Jan 152022

We started the new year of 2022, after we had our mini break, by resuming the construction of Bedroom Two. We needed to finish the floor and to that goal, we created our next air distributor module. Using more left-over floorboards, we made a triangular shape that takes in the incoming air through a 110mm wide socket and goes out four 50mm outlets. It measures 300mm deep so it has time to compress and spread the air out and we also included two manually adjustable flaps to deflect some of the air from the outer most outlets so we can balance the air flow down all four different length ducts to the dispersers locations.

Floor and Walls Constructed for Bedroom Two and Tech Cupboard


Floor and Walls Constructed for Bedroom Two and Tech Cupboard


After it had an overnight of drying and curing, we installed the module in the doorway and then connected up the four orange 63mm flexible ducts and we tested it. Using our mobile Air Generator, we blasted air into the distributor module and out at all four wall dispersers and measured the air flow rate coming out the two sideway facing tubes. With the Air Generator running at maximum speed, we were getting values of 40km/h for the shortest conduit length and 30km/h on one of the longest lengths. We noticed that the rate coming out of the right and left arms of the disperser were not exactly the same which was curious, must be something to do with the way air twirls inside the conduit etc but it did seems to be always the right arm having the higher rates. Anyway, we turned down the fan to its minimum speed to get closer to “normal” flow rates, and then we balanced as best as we could by adjusting the two flaps so all four dispersers were outputting approximately similar air flow rates. Even this test, the air flow rate being used here, is far more than what will be the everyday background rates as for example, this bedroom is about 36 cubic metres of air and we desire about 1 complete room change of air for every hour. That means 36 cubic metres or 36,000 litres of air need to flow in (and out) of the room per hour, this means 10litres per second in total going into the distributor module but splits up into our eight dispersers which means approximately 1.5litres per second for each arm. Our test we did today actually had about 12litres per second of air coming out of each arm and that was the lowest fan speed and it was only a gentle breeze coming out. This means that to satisfy our requirements of 1 room change of air per hour, the air flow is going to be very very gentle indeed for our background flow rates but we can increase the rate when we need to, perhaps to remove solar heat coming in our large windows.
After all that mathematics, we got back to the nitty gritty work of putting in horrible glass wool insulation into the floor space to fill up the remaining air volume above the PU foam rubbish. We used all our left-over chunks of rock wool we had lying around for years and spread it out so it fills it up to touch the underside of the floor boards when it goes down.
Floor and Walls Constructed for Bedroom Two and Tech Cupboard


Then we had to grab 14 more sheets of our 22mm thick floorboards from our outside piles under the tarpaulin but we discovered that our tarpaulin, even though it was double layered, was letting a small amount of rain water through and wetting our chipboard floorboards. It is quite annoying and it is so difficult to keep such material dry. We pulled off our 14 sheets we will need and even though it is wet, it doesn’t look too bad. we used our trolley to transport that load into the house via the front door and laid them all out all over our hallways to dry off overnight before we actually laid them down. We have two sheets that has been indoors for a few months since doing the hallways and we will compare them.
The main pile outside, we put on two more fresh plastic sheeting to try to reduce this water problem and also we laid down a sacrificial OSB board to act as a protective layer to stop sharp claws from birds and cats in making holes in our plastic tarpaulin but we have decided that we will have to move the entire stack all into the house as soon as we have finished Bedroom Two.
Anyway, we proceeded to cover the floor with these 22mm thick chipboard sheets, needing just over two lengths to do each row.
We got it all done but it was noticeable that some of the boards had small swollen sections caused by the rainwater so we will have to sand the whole floor later on to smooth it off and get it ready for the future underlay and carpets.
Floor and Walls Constructed for Bedroom Two and Tech Cupboard


The next job we tackled was to start building the wall finishing layers, including the air channel running around at the bottom. We inserted a line of 150mm high MDF 6mm thick cut sheets to provide a chamber for the air to flow along sideways and drift gently into the room. We did have to make some adjustments to the air disperser because it needed to sit further backwards and avoid being squashed by the main OSB boards when those are mounted on the framework. The disperser under the window was especially tight and we had to split into the vapour barrier membrane and remove some of the glass wool and even a bit of the PU foam insulation too. We recovered the slit with another layer of the black plastic and resealed it with our conformable extra sticky tape. Then we inserted two vertical pieces of plywood behind the CLS horizontal rails around the air disperser and then a 25mm thick batten piece to anchor the disperser back into place.
Then we continued inserting our MDF pieces and completed all the round the whole room, just skipping pass the two doorways, and cutting small rectangle holes to let the air dispersers through. Finally, the top and bottom edges were sealed using black modified silicone glue to both fix the board into place but also to seal it against any air leakages.
Floor and Walls Constructed for Bedroom Two and Tech Cupboard


While we waited for the black sealant to dry and cure, we got on with the two remaining walls inside the Tech Cupboard, putting more 18mm thick OSB sheets. Then, we glued and screwed a collection of 63mm CLS timber pieces around the circumference of the little room at the floor level, then put in two cross rails going front to back and finally put in three further cross rails but this time going side to side, all glued and left to dry and cure overnight.
We nicked one of the floorboards we had lying in our Utility Room, acting as a temporary floor covering so we swopped that one with our left-over rather damp one and use the good one to put in the flooring inside the cupboard, cutting around the metal leg of the Skylight and making room for the cables running down the walls and down under the floor.


We went back to Bedroom Two, continuing with the walls by applying black paint along the bottom of the Air Channel to hide any bright gleam when the carpet is laid down. Next, and finally for the week, we put up two rolls of 100mm thick glass wool insulation and inserted layers inside the structure of the walls between Bedroom Three and Bedroom Two, providing more sound insulation, followed by horizontal strips of the wool insulation to fill the gap up between the horizontal rails, to also reduce any hollow sounds too.
Floor and Walls Constructed for Bedroom Two and Tech Cupboard


We ran out of 100mm thick wool so we will need to order some more rolls to finish off this room but also to fill in all our other rooms too. That will take a few days to arrive so we will get on with the next job of putting up some of the wall panels that have a complete coverage of the glass wool like on the window wall and one of the short walls or we continue with our software and hardware development.

 Posted by at 6:00 pm
Dec 242021

This is a long single report to cover the work during the month of December on Bedroom Two and other jobs. We wanted to get going on creating Bedroom Two so we could move the final loads of PU foam rubbish we got stored outside in the alcove in between Bedroom One and the Great Room’s windows before Christmas arrived.
So one of the first steps was to clear everything out of the room including the huge pile of sheet materials, which got all moved into Bedroom One. Then the horizontal rails, using more of our 63mm CLS timber pieces, were positioned on all the four walls, using the green laser level to ensure consistent height, the level of our flooring. Next, was putting single piece CLS timber across the room, spaced apart by a uniform 600mm distance, each piece being just over 3700mm long. Each one having a leg fixed at every 600mm along the joist for support. A section near the on-suite doorway was doubled up around the floor joist support because this will have a removeable lid to gain access to the control devices and plumbing modules that will serve the various features in the ensuite.

Started On Building Bedroom Two plus Running Water Pipes Under Floor


Then we laid down six sheets of OSB boards to provide a temporary floor surface for us to move around more easily and we carried on nailing up more horizontal rails all the way around the four walls like before. This forms the Utility Channel structure that allows us to route wires and cables around plus also in and out of the room. A half a dozen conduits had to be inserted into the new Utility Channel to route the cabling around windows and doorways, plus also to provide a connection to various features like the shower mixer, the vanity unit and the toilet itself. A control box provision was also created near the room’s entrance and this section will contain the computer equipment and other electrical safety devices that this bedroom will need.
Started On Building Bedroom Two plus Running Water Pipes Under Floor


The window’s sill was finished by creating a chamber underneath the window seat that will hold a place for the window blinds mechanism and possibly a secret storage location too. Another conduit was inserted so wires could travel in and out of the window seat chamber, to the Utility Channel.
Started On Building Bedroom Two plus Running Water Pipes Under Floor


The next job was the plumbing running along under the hallway flooring. We needed to route a couple of 15mm water pipes from the Energy Module situated under Bedroom Two and travel all the way back to the Equipment Cupboard in the Utility Room in a neat manner. We screwed a regular set of horizontal battens across the middle set of legs that will do a double role of holding up the air duct but also provide a mounting point to keep the collection of plastic pipes neat and tidy using cable ties pushed through a drilled hole in the batten.
Started On Building Bedroom Two plus Running Water Pipes Under Floor


Started On Building Bedroom Two plus Running Water Pipes Under Floor


We continued in placing more conduits, this time under the flooring for things like the temperature sensors that surrounds the buried Energy Modules plus also a watering system for routing water to any hanging baskets from the gutters outside. We had to put in extra conduits from Bedroom Three to serve the ensuite because we had forgotten to make the connections when we were doing that bedroom earlier the year. Another conduit was laid in for our compressed air, to route it up to the top of the sliding door so it can power the movements of the doors. We put in a complete circuit of conduit around above the window and doors and this will contain the hearing loop wire to provide extra audio connections for deaf people. This circuit comes in and out of the control box.
Then the load of PU foam rubbish was brought in and laid down in the floor space, to provide insulation against the cold concrete, especially near the outside walls but also to provide some insulation against the buried Energy Module which will get warm during the summer and autumn months and we don’t want too much excess heat getting into the room.
We managed to completely empty our large external “bag” of rubbish bits and pieces and we now have been able to collapse and tidy away the plastic tarpaulin we used to construct the temporary bag. The alcove, situated around the back of the house, outside the windows of Bedroom One and the Great Room is now all neat, ready for us to dig a hole to install a couple of electrical junction box plus also an external mains electric socket.
Then we created four standard air dispersers, which were fixed to the bottom near the middle of each wall, then connected to flexible orange 50mm (the interior dimensions) twin-wall plastic conduit, going from each wall and back over to the doorway, ready for the main air splitter chamber.
Started On Building Bedroom Two plus Running Water Pipes Under Floor


Started On Building Bedroom Two plus Running Water Pipes Under Floor


The circulating hot water was next, to continue the twin lines of 28mm diameter water pipes coming from Bedroom Three, going across Ensuite Three, through the Bathroom, turning into Hallway Two and heading into Bedroom Two to arrive at the access chamber just outside Ensuite Two.
But first, we needed to get the waste plumbing pipework sorted for Ensuite Three and the Bathroom so we installed a boss fitting to the sewage stack, right down at the bottom nearest to the concrete, to allow the maximum amount of liquid level drop coming from the various waste outputs like the basin and the shower plus also the bath too. The shower’s waste is the critical one because we wanted to install a heat recovery system to recycle the hot energy from the waste water and put as much of it back into the fresh clean water going to the shower. To achieve this, the module will need space and time to maximise the energy transfer from the waste water to the clean water, before the waste water flows out and down the sewage stack.
So we put in a couple of 40mm waste pipes, with a gradient to make the water flow towards the sewage stack and got three connection points ready for future installations.
After that, we laid down a layer of 90mm thick PU foam boards going across the Ensuite and the Bathroom, 250mm wide, following the path of the Hot water. On top is another layer of PU foam, this time 100mm thick which had two grooves sliced out to encapsulate the 28mm wide plastic plumbing pipes. The path is a straight line across the two rooms but also keeping tightly to one edge so to avoid the sunken bath tub itself, where the sloping ends will be. The second layer continued into the Hallway Two section, turning towards the next plumbing destination, the ensuite in Bedroom Two. The hallway section will have many different control modules and plumbing units, having to serve plenty of surrounding rooms like the Bathroom, the Cloakroom and even to the upstairs toilet and shower too. The 28mm pipes finally continued into Bedroom Two and currently terminates inside the service chamber outside Ensuite Two. The whole lot then had a third layer of more 100mm thick PU foam to cover the plastic pipes and insulate the hot water that will be circulating continuously, to minimise the time to get any warm water coming out a tap or shower. This is very similar to a traditional central heating system and its circulation hot water and using heat exchangers or radiators to “transfer” the heat into the clean cold water or fresh air.
One of the last things we did before we closed down for Christmas was to run alongside the hot water, a cold water feed. This time we are using a bigger 32mm diameter polyethene pipe, a blue one, to provide the clean water to all the various outlets distributed around the house. It ran alongside the PU foam, following the same path and it also is currently terminates in the ensuite in Bedroom Two.
Started On Building Bedroom Two plus Running Water Pipes Under Floor


Started On Building Bedroom Two plus Running Water Pipes Under Floor


Started On Building Bedroom Two plus Running Water Pipes Under Floor


Started On Building Bedroom Two plus Running Water Pipes Under Floor


The next job when we restart in the new year, probably about the 2nd week of January after a couple weeks of holiday, is to make an air disperser unit and put in an extra electrical conduit beside the window to have ready a connection for automated curtains and lighting if we want to have such a thing.

 Posted by at 6:00 pm
Nov 272021

We finished off the two air ducts we started last week. We put on the extra layer of MDF boards underneath to complete the downwards chute before it runs into the PU foam boards. We coated the MDF with several layers of acrylic varnish to seal the wood material against moisture and also sealed the […]

 Posted by at 6:00 pm
Nov 132021

We had a week of slicing and pushing loads of PU insulation foam boards up into the rafters! We carried on with the task we started last week where we wanted to get rid of all the random collection of 2nd grade of expanded polyurethane foam boards we acquired very cheaply, slice it up and […]

 Posted by at 6:00 pm
Nov 062021

Among several interruptions during this week’s work, we got on with installing new framework for two sliding doors for our stand-alone Bathroom as well as for Ensuite Two. Both of these rooms are going to have two half¬†sliding doors, built into the body of the walls themselves (pocket), not exposed, mounted on the surface. It […]

 Posted by at 6:30 pm
Oct 192021

This week we finished cutting hatches into the hall floors on Monday and Tuesday. Then we needed a way of lifting the panels easily. So we drilled a hole 100mm diagonally in from each corner and inserted a ‘Pronged T Nut’ into each hole from below, then we could use a bolt with a T […]