This is an exciting opportunity to influence
the high quality conversion of a barn.

Site Diary / Sep 07 - Nov 07
 

September

Whilst concentrating on the Dairy we did do remedial repairs to the Barn West Wall to ensure that it didn’t deteriorate any further (the West wall of the Barn used to be an internal wall as it was protected by another barn that has since collapsed) and also the internal beams as they looked as if there had been a fire once upon a time and therefore were beyond repair. With acros in place to hold the trusses in situ we started well & truly on the Barn by firstly taking down the internal first floor and all the old pantiles from the roof. A lot of the tiles were not worth salvaging so the vast majority were thrown down into the barn itself. The lovely clean barn that I had recently swept out quickly resembled a building site once again. The taking down (or throwing down to be exact) of the tiles soon exposed the true condition of the rafters. Thank fully a lot the rafters were in good condition and only required repairs where they attached to the wall plates. The wall plates themselves needed replacing. The queen trusses were also salvageable – although 95% of the trusses were in condition the parts that had be exposed to the elements had started to rot.



A brilliant solution to this problem rather than replacing the lovely old trusses was to scarf away the rotten parts of the beam & replace with magnificent shoes. A local ironmonger ‘Paul’ crafted the specifically engineered shoes which Andrew & the team then fitted (this was a piece of art in itself). Talk about the Egyptians and their wonderful construction techniques, I think Tutan Karma would have been jealous of the Thealby Grange Development team. With the help of a scaffolding tower ( kindly loaned from Railton Price), a block and tackle wrapped around the rafters, the extremely heavy shoes were hoisted into place. It was amazing to watch the team work so closely together ( although their language seemed a little foreign in places). Once secured in place by the biggest of bolts it was time to do my bit by spraying the shoes with beautiful red anti corrosion paint (this of course was the most important bit !)
Once the trusses and rafters were repaired it was then time to felt and batten the roof, and insulate with the high tech thinsulex insulation.

October

Whilst the felt & battening, insulating of the roof was being done, the rest of the team concentrated on repairing existing window & door openings as well introducing a couple of new ones (as per planning consent). Thank fully the weather was still on our side therefore our builders managed to soldier on quite effortlessly.



It was very exciting to see the Kitchen opening to the garden being created as it opened up the hallway, lounge and kitchen quite significantly. With needles in place it was a tough old job boring through the ironstone walls which were certainly built to last !!! Although at times we felt we were using our teeth, we did hire an excellent hand held pneumatic drill to make the job less painful ( I even had a go with this which was great fun). It was also back breaking work removing the stone ready to be reused else where on the build but I kept thinking of the calories that I was burning which made me work faster (nearer to coffee time and a choccie biscuit).

Attention then turned to part of the Barn sub-floor. As the ground floor hallway and lounge will be on split level then the upper level was prepared firstly for the concrete subfloor. At this stage a lovely couple also fell in love with the the development and subsequently put in an offer for the Barn which we accepted. They decided that they would like ground under-floor heating which was perfect timing before the concrete was laid. This therefore meant that rather than sand blind, damp proof visqueen and floor insulation being laid prior to the sub-floor, we only laid the sand and damp proofing (in under-floor heating the floor insulation is added after the sub-floor). A former was made for the step down to the lower level of the ground floor.

As in the Dairy, we called Easimix (who only charge us on the concrete that we use and are extremely professional and patient). Concrete was mixed and poured through the entrance to the barn whilst the gang (donned with attractive wellies) levelled the floor . Mr Clyde ( site security) decided that the barn was his paws of fame and pit pattered across the fresh concrete –thank fully it wasn’t the screed that was being laid.

Whilst the subfloor was setting the builders covered the internal wall to the kitchen, lounge, in the ironstone that was removed from kitchen/garden opening. My husband Andrew had the lovely job of cutting the stone with the chain saw which was one of the most messiest and back breaking tasks imaginable – it was certainly worth it in the end as the wall looks fantastic and will make a real feature in the living area.

Progressing onto lintels, the RSJ kitchen lintel and the reclaimed (planed and sanded by my very hands) beam from the lounge, kitchen was raised into place.

A Sovereign injected damp proof course was inserted in and around the Barn walls and tanking in the kitchen area, whilst the step down to the lounge floor, and Dean’s creative curvy wall in the hallway housing the downstairs toilet and wall of the study was being composed.

Andrews idea of opening up the stairwell from the hallway to enable views of the ceiling rafters and skylight is an excellent one and again will add to the beauty of the barn. He is also proposing to continue the curve of the downstairs wall upstairs through to the upper hallway to ensure continuity of shape.

The lounge and kitchen sub-floor was then prepared ready for the concrete to arrive again, which enabled the builders to wear their wellies again!!

Whilst work was progressing internally the frames for the skylights were made and put into place ready for the windows to be fitted prior to tiling the roof. As the Barn is Grade II Listed, the skylights are conservation style with two of them having rain sensors on for convenience as they would be impossible to reach to close once the conversions completed.

The roofers job was then to tile the Barn roof using traditional pantiles in keeping with the Grade II conservation of the development. It is amazing to watch how quickly and efficiently the roofer moves along the battens with a pile of tiles on his back. In no time at all the Barn roof was wind and water tight and looking great. The detail around the eaves was particularly impressive and really sets off the gable end of the Barn.

Once the roof was completed then attention was paid to the Gable end of the Barn by replacing the old bricks around the window and door opening and chipping out and repointing the old lime render.

October was certainly a very busy month but again a lot was achieved by forward planning and hard work.

November

For the flooring for the 1st floor it was decided to use TGI silent flooring which was recommended through Howarth Timber. Brilliant service from the Howarth Timber team as they provided a detailed design in order for the first floor to be installed to spec.

In preparation for the beams and floor joists the builders measured and knocked out holes in the walls which meant once the beams arrived they could be hoisted into place. When the beams arrived thankfully the Howarth Timber driver not only parked his lorry as close as possible to the Barn entrance to make life easier, he helped the team lift the beams off and into the Barn lounge area (they were mighty heavy but look the business once in situ!!). Once inside the Barn the men could then hoist the beams up into place. Again Tutankarman would have been impressed as the good old block and tackles were hired again

Beams up, joists up which meant it was time to lay down the 18 mm thick chipboard for the flooring by glueing and nailing the boards to the joists. In no time the Barn started to look more like a home which is made easier to visualise each of the rooms (we are becoming more & more excited about the conversion, which is equally shared by the couple who wish to live in the Barn)



The next task on the agenda was to frame and stud all the internal walls ready for the insulation and eventually the plasterboard. A million cuts and a million nails later (thankfully modern technology meant circular saws and Paslode Nail guns made life a lot less ardous) both the downstairs and upstairs of the Barn was completely studded out in one week only!!!. I cannot believe how Andrew managed to frame and stud the gable ends in such a short space of time as it is a mammoth task in itself.

Once again deadlines were met to enable the Polyurethene guy from UCS to spray the insulation to the walls and roof to enable the Barn to reach far beyond the recommended U values that are so important in today’s buildings. This was brilliant to watch. Once UCS taped off the exposed beams and around window and door openings then they set to spraying firstly internally under the ceiling rafters and then the 1st floor and ground floor walls. Fasinating stuff as the Polyurethene is squirted out of the contrapsion at above boiling temperature which then reacts with the oxygen and sets like a foam. At the end of the 3 days the Barn was insulated

Whilst the Barn was being insulated the rest of the team turned their efforts onto the Dairy again.

 
 
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