and then re- pointed  the wall. We also introduced a stainless steel bell bead and flaunched it to protect the lead flashing joint. Finally we need to paint a breathable waterproofer called Kingfisher on..... hopefully it will work.
The other Gable end
Sarah and Jonny helped us to point the North gable end- CW their names in the pointing.

First fix electrics
Steve the sheep man who is an electrician did the first fix with me assisting him for about 8 days- lots of up and over the inside of the pitched roof - with one channel of cables  behind the main room stud wall.

M1 motorway for cables

Kitchen

Positioning lights

Lots of pulling cables through and cutting slots in insulation

drilling 3 foot walls

A bit drill bit

Studwork
We fitted the studwork 3x2 studs to all the inside of all outside walls, and 70mm of insulation between, and then 25mm insulated plasterboard over the top.  It all took some time and effort but its nearly all done now.
We used a breather membrane behind the insulation

Bathrooms
I think we have decided that we need a small bathroom in the loft which is sort of above the downstairs bathroom- so that should make sorting out the services easier.
I've just got to remember how to do the plumbing again this time mainly plastic and push fit.
The loft will need a stud wall and we might need another velux.

Bedroom and bathroom internal stone walls
Jen spent a lot of time raking out, cleaning stonework,  [ which had had a lot of cows rubbing on it], and then repointing the walls. Good job Jen.

Kitchen door and the ~Bifold
Ewe plastics in Caernarfon provided the doors, composite from Endurance which are really good, and easy to fit- even though they don't provide fitting instructions!
The Bifold door also finally arrived after some faffing.
I built up the external wall with clockwork cut down with the big angle grinder, and then 4 of us did a trial fit with the doors in but class work out. It was a great fit - and should have been given that I measured it about 20 times.

The bifold ready for delivery from warm core- 

Its quite big at 3620mm- it took 4 of us to fit it

The big challenge was to get he threshold right - I needed to build up the clockwork about 100mm and we had a double DPC

The opening 

The view out

The bifold in- all the finishing would take some time including toe and heeling the glass, fitting the expensive triangles above the bifold and the trims. 

Kitchen door- by Endurance- what a nice composite door

James needed to adjust the steelwork above the bifold to accept the triangular windows- and he then did a reeled which was a great job.
The biggest issue in measuring was the external threshold level and the internal finished floor level.
I made a template to work this out. Then we screwed it into place using steel self tappers into the gable frame which was easy, and used one of the DPC's to lap over the blockwork and a lot of sealant.
What was more challenging was drilling the steel channel at the top of  door.  I drilled pilot holes and then finally a 6mm bolt passed through- there were about 8 of them.
Then we sealed the edges ready to an eternal fillet of cement to match the exterior stonework.
Then we fitted the 2 glazed triangles above the bifold- this was straightforward.
We bought anthracite grey soft board to make the exterior finish- using rapid set mitre glue [ tape surrounding area to prevent glue dripping], and screws with plastic anthracite screw covers to finish off.
We then heel and toed the glass and put he beading in.
To finish of we adjusted the height of the door roles,  and all was good.
Now we just need to finish off the inside.

Plasterboard and Pastering
Next up we are waiting for Dylan to do the plaster boarding and plastering- I have had a small hernia operation so not lifting for a few weeks.

Finishes
We are now in the process of finishes, its a headache, we want to keep as much authenticity for the barn as possible...

Final Stone wall
Steve finally came back and built the short 5 metre wall to enclose the courtyard.

Stone ready for walling

Steve finishing of his arty wall building- he has a great eye for a wall.

A few other pictures

 The field has been cleared of a couple of hundred tone of earth and re- seeded

 The Swallows

The swallows tried to nest in the barn, but we finally encouraged them to bred in the workshop- they have had 2 broods and come to the barn often to see whats going on.
They will be off soon to South Africa.

 

 The arrow
That was for the small hernia operation I needed which has forced a short halt to heavy lifting!

How many ladders does it take, Jen applying kingfisher breathable sealant to the kitchen.