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Lancashire Hot Pot – a new oak framed home


Janet and Peter met us at the NEC Homebuilding and Renovating show in 2015 with the vague notion of incorporating an oak frame into a budding self-build project.

Nearly 2 years down the road, we finally delivered their oak framed house from our workshop to Leyland in Lancashire last week, and spent 2 days erecting the fruits of our labour.

By way of introductory context, Janet and Peter are an extraordinarily intrepid couple who (amongst myriad other things), find the time to be practically self-sufficient, have been running a wood turning business for 40 years, and can build narrow boats from scratch to sell on – they have just completed their 4th! All these activities may need to be set aside for a while, as they get to grips with their new project: no doubt they will be launching into as many aspects of the self-build as is humanly possible!

Loaded up at Castle Ring

We travelled up to Leyland on the Monday night and were greeted on Tuesday morning by the clear dry and still weather we had been praying for. We forgot to ask for a bit of warmth and so obviously it was punishingly cold…..but you can’t have everything.

Once the crane was rigged and positioned, we spent a good hour sorting the packs of wood: sod’s law…..everything you need is always at the bottom of the stack, and were ready to start erecting the frame by 10am.

The house comprises 7 crossframes, so we start at one end and keep going until we run out of components at the other. Post, beam, post, rail, post, wallplate, beam, post, rail, wallplate – and of course, not forgetting the braces. Concentrating on one timber at a time can be meditative and helps to prevent worrying about whether you are on schedule or not, and before you know it, there’s a big structure taking shape.

Castle Ring Oak frame

Dropping in a wallplate

Timber frame house

Jake and Sylvan inserting podgers to temporarily hold the frame together

Oak Frame house

Working along the frame

Castle Ring Oak Frame

Mexican standoff

Castle Ring Oak frame

Meeting of beam, post and brace

Castle Ring Oak Frame

Down tools, lunchtime Day 1.

Another of Janet and Peter’s skills was hospitality and we were treated to epic homemade catering fests. Day 1 featured hot dogs, jacket potatoes, baked beans and cheese (perfect for a cold winter’s day) Day 2 was possibly even better – Lancashire hot pot (what else?) all washed down with homemade cake and lashings of hot tea. On Tuesday evening, Rob, Jake and Sylvan were treated to a Lancashire Fondue (?) with various home brewed beverages – cider, strawberry wine and blackcurrant gin!

Castle Ring Oak Frame

Hot Pot – Jake, Sylvan and Shawn the crane driver tucking in.

By the end of Day 1, the main structure was up, and the trusses in place.

Day 2 was equally generous, and we enjoyed the same clear skies and frosty morning. By mid-morning we had installed the purlins, ridges and wind braces. The single storey “extension” was in place by lunchtime and then all that remained was to drop in the joists for the gallery/walkway, peg up and take some photos in the fading light.

Oak framed house

Flying in the purlins

Castle Ring Oak Frame

Castle Ring Oak frame

Castle Ring Oak frame

Oak frame extension

Single storey bedroom extension

Castle Ring Oak frame

Joisted gallery and walkway

Castle Ring Oak Frame

We were sorry to say goodbye and left bearing gifts and fond memories.
Thanks Janet and Peter for a great raising.

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Hitting things with dead buffalos


Ok, I admit I was trying to get your attention…..but there is some truth in this headline grabbing blog title. Read on:

You might think the ancient and civilised craft of timber framing is performed in a hushed and reverential silence broken only by the subtle squeak of a hand plane, or the reassuring purr of a handsaw across the compliant grain of subjugated timber……

Far from it.

The music gets cranked up to 11 to get us in the mood (it could be AC/DC, Beethoven’s 9th or the Sex Pistols) before we unleash a clamorous cacophony of machinery in the form of chainsaws, morticers, circular saws and drills. In amongst this infernal hullabaloo we find plenty of time to bash and smash things with various boshing instruments most of which are made from the rolled up hide of buffalos (dead ones of course). I’d like to know how the mallet designers arrived at the conclusion that buffalo is best? Personally I’ve always fancied a vegan potato skin mallet but still haven’t managed to source one on the dark web.

We hit and pummel chisels, offset prickers, bits of wood (to move them, or just out of frustration), podgers, and occasionally each other. If something doesn’t quite move as desired, or a chisel is too blunt, there is always a bigger mallet to use, and we like to name them accordingly – the Commander, the Peacemaker, the Persuader, Brian.

Here are some of them. Collective term for a pile of mallets anyone?

castle ring oak frame rob

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The Cairngorm Kitchen


Way back in 2011 when the world was a very different place and I still had some of my own teeth, Bruce and Carole got in touch via letter – yes, pen and paper was an acceptable form of communication back then.

Carole had come across an article in Homebuilding and Renovating magazine in a B & B up in the Highlands of Scotland, and was taken by the story about how we had built our house and wanted to see if there was any way we could erect a timber frame for a future project of theirs in Aberdeenshire. At the time, the timber of choice was to be larch or douglas fir. We corresponded for a while and then Bruce and Carole popped in to see us on a trip down south and we were able to show them at first hand the kind of work we do.

Eventually, 7 years down the line on Tuesday of this week, we put their oak frame up (choice of timber had changed) in the heart of the Cairngorms national park, and so fulfilled Carole’s dream.

oak framed house extension

The journey through planning, not to mention the 450 miles up to Scotland, was a long one, but plans were finally approved and we designed and fabricated the simple single storey frame which was to create an extension to their vernacular stone longbarn – essentially an open plan kitchen, dining area as a counterpoint to the cosy stone crofters cottage that they had already restored.

As is sometimes the case with geographically distant projects, our first trip to site can be when we actually turn up with the frame. This is obviously fraught with all sorts of potential pratfalls regarding access, scaffolding, groundworks etc which could potentially scupper the raising. Turning up in Scotland and being unable to raise the structure would have made for a much shorter blog though!

As it was, we set off at the crack of dawn on Monday morning having loaded the lorry, only to receive a call from the crane company within the first hour of our journey to say that high winds were forecast in the Cairngorms the following day and that they were pulling out. B*!x$? Not only were we faced with not being able to put the frame up, but there was also the distinct possibility now that we wouldn’t even be able to get the oak off the lorry……

oak framed timber frame

Thankfully, we no longer have to correspond with letters, so emails and phone calls were sent from the M6 motorway to Bruce up in Scotland. Within an hour he had organised for a telehandler and operator to be on site for the following day, and Sylvan and I could settle back into the monotony of our long road trip. Skip forward numerous service station stops and we veered off into the magical landscape of the Cairngorms national park, traversing heather and granite, mountain and moor.

Cairngorms

Scotland oak frame house

Carole and Bruce hosted us on our weary arrival with a sumptuous meal and a warm welcome. The morning of the raising broke with clear skies and almost no wind! Maybe the crane company just didn’t fancy the job…..

Perfect conditions and the most breathtaking backdrop which took in Lochnagar, a mythical mountain rising to nearly 4000ft and part of the Balmoral estate, meant that the raising zipped along effortlessly.

Scottish homebuildScotland oak frame house

Oak frame home

oak frame

frame raising

By mid morning bait (or “fly” as they call it in Aberdeenshire) the jowled posts and wallplates were in place, by lunchtime we had assembled and installed the four trusses with curved collars, and by mid afternoon (tea and Battenburg cake, Balmoral style) we had dropped in the purlins, ridges and wind braces. All that remained was to peg everything together and fix down the purlins and ridge – 150mph winds were not unheard of up here so we didn’t want the roof blowing off.

oak framed house

roof ridge purlins

oak frame extension kitchen

What a truly amazing experience and thanks to Bruce for mucking in cheerfully with the raising and for Gary and his telehandler for providing expert lifting: calm and assured, just how we like it. Most of all, thanks to Carole for finding that magazine all those years ago and for sticking to her dream.

oak kitchen extension

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Dawn of the Shed


Presteigne, our local town, is home to a kooky and creative community of people, some of whom have got too much time on their hands.

So it was that one of them, who need not be named (Owen Rimington), decided that what Presteigne needed, to get itself noticed even more, was a shed building competition. Rumour has it that the rather too cleverly titled “Dawn of the Shed” was the chicken that preceded the egg…

Not being nearly busy enough with timber framing (our day job), we decided to support Owen and the Sheep Music backed event. After all, how difficult could it be to build a shed out of recycled materials over the course of a weekend? It might even be fun.

We gathered together as many materials as we could lay our hands on – waste bits of studding, unused and old weatherboarding etc and struck gold with some decaying and dilapidated window frames that our friends Tony and Christine were about to consign to the tip (if such a thing existed in Powys anymore). Now it was time to assemble a team of crack (heads?) guerrilla carpenters who would sweep our funky shed, with a combination of inventiveness, imagination, and distilled genius, to Presteigne immortality…..and the glory of the coveted Shedwrights crown to boot.Presteigne order of shedwrights

As it happens, thankfully, there were no elite, crackerjack carpenters available, so rather like the shed itself, the team was comprised of various recycled, discarded, misfits and vagrants who had nothing better to do, and were attracted by the prospect of free beer and food for a whole weekend.

Saturday arrived and we assembled on site at a leisurely 11am to find that the other competing teams were already busily cutting, hammering, nailing and erecting. Realization struck. We had a lot to do and better get on with it.

Our fag-packet design was shared with the team,

Rob Dawson Tom Carter

Team Castle Ring

and we knuckled down, sorting the windows,

Presteigne Dawn of the Shed

and building the studwork walls to receive the windows, and fit on the pre-prepared base.

Presteigne

Dawn of the Shed Presteigne

All around us other sheds were taking shape and we were beginning to feel the pressure, and that we’d seriously misjudged something – either our abilities, time, or the quality of the opposition…

Presteigne went's meadow

Bar Presteigne

shed building

Gordon7sheds

Rimington Presteigne

Finally at around lunchtime, we had the genesis of something that might one day resemble a shed and we raised three walls, to a distinct lack of fanfare I might add.

Spirits had been raised by this small sign of progress, and buoyed by some hearty supplies that were eaten on the hoof.

picnic presteigne

We beavered on into the afternoon, continuing with the studding and inserting the crumbling but stylish windows and door frames.

shed building

shed building tiny house

At least now our shed was “lockable” ( we even had a key) although we did have to lean the frame outwards to ensure that the doors could open.

upcycling

Day one drew to a close, tools were downed and drinks and food were provided in the newly constructed bar.

Competition rules (such as any existed) suggested that no prefabrication was allowed, or the use of any glass. Well, we had ignored the frowned upon use of glass, so, in for a penny….we decided to pooh-pooh the prefabrication clause for good measure and make up the roof trusses back at home. My Saturday (evening) and Sunday morning were therefore not as relaxing as I would have liked, as I frantically endeavored to cobble together some fashionable and eye-catching roof trusses from curved oak offcuts. These were smuggled onto site on Sunday morning by which time everybody was too tired to notice, or too busy, or just didn’t care……I think we got away with it.

The trusses were lifted onto the wallplates, and now we really did have something that was starting to look like something!

Castle Ring Oak Frame shed

For the rest of the afternoon, everything went beserk as boards were ripped, crosscut, and slapped willy nilly onto the outside of our rapidly evolving construction,

Presteigne shed

Oak frame shed

whilst around us the other teams seemed to be in a similar frenzied state.

dawn of the shed

Gordon Langton builder Presteigne

Doug, Coral, Tom, Harold, Peter, Alithea, Dorothy, Jack, Richard and Malcolm put their collective shoulder to the wheel and somehow or other conspired to drag our shed towards a state of presentable completion. A 30 minute stay of grace generously bestowed by the junta of 3 impressively professional looking judges (suited and booted and complete with matching clipboards) gave us just enough time to literally throw on a few sheet of wriggly tin.

The bell tolled. Everyone collapsed in a sweaty heap. Thankfully it was all over.

Rob Dawson Castle Ring

Not quite in fact. Now we had to face the judges’ “interrogation” and discuss the so called “concept” of our shed.

Dawn of the Shed Presteigne

We tried to impress them with suitably sounding words – “recycled….community…..sustainable….creative”,  but I could tell by the impassive and cold look in their eyes that they could see through my flannel. I might just have well have said “we made it up, didn’t we. Isn’t it obvious?”

Suffice to say we didn’t win. Lewers Firth and his brilliant team of nail gunners from Firth Construction pulled it out of the hat with their inspired hinged extravaganza, and their theatrical, musical unveiling, which clearly swung the deciding vote. Worthy winners.

Dave Luke Presteigne Firth Construction

For once, this really was about taking part.

dawn of the shed

Sheep Music Presteigne

Thanks to everyone involved for a memorable weekend, and don’t forget to come down to the Sheep Music workshop event this weekend which will be using the sheds as venues.

Sheep Music Presteigne

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Timber frame house – from Welsh Borders to Scottish Borders


Last week Jake, Sylvan and I ventured to the border with Scotland to put together a large house frame we have been building for Andy and Sue a couple of miles from Gretna Green.

Castle Ring Oak Frame workshop Presteigne

Castle Ring Oak Frame

Rob and Alithea Dawson Castle Ring Oak Frame

As usual with frame raisings, as the time approached, so our apprehension grew. So many things have to come together for a raising that at times it feels an almost impossible task. Will the groundworks be accurately set out to receive the frame? Will the scaffolding have been erected correctly? Have we made enough oak pegs?

oak pegs timber frame house

700 oak pegs laid out to dry

Have we remembered the oak pegs? Will the crane turn up? Will the weather be kind to us? Would there be any tea and biscuits? See what I mean?

We motored past the Lake District along the M6, taking in the spectacular Cumbrian scenery, and arrived on Monday evening in time for a quick site inspection with Andy and Sue, ready for an early morning start the next day

You’ll be pleased to know the groundworks were spot on, the scaffolding perfect, and the oak had already arrived and been offloaded. So far so good

Next morning the crane arrived with Graham our operator for the next 2 days, and we ran into our first real issue – the crane’s stabilising outriggers on the one side were pushing through the stoned ground and disappearing into peat bog! If we couldn’t safely stabilise the crane, the frame wouldn’t go up. We needed railway sleepers. Lots of them. Strangely and fortuitously enough, Andy had an impressive railway sleeper collection in his garden which we were able to pilfer, and we kept stacking them below the crane’s outriggers until they stopped sinking. We had lost valuable time at the start of the day, but at least we could begin to assemble the frame

The weather was set fair, we pinned up the drawings, sorted out the multitude of curved braces and made a slow and steady start. As is usually the case when we raise frames, taking photos of progress gets forgotten due to time pressures and our frame sequence generally follows the same pattern 1) picture of open site ready for frame 2) picture of completed frame. This frame was no exception

So here’s a picture of the scaffolding….

Castle Ring Oak Frame

And 3 days later, here’s the completed frame:

In between times we lifted in bay posts, girding rails, floor beams, wallplates, trusses, floor joists, purlins, ridges and rafters, at times in the dry, but more often than not in the driving rain. By the end of the first day we had raised the main frame including the trusses, on the 2nd day we lifted in the double purlins and ridge using the crane, along with all the floor joists by hand, and finished knocking in the 700 oak pegs. By mid afternoon on the 3rd day we had fixed the common rafters to the roof and invited Andy to “top out” the frame with an oak branch scavenged from a nearby hedgerow.

Castle Ring Oak Frame

Jake sorting out the numerous braces

Double jowled ground floor post with multiple braces

Oak frame house

More rain

Oak floor joists

Floor joists dropped into their housings

Castle Ring Oak Frame Rob Dawson

Making a start with the rafters

Castle Ring Oak Frame

Andy helping out on the roof

Castle Ring Oak Frame

Chunky curved sling brace in the master bedroom

Rob Dawson timber framer

Rob fixing the last rafters

Castle Ring Oak Frame Welsh Borders

View through the upstairs

Topping out timber frame oak

Andy and Rob topping out the frame

Castle Ring Oak Frame

The roof is done

Oak frame house

View from the top

Sue kept our spirits up and our soggy bodies going throughout with a constant supply of bacon butties, cups of steaming hot tea, muffins, scones, tea cakes, haggis (yes really!) and best of all, the amazing, never to be forgotten self-filling box of chocolate biscuits, which replenished itself constantly and mysteriously for three whole days.

Jake Castle Ring Oak Frame

Timber frame

The magic chocolate box – every frame raising needs one

Thanks to Andy and Sue for their kind hospitality and for giving us the opportunity to play a part in building their new home

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Outside of the comfort zone


Sculpture project for Studio Morison

We are timber framers. We generally work in a warm and dry workshop with a more or less flat floor, more or less square and straight timber, interpreting more or less decipherable frame drawings that have been prepared in autocad by a more or less qualified frame designer, building more or less recognizable traditional buildings with walls and a roof.

We are definitely not sculptors. Oh no.

So, imagine our surprise when Ivan and Heather Morison of Studio Morison contacted us to see if we were interested in building a large roundwood sculpture that they had designed and which had been commissioned for a new amenity space near Cambridge.

How large? What? Where? Why?

Our curiosity got the better of us and we made the mistake of taking a trip to the Morison workshop in nearby Weobley to meet Ivan and Heather to talk things through. We looked at their plasticine scale model, inspected the debarked chestnut logs coiled and stacked expectantly outside, scratched our heads and ended up feeling excited by the whole idea.The bait had been set, and before we knew it, we had shaken hands and agreed to fabricate the “Bronze House” – it even had a name…

How?

This was of course the key question that now started to occupy our minds. Night and day. Thinking about constructing a 9m tall structure out of seriously wonky roundwood ended up being quite stressful but with the help of Greg Cohen, the responsible structural engineer, we came up with what felt like a suitable theoretical jointing method. Now we just had to put it into practice.

sculpture Studio Morison Castle Ring Rob Dawson

Castle Ring Oak Frame round timbers
The timbers were duly delivered to Castle Ring for fabrication (a mere 25 tons in all) and we were confronted by the enormity of what we had undertaken. In reality however, making a start meant we could stop worrying and start doing. The sculpture is based on 4 tripods with a dozen or so connecting timbers all of which had to be positioned to match the model. This was critical for the final positioning on site in Cambridge.
So we picked the first tripod. We created a flat on the first log with a chainsaw and planer, and laid up the second log so that we could scribe shoulders and a tenon. The mortice and tenon is secured with oak pegs and reinforced with stainless steel rod, washers and nuts. Now things got trickier as we had to find a way to correctly position the foot of the 3rd leg relative to the other 2. Up in the air! All this before we could scribe and cut the joint. As you can see we used the telehandler for lifting, with ropes tied to the correct lengths at the feet to form the base of the pyramid.
Castle Ring Oak frame
Rob Dawson

Castle Ring Oak Frame Castle Ring Oak Welsh Borders Oak Framers Herefordshire Jacob at Castle Ring Oak Frame timber

Studio Morison sculpture Castle Ring Rob Dawson

It worked!

With the 4 tripods now jointed on the ground, it was time to think about erecting them in the yard so we could continue working on the connecting timbers. We booked a crane, 2 telehandlers and a cherrypicker and prayed for a calm clear day, not always a given at the beginning of November…. We got lucky, and were able to successfully assemble the tripods in the air, taking care to brace the feet with 6″ x 2″ timbers to avoid stressing the joints. The tripods were then lifted independently and repositioned relative to each other. I’ve got no idea what the neighbours thought we might have been up to….. Castle Ring Oak Frame Castle Ring Oak Frame team Rob Dawson With the fundamentals of the structure in place, we could now focus on jointing the upper connecting pieces in place. Everything so far had taken place with the security of the earth beneath our feet, but now we had to step even further outside of our comfort zone with scribing and jointing happening 30 ft up in the air. Painstaking and dangerous work for sure, but slowly, piece by piece the sculpture took shape and 2 weeks ago, we were able to show off our work with an open viewing attended by over 80 interested and inquisitive spectators. Rob Dawson timber framer chestnut round timber The Bronze House sculpture wood Castle Ring Oak Frame chestnut timber Rob Dawson Ivan Morison sculpture timber frame Oak frame workshop Castle Ring Oak Frame sculpture

We’ve enjoyed making it, living with it, walking underneath and round it. It’s been all consuming at times and has pushed us far beyond our normal physical and technical limits. But we did it, and the warm glow of achievement hasn’t quite worn off yet, even though it was dismantled recently to begin it’s final journey to Cambridge. If you’d like more info on the project and where it’s going, head to Hobson’s Square in Cambridge.
Special thanks to our brilliant photographer Alex Ramsey for finding the time to capture it before it disappeared – his wonderful photos are here below and top image:
Alex Ramsay
20 Alex

Alex Ramsay Alex Ramsay sculpture

 

UPDATE – May 2017

The Bronze House – raised!

Last week we went to Cambridge to raise the sculpture which we built for Heather and Ivan Morison. The chestnut timbers had been scorched by the Morisons with a giant blow torch, then tarred and finally rubbed down by hand with a wire brush. The large-scale public sculpture was raised on Hobson’s Square, Trumpington in Cambridge. It sits at the centre of the square referencing the Bronze Age archeology found on the site.

Castle Ring Oak frame studio morison cambridge

Castle Ring Oak Frame sculpture

Bronze house cambridge sculpture

Studio Morison Cambridge

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Retired? Not likely!


An oak framed barn in Herefordshire

A couple of weeks ago we put up a glamorous rural tractor/storage shed near Leominster in Herefordshire, a stone’s throw from our base at Castle Ring. Richard and Christina commissioned the frame as part of ongoing work and projects associated with their house and grounds. Most people of Richard and Christina’s age might possibly be winding things down and heading for beige knitted tank tops, but not this intrepid couple. Both were positively excited and energised by the whole idea of an oak framed barn to home their vintage Massey Ferguson and visited us in the workshop to see at first hand their frame being built.

Timber Frame Barn

Day one

After a couple of weeks in the workshop we were ready for the frame raising in the corner of their bountiful orchard of apples, pear and ripe plums. Christina had given strict instructions to preserve, if possible, a delicate fruiting apple tree right beside the foundations. Would it survive the rigours of a Castle Ring raising? Would there be any apples left by the time we’d finished?

The frame went up smoothly and by 4 o’clock we had finished the main 2 bay structure, complete with a joisted floor platform, single purlin, ridge and windbracing.

timber frame barn

oak frame barn

oak frame

Castle Ring Oak Frame

Christina and Richard kept us plied with tea and home made cake, which along with all the fruit in the orchard meant we could barely move all day.

Day two

We were more than happy to return to finish off the roof the following day, which involved fitting the common rafters ready to receive the roofing batten and slates.

common rafters oak

oak timber frame barn

timber frame barn by Castle Ring Oak Frame

A lean to structure at the rear of the  building will be used to store and dry logs. A stone “staddle” or plinth was still being sourced for one of the posts, so we made do with some temporary blocks of wood.

9

By early afternoon we had “topped out” the frame:

topping out a timber frame

…managed to not kill Christina’s precious apple tree:

timber frame barn in orchard Herefordshire

 …and Richard and Christina were chilling out in their stunning new barn. 

We enjoyed the whole experience as much as they did and look forward to seeing the the barn finished. But please. No more plums!

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The Bromyard balcony


An Oak Frame balcony

A recent project: the “round the corner” balcony for a new build in Bromyard, Herefordshire, which featured the longest scarf jointed plate we have ever made here at Castle Ring. The house has a contemporary split pitch roof design with lots of modern features. 

3D model of the frame –Oak balcony timberframe

Before we started work on the balcony the builders prepared the bases for the concrete staddle stones and posts. Galvanised brackets were built into the wall to receive the tie beams – this means there are no posts against the wall. The brackets have to be millimetre perfect for the balcony to fit. You can’t tell, but behind the camera there’s a lot of stress going on at this stage!

Balcony oakframe oak frame

Work begins in the workshop. Here’s Rob chisel marking the joints.

chisel marking

Cross frame “3”.

Castle Ring Oak Frame

Frame “4” with table scarfed plate, post and curved bracing all held together with podgers:

timber frame podgers

Possibly the longest scarf jointed plate we have ever made – over 16m! Poking out the workshop here at Castle Ring:

scarf joint timber frame

Balcony scarfed wallplate with rebate. Notice the central mortice which receives the tie beams from the top of the post to the wall bracket:

timber frame joint carpentry

Wall frame of the balcony finished and ready to come apart for the raising. We left the posts long so that we could cut to length according to the “staddle stones” on site.:

timber frame oak frame workshop

On site:

Oak balcony

Castle Ring Oak Frame balcony

Table scarf and braces for crossframe 5. Roman numerals much easier to chisel.

Table scarf and braces for crossframe

The neighbour’s development with a balcony we supplied a few months previously:

IMG_2817

The balcony deck will be dropped into the 30mm rebate set down into the oak beams. You can’t see from this photo but the joists drop in with a dovetail joint:

View out from the upstairs living room through the sliding doors.

IMG_2826

If you’re worried about the balustrade (or lack of….) it’s going to be made of glass so as not to obstruct the beautiful southerly views of the Malvern hills:

IMG_2823

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Swansea hipped roof


Some of you with long memories may remember an enormous hipped roof we assembled (in 3 stages) in the workshop a some time back – here are a few reminders:

Castle Ring Oak Frame

Castle Ring Oak Frame

Castle Ring Oak Frame

Hips and jack rafters

After myriad problems down on the building site, adding up to a full 9 months delay, we finally got to truck the timbers down to Swansea for the raising. It can be difficult, even disappointing, to break the flow from the workshop to the raising as we are always keen to “finish” the process so that we can properly move on to the next frame. Gnawing away is always the thought that the frame might not fit, or that we’ve lost some vital components somewhere amongst the piles of timber filling up the yard…..or more seriously that we’ve forgotten how it goes together!

Before we could worry too much about such trivial matters we had to worry about the rain. LOTS of it. And then some more. We’d been lucky with dry raisings for a while but now our luck had really run out. On an exposed site looking down towards a misty coastline, we took a soggy battering but had to grit our teeth and keep going as the crane was booked for the day. A couple of strategically placed temporary downpipes ensured that we occasionally received a cold spout of water down the back of the neck to keep our squelching wellies topped up to the brim.

Swansea oak frame

Up and over through the mist

Swansea oak frame raising

Somehow we survived and made slow but steady progress, assembling the 4 trusses and craning them over the top of the building to the other side through the mist and rain. The trusses were located onto the oak soleplate on the one side, and into holes cut in the masonry on the other. Four “dragon ties” at the corners provided the base for the “hips” and a beautiful internal feature.

Dragon tie oak frame timber

Dragon tie with simple decorative detail

Fitting the heavy 6″ x 4″ rafters turned out to be harder and more time consuming than planned – in fact a whole day more time consuming, but on the plus side by the time we had finished, it had stopped raining long enough for us to take a few photos of our work.

Castle Ring Oak Frame

Jake and Florian fitting the jacks

Castle Ring Oak Frame

Castle Ring Oak Frame

Castle Ring Oak frame

Huge prow ready to be glazed.

 

Oak truss Castle Ring Oak Frame

Shallow pitched truss with brace to ridge

Castle Ring Oak Frame

IMG_2818

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A douglas fir timber frame and reluctant machinery


Well we’ve somehow survived our latest batch of raisings – 3 in the space of a week so we thought we’d share with you in a bit more detail what went right and what didn’t, plus what was fun, and what really wasn’t.

We started off with the raising of a douglas fir frame near Knighton, Powys, with the help of our friend Angus from the local village and his telehandler. The 10 minutes drive from our base at Castle Ring was always going to make this raising relatively stress free; knowing that you can realistically forget stuff and get away with it takes a lot of pressure off….and yes, we were half a dozen pegs short at the end of the day, so no dramas.

What went well? The weather (calm and balmy), douglas fir (less than half the weight of green oak so nice and easy on the back), very local (extremely civilised 8.30 morning start).

Douglas Fir timber frame

Nice, light douglas fir…

Assembling the trusses.

Assembling the trusses.

Timber frame pegging trusses

Pegging the trusses

Remembering to install the handrail and balustrade which is part of the frame...

Remembering to install the handrail and balustrade which is part of the frame…

Floor joists in place

Floor joists in place

What didn’t go so well? Angus’ telehandler had a strop and its stabilising feet literally dug its feet in and refused to cooperate from midday. Angus is never one to panic however, and after some grunting and tinkering with a spanner and an oily rag, he was able to temporarily fix the reluctant beast so that we could at least crane the trusses into place.

Lifting the trusses into place

Lifting the trusses into place

We gave up after that and resorted to manpower to install the purlins and ridge. Again we were more than thankful that it was a small frame and that we weren’t dealing with weighty oak.

Douglas fir for timberframe house

Angus helping out after his telehandler woes

Resorting to manpower

Resorting to manpower

When we raise a frame we are generally fairly relaxed about its initial positioning as experience has shown us that we can move it to its exact location at the end of the day. This we do by “tapping” the posts a tiny fraction at a time. Unbelievably you are able to shift a 20 ton frame by an inch or more if you need to.

We expected to be able to do the same with this frame, especially as it was much lighter. No chance. The friction created by the rear and side plates bearing on the masonry walls meant the frame wasn’t going to budge – a bit like Angus’ telehandler. It was stuck fast and we still had 40mm to move! After a brief pow-wow during which we considered ever more outrageous options, including the use of Chinook helicopters, we decided to try and put some tension on the frame.

There were no available trees so we attached a 5 ton ratchet strap to the back of the pickup while we tapped the frame over. It took about an hour, and involved a great deal of jiggery pokery, but we got there in the end.

Gently helping to move the frame

Gently helping to move the frame

Lesson learnt.

Bright orange frame....you can probably see this from outer space.

Bright orange frame….you can probably see this from outer space.

 

Here’s a handful of photos of this frame in the workshop at Castle Ring:

Douglas Fir timberframe

First crossframe assembled in the workshop with the scarfed soleplate laid up and ready for scribing

Chaos in the workshop as all the component timbers are separated to be tenoned, morticed, drilled...

Chaos in the workshop as all the component timbers are separated to be tenoned, morticed, drilled…

IMG_2656

..then it is all reassembled one last time

The douglas fir frame has a fully joisted floor. Here the joists are laid up on the floor beams ready for scribing

The douglas fir frame has a fully joisted floor. Here the joists are laid up on the floor beams ready for scribing

IMG_2667

 

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