WESTLETON PROJECT – MODULAR HOUSE BUILD
Our client approached us to build them a dream holiday home in Suffolk, for which they already had project plans for a traditional brick and mortar house. At the very start, we encouraged them to explore the timber frame modular buildings, which are not only quicker to build but also more affordable, energy efficient and made with high spec elements, such as triple glazed windows which are standard.
Design opportunities are endless, whether your style preference is contemporary or traditional or if sustainability is of the highest importance. This project took just under 12 months to complete, including all the ground works, 400m2 main house assembly with all internal finishes, building 30m2 summer house with the bathroom, all the landscaping works and granite cobbled driveway.
We have worked together with our clients every single day, offering advice and our experience for this type of build which is new to most people but offers an incredibly interesting journey to your dream home.
Site preparation and foundations dig
Clearing and widening access to site from the main road forming wide comfortable entrance, shaping the ground for the next steps. First step was to start clearing and levelling the site.
Use of the digger was essential as it enabled us to quickly shape the grounds, establish different site zones and exact positioning of the house, garden and the summer house. The back of the plot was built up higher with the soil that was removed from the front of the site.
Building a retaining wall
Accurate excavation for the house footing is of great importance for further planning and positioning of the services such as rain water pipes, electric supply, water supply.
Installation of services such as drainage, water mains and electric supply must be planned in detail because every service has to comply with different building and health and safety regulations.
Building the retaining wall for the rear higher garden level area which later developed into nice sunset watching spot.
The wall was built with the damp membrane to prevent future water penetration and render damage.
Building a retaining wall
Accurate excavation for the house footing is of great importance for further planning and positioning of the services such as rain water pipes, electric supply, water supply.
Installation of services such as drainage, water mains and electric supply must be planned in detail because every service has to comply with different building and health and safety regulations.
Building the retaining wall for the rear higher garden level area which later developed into nice sunset watching spot.
The wall was built with the damp membrane to prevent future water penetration and render damage.
Making a reinforcement layer
Forming the reinforcement layer from overlapping wire mesh on the hardcore base, is necessary for the overall stability of the main house slab.
Accurate excavation for the house footing is of great importance for further planning and positioning of the services such as rain water pipes, electric supply, water supply.
Installation of services such as drainage, water mains and electric supply must be planned in detail because every service has to comply with different building and health and safety regulations.
Providing a solid bearing surface
We used 7 concrete mixers to deliver consistent quality of material to achieve best technical standards. On the length of 24m our imperfection was 8 mm, which was a great achievement.
This phase completed ground works and site is ready for the crane and scaffolding.
The grounds next to the house slab was covered with crushed concrete and hardcore to provide solid, stable, load bearing surface for the crane used to lift the house elements, but also for the future car parking.
We are ready for assembly.
Providing a solid bearing surface
We used 7 concrete mixers to deliver consistent quality of material to achieve best technical standards. On the length of 24m our imperfection was 8 mm, which was a great achievement.
This phase completed ground works and site is ready for the crane and scaffolding.
The grounds next to the house slab was covered with crushed concrete and hardcore to provide solid, stable, load bearing surface for the crane used to lift the house elements, but also for the future car parking.
We are ready for assembly.
House assembly
Crane in position and scaffold frame erected as the final preparation stage before the house assembling begins.
Scaffolding is only 300mm away from house walls to provide safe and comfortable working distance.
The site restrictions such as electrical cabling across the plot as well as tight space for the crane positioning always meant extra safety measures.
Craning the large, glazed wall and installing into position on the ground floor
Our timber frame walls and floors are manufactured in factory and delivered in large lorries. Triple glazed windows and doors are standard and structural timber elements are fully insulated and engineered to provide additional strength to the structure beyond what is required by the building regulations.
Large external wall (8m) lowered into position ready for fixing. One of the main challenges was the wind, so every panel was lowered into place with extra care and health and safety was always our first priority.
Craning the large, glazed wall and installing into position on the ground floor
Our timber frame walls and floors are manufactured in factory and delivered in large lorries. Triple glazed windows and doors are standard and structural timber elements are fully insulated and engineered to provide additional strength to the structure beyond what is required by the building regulations.
Large external wall (8m) lowered into position ready for fixing. One of the main challenges was the wind, so every panel was lowered into place with extra care and health and safety was always our first priority.
Ground floor and wall partitions build
Formed ground floor with all internal partitioning walls, ready for the floor and first floor install. Walls are fixed with metal brackets and 14mm anchors into our concrete slab distancing 700-1000 mm between.
Our panels have preinstalled water pipes and electrical conduits, which we checked during the installation.
Installation of the floor panels (8x3m) inclusive of the metal structural elements.
They are fully insulated and supplied with preinstalled pipes and electrical conduits. Each panel has marked position of fixers to the walls and that makes easier to develop best assembling results.
Roof construction
Roof construction in progress of assembling before the insulation and covering. All structural elements such as walls, floors and roof rafters, are made from laminated timber (smaller pieces of timber are glued together to form bigger, stronger planks).
Our structural size are 80mm wide and 300mm thick, which exceeds todays building standards.
Heavy duty brackets and extra strong timber are used to form structural support for Velux windows. All structural elements such as floors, walls, roof rafters are made from laminated timber which gives extra strength.
When roof structure is set and levelled to perfection, we covered roof with breathable membrane, cross battens (to provide ventilation) and finally tiles.
Roof construction
Roof construction in progress of assembling before the insulation and covering. All structural elements such as walls, floors and roof rafters, are made from laminated timber (smaller pieces of timber are glued together to form bigger, stronger planks).
Our structural size are 80mm wide and 300mm thick, which exceeds todays building standards.
Heavy duty brackets and extra strong timber are used to form structural support for Velux windows. All structural elements such as floors, walls, roof rafters are made from laminated timber which gives extra strength.
When roof structure is set and levelled to perfection, we covered roof with breathable membrane, cross battens (to provide ventilation) and finally tiles.
House and landscaping is complete
On this project we have installed best of composite decking boards on the market-Millboard decking. All house entrances are DDA friendly.
The project was a stellar success. The work was completed on time, in fact half the time it would take to build traditional brick and mortar house and it was almost half the price. Please check the photo gallery to see how we completed the interior of the house.