After a week of calculating, analysing responses and digesting options, we have finally placed an order for a collection of Joist Beams to build our First Floor support.
There are 61 joists and 455m in total, ranging from the shortest one of 3.2metres and all the way up to 10.8metres. These joists are a specialised hi-tech product, made entirely of natural timber materials but done in such a way that the weak points of using raw untouched wooden planks are almost completely eliminated. The joists are a wooden version of the classic steel RSJ beams (after all, RSJ stands for Rigid Structural Joist) and they have both that shape of a capital letter I, a large vertical webbing with a fitted top and bottom flanges. In the case of these wooden versions, the webbing is made of plywood or OSB to a thickness of 10mm and the flanges are a thick 36mm multiple layered plywood too. The only different is the width of these flanges, depending on how strong you want the joist to be. Of course, the other way of making stronger joist beams is to widen the webbing to spread apart the two flanges thus increasing the both the compression and tensile loads and stiffening up the whole beam. We have chosen to use one of the smaller webbing depth so that our joists are 240mm high. As part of the structural loading calculations we did several years ago as part of our submissions for planning approval, we knew that 240mm is sufficient for the job. We are using two size of flange, 96mm for the joist which extend out for the gallery and 53mm for all the rest.
So after a round of sending quotes off to various suppliers, bouncing back questions like what happens to the waste pieces and what stock length they hold in the yard, we have settled on buying their original stock lengths of these I-Beams and cut them up ourselves. It is slightly more expensive this way because it seems that one of our suppliers makes use of all the waste pieces in other projects but in contrast, the alternative supplier (we had only 2 to choose from in the end) didn’t bother with that and always charged us for the use of the entire length of the beam and presumably threw away the waste pieces and only supply our 61 pieces at our specified lengths.
But we had a very good idea of using these waste pieces ourselves to make noggings to help brace all the joists as required. We were going to use 18mm OSB sheets, cut up into appropriate sizes and jammed in between each joist to stop them slipping sideways and twisting. But making use of the waste I-Beam pieces, we got a much, much better and far stronger bracing the entire First Floor Joist structure together from one edge of the house to the other side.
Hence we were quite happy to spend a further £400 to buy a total 593m of beams and getting these waste pieces ourselves and will have a far better finished structure. The final choice came and after the second supplier added on their delivery charges (which turned out to be quite a major and surprising extra cost), we selected our first supplier, placed the order, then got the money transferred over and now we wait for our delivery slot which is a long three weeks away.
So in the meantime, we get on with different jobs like drilling holes through the exterior walls to install conduits to the outside world, putting glass wool and vapour barriers up on our walls and start putting on horizontal rails on all the walls and so on.