The Coach House

A 200-year-old former coach house of Cotswold stone surrounded an outstanding 2 level garden, which the clients designed. The Dutton’s wanted a flat parapet roofed extension of Cotswold stone, oak, and glass so they could, in a sense, bring the house into the garden. Above the flat roof we would add an oak dormer in the main roof to overlook the garden from the first floor.

Logistics

  • Site preparation was done by establishing a perimeter of the area of the work to limit the impact of the traffic in the garden, which made it easier to re-establish afterwards.
  • As the work was intrusive to the roof of the main structure it was vital to ensure the interior would remain dry throughout the process. To do this, we had a canopy put over the portion of the building effected during the scaffolding process. We saw that there were many advantages to this that more than made up for the additional cost. Along with avoiding an interior flood, work would continue regardless of the weather. It also enabled us to mill the oak beams and facade on site, and in the dry until the roof was completed.
  • The flat roof consisted of a parapet around the perimeter of the roof with a pitched overhang with 5 courses of slate. Behind the parapet wall we set out 2 lead gutter channels and then directed the deck fall to those points. Then a membrane was fitted on the deck and the back of the parapet. Lastly, a lead capping was formed and welded in situ along the top of the parapet and over the slates.
  • The dormer was problematic as we knew it had to be opened first but slated only after the flat roof was complete and the membrane fitted. 
  • We milled the oak facade once the walls were constructed to ensure accuracy. First, we milled the sill and mortised for the posts. We then mortised the beam to match. Using a chain block, we set the beam onto the tenons of the posts, establishing the door and internal glazed openings. Once the double-glazed panels arrived, we milled battens to match the thickness of the gazed units plus 6mm to fit the rubber perimeter seals once we had added an external layer to close in the glazed panels, finishing the facade.
  • Internal work included the removal of French doors to open the extension to the main house. The existing oak floors were sanded and refinished which matched the oak floor in the extension perfectly. Oak internal sills were fitted, and the interior woodwork was finished with tongue oil.
  • The stone porch and reinstating the garden were the last tasks to be completed.
  • Neil Ashman, the building control officer put us forward for the annual builder's excellence award for 2022, which we are pleased to say we won!

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