Church Farm Case Study 2021

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Church Farm – Somerset

Architect: Client: Autograph Homes Project: 44 detached homes Cost of Build: Location: Rode, Somerset Type of contract: Private sector, Design and Build

Executive summary: Thin-Joint blockwork was chosen for this development of two, three, four and five-bedroom homes in rural Somerset.

Planning regulations required a natural stone façade for the homes, requiring specialist stonework contractors. The developer chose to use Thin-Joint blockwork for the fabric of the houses as the entire weatherproof structure could be completed independently of the façade, speeding up the build process.

Project description: This new community, in picturesque Somerset countryside, is designed to attract discerning homeowners looking for village life. Combining traditional craftsmanship with high quality contemporary design, the homes are generously sized, with distinctive architectural detailing, including chimneys, generous stone lintels under traditional-style timber windows and attractive clay-tiled roofs.

The development is arranged around a series of courtyards to encourage the sense of community.

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Church Farm – Somerset

Reason for choosing H+H aircrete: Autograph Homes is a progressive regional housebuilder, always looking for ways to improve the speed and quality of its building process. For this traditional style development, the builders felt that their buyers would expect the reassuring solidity of masonry so some type of blockwork was always going to be the preferred building method.

Aircrete was the obvious product for its inherent thermal insulation: meeting very high standard of energy efficiency is a core principle for this housebuilder.

However, Thin-Joint was chosen above standard blockwork to exploit the advantages of using a Modern Method of Construction (MMC) on this relatively small development.

Simon Taylor, MD of Autograph Homes, outlined his thinking: “We have looked at many MMC options, but those based on significant offsite prefabrication are really better suited to larger developments of standard house types.

We need the flexibility to build individual homes at the speed to match our customer demand, so blockwork is a practical solution.

“We were looking for a quicker way to build that is less dependent on good weather than traditional blockwork. Thin-Joint offered a solution that was well aligned to the skills we had on site.

It’s the first time I have used Thin-Joint and I found it very good. It’s easy to do and the trainer who came to site was very helpful. Some of our tradespeople took a little time to get used to the process, but I can really see this system taking off and I would recommend that we use it again.”

Dean Stephens, Technical Manager at Autograph Homes

“Thin-Joint really is a step forward from standard blockwork. It is more accurate and much faster, particularly as the Cellfix mortar used with the large-format blocks cures even in low temperatures or in rainy conditions, reducing the impact of the weather on our build process.

“The very thin 2-3mm joints give precise building and improved airtightness, but the main benefit is that the exterior brickwork – or, as in this case, natural stonework – is taken off the critical build path. The entire weathertight fabric of the house is completed independently of the stonework, allowing the interior trades to carry on while the exterior is still under construction.”

Although widely used in Europe, Thin-Joint is still relatively uncommon in the UK, so the technical support available from H+H was an important part of the offer.

“H+H was able to send its site trainers to Rode regularly in the early stages, ensuring our brickworkers were completely up to speed with what was a new technique for them. The H+H team has continued to visit as required when new bricklaying teams join the site and their support has been very welcome.”

Products used / aircrete specification: H+H Standard Grade Blocks (3.6Nmm2) with Celfix Mortar, designed specifically for use as part of H+H’s Thin Joint System.

For many of the houses, the Thin-Joint blockwork was supplied as part of the H+H RäBuild package. RäBuild is an all-in-one package approach to building including ground floors, exterior walls, upper floors and partitions combined with technical support and on-site training.

Foundations: Block and beam foundations.

External walls: Cavity wall construction with aircrete inner leaf, mineral wool insulation and natural stone façade, some of which is in the form of preformed panels. Cavity walls provide thermal insulation to meet Part L of the Building Regulations.

Roof: The roofs are traditional pitched design with timber trusses – some provided to site as prefabricated units - supporting red clay pantiles.

Floor: Wooden joists with chipboard.

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Church Farm – Somerset

“It’s great to work with a regional housebuilder looking to use MMC in a way that suits them. We were pleased to support the company with training and technical advice throughout the project.

“We appreciate that learning a new way of working can be challenging for tradespeople who have been building in the same way all their working lives.

Support from forward-thinking companies like Autograph Homes is essential if new methods are to gain widespread adoption in this country.”

Amos Rodrigues, H+H Sales manager

Product benefits: Easily meets or exceed Part L and Part E of the Building Regulations Simplifies the construction process H+H aircrete products use up to 80% recycled material Achieves A+ rating in the BRE Green guide Other benefits include: Thin-Joint is faster to build, giving cost benefits through reduced site time Ra-Build gives certainty over technical detailing and project cost Aircrete achieves an air permeability of 0.12m³/hr/m² Has excellent fire resistance with a Class 0 rating for surface spread of flame H+H aircrete applications: Internal and external leaf in cavity walls Solid walls Separating / party walls Flanking walls Partitions Multi-storey Foundations

Aircrete is an excellent all round commercial and industrial building material. Used in partition and external walls (both solid and cavity), fire walls and as infill to steel and concrete framed buildings it provides durability, fire resistance and superb thermal and acoustic insulation.

H+H aircrete has exceptional sustainability credentials: not only does it provide excellent thermal and acoustic insulation and contributes to air-tightness but, being manufactured from up to 80% recycled materials, it is sustainable both in manufacture and in use.

We also have BES 6001:2008 accreditation for responsible resourcing of materials, in addition we have an A+ rating under in the BRE green guide on both cavity and solid

Contact details For enquiries call Tel: 01732 886444 or email: info@hhcelcon.co.uk Head office H+H UK Limited Celcon House Ightham, Sevenoaks Kent TN15 9HZ

external walls. Couple this with H+H UK’s rigorous approach to pursuing the highest environmental standards throughout the whole of its business and it’s easy to see why this innovative and award winning system is now firmly established within the UK.

For further information about the subjects covered or the H+H products used in this case study, please visit our website www.hhcelcon.co.uk