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Exisitng Extension

Construction of Bake House Extension in Colne Lancashire

On this project we were involved with the Groundwork & Building Work. The site is located at the top side of Colne close to Trawden & Crosshill. The existing building is in use as a Bakery, over 4 floor. The Bakery wanted to expand its bread baking facilities.

Russell Smith Joinery was the main contractors, they constructed the roof & internals.

Work commenced on the Extension project in April 2012, the build took 8 weeks to complete from start to finish.

Stone Walls to be Demolished

This picture shows the original rear view to the house before construction started on the Extension. The original rear Stone Wall was carefully dismantled & stored on site. This Stone Wall was re-used to construct the new side wall.

Inside the back yard was a small Extension that was being used as a preparation room. This was dismantled and removed from site.

The new Bake House Extension was cover the entire footprint of the rear yard area. New foundations had to be excavated & concreted. The original floor and yard area was excavated and a new Concrete Floor Slab was cast.

Existing Stonewalls

The original Stone Wall on the Gable Wall was also dismantled and stored on site to be re-used in the construction of the new Stone Wall. The external footpath is at a higher ground level to the floor slab of the Extension.

When we were Building the new House Extension a waterproof layer had to be installed during construction to prevent damp showing on the internal walls. This waterproof layer was installed on the external of the base blockwork. The existing Stone yard wall had been constructed on large flagstones, some of the original foundation were only just below ground level.

Dismantling Building

We started the Building work by removed the existing Stone yard wall, the Stonework was stored on site to be re-used at a later point in the project. Our Building Team then started to dismantle the existing Bake House Extension. Most of the material was disposed of via skips.

We used a small excavator and hi-tip dumper to aid with the demolition work. We also so used the excavator and dumper when digging the foundations for the extension. The Brick Wall on the adjacent side to the Gable had to be Under-pinned due to the lowering of the floor levels.

Demolition of Building

Once the existing buildings had been demolished the small site area was cleared. Our Building Contractors took just 2 days to demolish the existing buildings.

 

Blockwork in Foundations

We had to install new Top Water Drainage Systems and Foul Water Drainage. The existing Drainage system was install around 1930. We used osma plastic drainage. Most Drainage system around the Lancashire area date back to the Victorian period. If the drainage system is leaking this can cause subsidence, high water table & voids forming.

New Drains over Foundations

Here we have installed a new drain over the newly cast concrete foundation. We used pre-cast concrete lintels to bridge over the pipe, this stops any weight collapsing the new drainage pipes. All the drains inside the new Extension have been replaced, this is because when the Concrete Floor Slab is cast access will not be possible.

Building Blockwork

Once all the foundations had been excavated and concreted we built the foundation Blockwork to DPC level.

Our Builders have worked on many projects around the Lancashire area. We under take house extensions, basement & garage conversions, barn conversion, landscaping & building cleaning. Our workforce have a large wealth of knowledge in the construction industry.

Underpinning Brickwall

Here our Builders are underpinning the side wall to the new Bake House Extension. This is a original Brick Wall in the yard area. We excavated the foundation in small 1.5 m section, then filled with concrete. These sections were built up with Blockwork to take the weight of the above wall.

Constructing Extension
The rear Block Wall was constructed of 2 Blockwork leafs with a 65mm cavity wall insulation installed behind the inner leaf. Our Builders have laid many square meters of Blockwork. The rear Blockwork wall does not have a stonework layer on it, the blockwork will later be rendered with K-rend.
Excavating Deep Foundations

Here we are excavating the side foundation for the Extension, due to poor ground conditions we Excavated down to 7ft. The Foundations were then mass filled with concrete, mass filling with concrete saves time & is also cheaper then filling with Block work.

The existing ground had been filled with material probably about 100 years ago

Excavating Foundation for Extension

The excavations had to be excavated to a depth of 7 feet in places due to poor ground conditions. The foundations had to be cast in 8 sections. These sections of the concrete foundations were reinforced with steel mesh & bonded together with re-bar.

You can see the blockwork in the foundations of the extension to the right of the picture. We built on the concrete foundations as we were excavating the next section.

Building Extension
On this picture you can see the foundation stones we excavated. The existing stone wall was constructed on these foundation stones. We had on site a .5 ton excavator and a 1 ton hi tip dumper. Due to the site being small we could only store a small amount of materials on site.
Excavating Foundations
After excavating all the foundations and concreting, we removed the excavator from inside the building.
Installing new Drainage

A new internal drainage system was installed to remove waste water from a new floor drain & a internal rain water pipe from the roof.

We also installed a new internal inspection chamber, this linked a external rain water pipe into the new drainage system.

The existing drainage systems located in the back street are a combined system, meaning both top water & soil (waste) are disposed of in the same pipe.

We used a 110mm plastic osma pipe, this is standard pipe used for underground works now. The pipe work was bedded on and covered with 10mm crushed limestone, this is to protect the pipe from damage.

Compacting Extension Sub-base
Once the new drainage system was install and back filled, were used a crushed limestone called MOT1 to create a sub base for the floor. This was installed to a depth of 6", it was then compacted with vibrating plate. We then re-leveled the sub base to fill any low area created by compacting.
Stoning Drainage
Packing pea gravel round the underground drainage system.
Concreting Floor

After installing the crushed limestone sub base, we blinded with sand & installed a visqueen membrane. A reinforcing mesh was installed to the concrete floor stood on class b engineering bricks. A 6" thick concrete slab was cast to create the floor, this was trowel finished. Later a coloured resin fibre based paint was poured.

The external blocks wall were built with a 65mm cavity insulation slab installed. On the gable wall we laid a backing block and a 8" stone skin.

Extension in Colne

Once all the stonework and blockwork had been completed on the extension the roofing company applied a torch on roofing felt. Here on the extension the rear blockwork has yet to be rendered with a K-rend product.

The internal of the extension was fitted out with bread baking equipment. The rear door on the extension was made so all the equipment could fit into the extension.

A new lead flashing was installed on the roof with the existing building. The roofing contracting used a code 5 lead.

K-rend on Extension

Here we are applying a K-rend to the blockwork on the rear of the extension. We applied 2 10mm coat of K-rend to the blockwork. The K-rend was coloured to a Champaign colour, this means the K-rend will not require painting.

This was the last process to be completed on the extension.

Extension
Extension finished, just a quick wash down of the stone footpath and cobbles.

 

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