The Build - Photos

Progress of the build

The list below describes the key stages of the build with accompanying photographs for illustration. This list will be updated at regular intervals - the latest development being at the top of the list, the preceding stages descending the list.

Finishing Off - 19th Feb 10

The finishing render coats are completed and snagging of the interiors and exteriors continue. The project was delayed by a number of weeks due to both the severe flooding in the Cumbria area (thankfully did not directly affect this site) and the harsh winter.

However, things remain on course for a planned handover to the client on March 8th 2010.

Acoustic and air-tighness testing is completed (figures will follow) which gave very satisfactory results and the necessary approvals gained.

Landscaping, snagging of the properties and general tidying up continue.

Render Coating Applied - 9th Jan 10

The completion of the reinforced layer application now means that work can be quickly completed on applying the final, texured and coloured render coating. This is simply applied as with any render coating giving the properties their final appearance.

Pre-rendering Preparation - 9th Nov 09

The external insulation layer has had a mesh reinforcement layer adhesively cemented in place across the entire surface and then covered with another layer of powerful, hardening adhesive. This results in an extremely strong, resilient, airtight and water proof structure.

The next step is the final finish of render which will be coloured to match existing housing in the surrounding area.

External Insulation Goes On - 2nd Nov 09

The 125mm thick layer of Neopor insulation is fixed to the entire external wall surfaces. This is achieved by using a powerful adhesive and is then mechanically fixed to the wall with screw-in fasteners.

In the photos opposite the insulation layer has been adhesively and mechanically fixed to the wall. The next step is to apply the reinforcing mesh prior to applying the final render coating.

Roof Tiled & Windows Fitted - 23rd Oct 09

The buildings become weatherproof as the roofs are completed and the windows are fixed into position.

The windows being used are high-performance, argon filled triple glazed units with a u-value of only 0.8.

The roof tiles were specially selected for style and appearance to be in keeping with the local area.

The Roof Takes Shape - 12th Oct 09

The roof, constructed from Thomas Armstrong Timber Ltd trusses begins to take shape. Soon the building will become weatherproof.

Internal Walls Continue - 5th Oct 09

Work continues to bring the Airtec internal walls up to full height.

Airtec blocks are easily cut into thinner coursing units as required.

Roof Goes On - 1st Oct 09

Timber roof trusses supplied by Thomas Armstrong Timber Limited are delivered and installation commences.

Thomas Armstrong roof trusses are produced in accordance with the latest Alpine Automation software design package and treatment of all product is carried out using Protim E415 micro-emulsion wood preservative. Fully qualified designer/estimators are available to provide total roof package solutions.

All trusses are manufactured to ISO 9001 and BS 5268. We are members of TRADA and the Trussed Rafter Association.

The roof is designed to achieve a U-Value of 0.10 W/m²K

Roof Level Reached - 28th Sep 09

The external walls reach roof level, the internal walls progress upwards. The aim is to get the external walls and roof on to weatherproof the properties.

The Airtec walls offer a stable and easy substrate for fixing roof components, joists and lintels onto and as the picture opposite shows, Airtec blocks can be easily cut into special shapes to accommodate fixings if necessary.

The exposed, free-standing gable end wall remains stable and strong due to the strength of masonry walls glued together by thin joint mortar adhesive.

Internal Walls Start - 23rd Sep 09

Airtec Party Wall blocks (100mm in thin joint) are used to create a double leaf Robust Detail compliant party wall between the dwellings.

Extra credits can be obtained in the Code for Sustainable Homes for using Robust Detail party walls.

External Walls Start - 21st Sep 09

The solid external Airtec XL walls start to go up using thin-joint mortar construction. THis method makes for a speedy and simple build with drying times of less than 20 minutes per course. The unique dimensional accuracy of Airtec blocks is perfect for this way of building.

A layer of mesh specifically designed for thin joint construction is placed within the mortar layers to minimise the effects of any movement and point loading.

Thin layer mortar and ancilliary components were supplied by Thin Joint Technology Limited.

Block & Beam Floor - 2nd Sep 09

Beams for the Thomas Armstrong division ACP Ltd were used and Airtec Large Format 3.6N blocks were used as the infill.

ACP produce at four manufacturing plants using the most modern of methods and equipment, for the quality production of a range of Prestressed Concrete Products and Precast Concrete Products, ensuring that the highest standards of quality are achieved.

ACP (Concrete) Ltd is a full member of the British Precast Concrete Federation
and the Precast Flooring Federation

Each Airtec Large Format block is 620mm x 430mm x 100mm but weighs less than 16kg, making them easy to lift and install and as with all Airtec blocks are easy to cut, shape and bore through to accommodate services.

The floor will achieve a U-Value of 0.12.

Foundations Laid - 24th Aug 09

After site clearance, a ring beam foundation system is used for ease and speed of build. The external walls and external insulation layer will eventually be built directly onto these.