Category: Garage

The Garage

  • Back Wall Constructed

    We have constructed the back wall of our garage. It is still lying flat on the floor slab at the moment as we are still waiting for the delivery of the cement boards! All the joints and the OSB panels were glued and nailed together in a few hours (about 5 all together). We hope to reduce this on future walls when we employ our new glue dispensing machine! We have calculated that this wall will weigh about 300kg (660lbs) and we are planning to slide it up to the top of the mass wall up wooden slopes using the old fashioned block and tackle method. We have ordered a roll of rope and twin pulleys blocks to give us a 4 to 1 ratio pulling power!

    We just hope that the cement boards will come soon! Or there will be lots of grinding teeth noises!

    When we finished the wall construction @ 19:15Back Wall done @19:15 we realised we couldn’t close the shed door! So we had to push hard to slew the door round enough… Then we covered it in plastic to keep our hard work dry.

  • Lintels and corner posts

    The lintel over the windows of the back wall of the garage was constructed in one continuous 8.5metre piece. It was made up of two vertical 90mm by 38mm CLS timber with an 11mm OSB board sandwiched in the middle and topped with another 90mm by 38mm timber lying flat. All was glued and screwed together as per instructions in our Structural Engineer’s report.

    We also made the same sandwich construction of two 89mm by 38mm CLS and 11mm OSB to make the corner posts (4 of them) to allow maximum connective forces when we join the walls together.

    The air nailing gun is not working!! oh drat! o bugger!

    We fell back to good old Turbo Gold screws!

  • Sometimes it’s the simple things …

    The back wall of the garage is very close to the fence and will need to be made in one piece and stood up as the will be no access to the back. The close proximity to the fence also means the wall will have to have a fire proof exterior.

    Simple we thought, just use fibre cement boards to cover the OSB! But when we asked Jewson for some they could only offer strips 125mm wide for soffits! Jewson checked their suppliers and came up blank (other than tile backing boards).

    Internet to the rescue! There appear to be dozens of different sheets available, now to find a supplier willing to ship only 10 sheets… we found a supplier who will send any number you want for a fixed delivery charge. Sheets were £14.50 each and delivery £55! Now we hope the will deliver fairly quickly…

  • Removed slab formwork

    As requested by Kevin we removed the formwork from the slab this morning. The slab as set hard already and can be walked on… though it is very slippery where it still wet!

    Slab has a nice smooth finish and you can see the fibres!

    Fibres in the concrete

  • Garage slab concrete poured

    After the problems bailing out the actual pour went smoothly!

    There were 3 loads of concrete (Agilia Force) delivered between 11:00 and 12:15. Each load only took 3-4 minutes to pour into the formwork! The mix was quite fluid and only need gentle encouragement to spread out evenly, we only had to walk around pushing with our boots to get a good level.

    When we were satisfied we had a even distribution of concrete the Lafarge rep (Kevin) brought out his agitator bars. These are round poles held horizontally with two handles rising up to hold. These had to be used in two passes, 1st pass involved moving up and down about 50mm then advancing by the width of the pole and repeating (this releases any traped air). 2nd pass was a light dabble over the surface to give a smooth finish.

    The rain continued to fall in showers (even hail) while we were working and Daphne bailed out some of the excess water from the corners where it had been pushed by the concrete.

    Finally Kevin sprayed a wax based agent all over the finished concrete to help the slab cure properly.

    Here is an edited and speeded up (16 times) video of the pour.

  • Water, water everywhere!

    Well we had 10.9mm of rain since we finished the DPM Yesterday. That’s over 800 litres of water to get out of the garage slab DPM.

    The job was not as easy as we thought when we started at 9 o’clock. First we tried the submersible pump – no go, the water was not deep enough. Then we used the drill pump successfully for 1/2 an hour before it overheated! At this point probably half the water had been removed. Third try was using sponges and towels! – this worked but was very slow. Then Shaun remembered the wet and dry vacuum cleaner – this worked well, better than any of the other things.

    By this time it had started to rain again! and Kevin (Lafarge man on the spot) said we had got rid enough water! So it time for the concrete.

    Ready for Concrete

  • Its raining !

    According to the weather meter we have had 3.5mm of rain in the last hour…

    This is nearly 270 litres of water in our slabs DPM ‘tank’ . We will have some bailing to do in the morning.

  • DPM is Laid and Sealed!

    The Damp Proof Membrane is lying flat and relatively smooth !

    We started early again (8:30am) to get the job done before the Building Control inspector came! Phew!

    We put down three separate strips, cutting holes where the conduits and pipes comes through and taped all the overlapping joints (at least 500mm!)! We folded like a parcel around the doorways which was a bit fiddly but plenty of duct tape and small pieces of DPM did the trick!

    We also drilled a side hole in the manhole chamber (to the rain water tank) and stuck a short piece of conduit in, to allow the pumped water pipes, electrical cable and perhaps data sensor cables into the rain tank. The height of the chamber was adjusted so that the lid will come just above the finished surface of the concrete slab!

    After lunch, we mixed some high ratio concrete, one and three quarter bags chucked into the mixer, a splosh of water until it was nice and creamy and then gradually put in four buckets (100Kg in total) of sharp sand and stones ballast, mixing all the while until the mixture is just a lovely texture!!

    This works out at a 2:1 ratio mixture which will provide a water tight and seal all the bases of the conduits and pipes to the DPM.

    This is important as the Agilia Force concrete from Lafarge is so liquid that it can find those loose joints and flow like water underneath the plastic and produce problems! !

    We finished off the afternoon by banging in plenty of stakes to hold the formwork and weighed it down with loads of concrete blocks. There is after all quite a weight of material in there and its acts much like a liquid with some sideways loading so we are making sure we don’t have a dam burst!

    And finally we finished off by roughly smoothing out the remaining portions of the driveway asphalt chippings and compacted it thoroughly ready for 3 24tons lorries to deliver the concrete !

    We finished about 6:30pm ! In the dark again ! O Boy!

    Garage Damp proof membrane in place

    Electricity conduits sealedconduit gaggle and rainwater tube sealedearth tubes sealedsewage tube sealedprocessor air supply conduit sealed

  • DPM for Floor Slab Approved

    Our inspector from the building control department came at lunch time and inspected the integrity of our DPM, ready for the floor slab of the garage and as long as we carry on and mix high cement concrete and push it in and around all the conduits and pipes to seal the DPM down solidly, he is happy!

    Well, that’s another box ticked !

  • Garage Slab Formwork done

    As we are on a tight schedule we started work at 9:00am and finished at 6:40pm, this is the longest day we have done so far!

    The morning was spent completing the sand fill up and compaction. Then I went round all the concrete edges and removed any sharp parts. Meanwhile Shaun was preparing timber for the form work.

    After lunch we constructed the formwork for the slab from 300mm high x 18mm thick OSB (recycled from the foundations) screwed to the edge of 150mm x 50mm timber planks. These formed a continuous structure for the sides. After positioning and aligning the sides we fixed then by banging stakes into the soil against the planks.

    We finished by making the front of the slab with the two doorways inset by 100mm, which ment forming  four corners. By this time we were working by floodlight!