Author Topic: The Kaya Project (building a new workshop)  (Read 18946 times)

kibi

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The Kaya Project (building a new workshop)
« on: August 13, 2012, 05:56:57 PM »
I have been living in my current home for the last 12 or so years. Tucked away at the end of the garden was an abandoned shed. My landlord (Alex) who lives abroad had a great deal of his things stored inside. As we never had the keys for this shed, we never paid much attention to it.
Recently, Alex was in the country and dropped by to collect a couple of his things. Unfortunately, without our knowledge, the roof had gone in many years ago it would seem. About 10% of the roof remained intact and most of the contents has been ruined.
We reached an agreement where I could use the shed provided I made repairs to it and store whatever was still in good shape.
This suits me because my workspace has expanded over the years to the point where some extra space would be most welcome. It may seem crazy of me to invest my own money in someone else's property, but I will save money by not paying for off site storage anymore. My return on investment is about 8 months.

So, lets get set to work.

Quite a mess, it'll only get worse though. Alex put polythene on the roof perhaps in some sort of panic.



Inside is pretty bad and even with no roof, it stinks of rot.









Upon removing the contents I found one of the walls had split from top to bottom. I pretty much pulled the whole wall down and built it up again from the ground. I put steel reinforcing band between each course.









Now it's time to get a new roof on. The entire roof had to be removed as the joists, although in not too bad a shape, were under spec'd. The joists really need to be 50x100mm treated timbers with 600mm centres. I also went for 18mm ply, expensive, but necessary in my opinion.

The old timbers are removed and the floor cleared. I had some much appreciated help from my brother and my friend Chris.



Now we have to get rid of loads of plants that have grown through the roof over the years.







Finally, the timber delivery arrived at 3pm. I had to get the roof on the same day because rain was forecast for the Sunday.

Roof timbers going up fast.







Now the ply goes on top. As a side note, if you ever have a project that involved driving a lot of screws, do yourself a favour and get self drilling Torx head screws. They save a great deal of time. No cam-out at all. My local store stocks a wide variety of the Paslode ones. They are more expensive, but well worth it. A great deal cheaper then buying a Paslode nailer ;)
Note that the correct tongue angle when performing this task is vital :)







Now the boards are screwed down, the surface needs to be swept and prepared for the one piece EPDM rubber roof.



The rubber is laid out and here I am applying the glue.





Just before dark, the roof is complete.



The next day I put up the roof trims and guttering.





So now, it's time to get the inside done.
I applied a liquid DPM (damp proof membrane) but I didn't get on with it much so I put polythene down on top of it. I then put stud work on the walls and floor to hold the insulation in place.



The insulation arrived on time. I went for high performance Celotex PIR insulation boards. 50mm for floor and walls and 75mm for the roof. This stuff is manufactured locally, some of the boards were produced just days before by the date code on them.



It's pretty easy to cut and install.



I used odd planks of wood from the ruined flat packed furniture to make the floor. I just trimmed the rotten ends off of the pine sheets to make a good solid floor.
The floor is mostly complete, just the odd shapes to be cut and screwed in place.



That's my progress so far. The next thing is to put a decent door up.
« Last Edit: July 01, 2015, 06:47:51 AM by kibi »

SeanB

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Re: The Kaya Project (building a new workshop)
« Reply #1 on: August 14, 2012, 12:25:42 AM »
Nice job Kibi, reusing the old blocks and putting the needed brickforce in as well. Probably your patch is stronger than the rest of the shed. Good idea to insulate the roof and floors as well, should be nice and warm in winter and cool if there ever is a hot day there. Are you going to put a window in to get natural light , and a nice insulated door?

kibi

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Re: The Kaya Project (building a new workshop)
« Reply #2 on: August 14, 2012, 06:34:52 AM »
I've done away with the windows, more hassle that they're worth. During winter it will be dark 95% of the time I'm in there.
I'm going to build a staunch door and insulate it with Celotex. I made a mis-calculation and have ended up with two full sheets of Celotex.

SeanB

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Re: The Kaya Project (building a new workshop)
« Reply #3 on: August 14, 2012, 01:55:00 PM »
What light and power are you going to put in? I would think a nice 4mm cable buried in conduit and then a separate mains breaker, ELCB and sockets along with a 1.2m double flourescent fitting will make it nice.

kibi

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Re: The Kaya Project (building a new workshop)
« Reply #4 on: August 14, 2012, 03:21:10 PM »
As soon as the ground is clear I'll be able to dig a trench for the services.
I need 4mm armoured cable for power, single mode fibre for data and an alarm cable. I'll then run spare UTP as space allows.
As for the lighting, I don't know yet, probably go with home brew LED. My electronics bench already has home brew LED lighting, I'll probably do the same above the machines.

SeanB

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Re: The Kaya Project (building a new workshop)
« Reply #5 on: August 14, 2012, 03:58:53 PM »
50mm PVC waste pipe is ideal for this, as you can run all of the data cabling in one conduit, and a separate one next to it for the power cabling. UV resistant and after you seal the joints waterproof.

kibi

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Re: The Kaya Project (building a new workshop)
« Reply #6 on: August 14, 2012, 04:06:19 PM »
Ja, my boet and I was just discussing this. It would seem that 40mm or 50mm is the way to go. Leave a draw wire in place in case you need more in the future.
I may also be necessary to put an earth rod down.
« Last Edit: August 14, 2012, 05:32:43 PM by kibi »

SeanB

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Re: The Kaya Project (building a new workshop)
« Reply #7 on: August 14, 2012, 04:28:27 PM »
If you put earth rods down connect them to the earth point with a 10mm cable, and cover the joint to the rod with grease overwrapped with first some broad tape then a layer of self amalgamating tape. That will not corrode through easily. Put 2 draw wires through extra, and when doing bends use large radius bends so that it pulls easily. Cheap dishwash liquid on the cable helps with the pulling.

kibi

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Re: The Kaya Project (building a new workshop)
« Reply #8 on: August 14, 2012, 04:47:04 PM »
Thanks for the tip with the earth rod. This earth also needs to be tied to the house earth so that the cabling doesn't conduct any currents produced by differing earth potentials (lightning for instance).
Only one draw wire is necessary if you are disciplined enough to draw a new one together with the new wire you are pulling through. If there is not enough space for a new draw wire then you don't need one, you need a new conduit :)

SeanB

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Re: The Kaya Project (building a new workshop)
« Reply #9 on: August 15, 2012, 12:37:17 AM »
2 draw wires means you have a spare in case the one breaks during pulling, or comes detached............

kibi

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Re: The Kaya Project (building a new workshop)
« Reply #10 on: August 15, 2012, 04:49:16 AM »
Good point, I like your thinking.

MJLorton

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Re: The Kaya Project (building a new workshop)
« Reply #11 on: August 15, 2012, 06:27:23 AM »
Yeeee Ha! Brilliant project Warwick! Thanks so much for sharing the details. I look forward to seeing how this cozy "nook" / Kaya is going to progress.

Cheers,
Martin.
Play, discover, learn and enjoy! (and don't be scared to make mistakes along the way!)

SeanB

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Re: The Kaya Project (building a new workshop)
« Reply #12 on: August 15, 2012, 11:57:40 AM »
Just saying............ You know how you get experience............

kibi

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Re: The Kaya Project (building a new workshop)
« Reply #13 on: August 15, 2012, 02:33:59 PM »
Yes I do. Now knowing the advantage of having two draw wires, I could now run a single one and watch something go wrong right away - guaranteed :)

SeanB

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Re: The Kaya Project (building a new workshop)
« Reply #14 on: August 15, 2012, 03:13:02 PM »
At least you can get to the conduit. I had a problem with a conduit that had a leakage to earth that eventually went hard short. Buried under 30cm of reinforced concrete, and it had rusted through somewhere. Went surface mount with the new cable........ It took the plumber who repaired a drain in that floor 2 days to make the hole with a jackhammer. Good thing though is that half the bricks he used were in the dug out sand under it. Bad is that the bricks were there in cement mix.......