Friday, 2 February 2018

Roof Ridge Cap Finished

A few smaller jobs have been completed since the big roof finish, not as exciting but still very necessary and important. The insulation was taped together on the inside, so that each section is joined without gaps to let the heat in. Surprisingly a very large amount of heat was sneaking through where the insulation was joined, even though there was a 100mm overlap. The special insulation tape does a fantastic job of cutting most of this heat out. This job involved climbing up a ladder dozens of times to reach the many joins, with about 8 pieces of insulation on each side and 5 lengths for each join to fit inbetween the roof purlins.

Next we installed some bushfire mesh underneath the ridge cap, wedged between the roof sheets and the insulation underneath it. You can't really see it in this photo, but you can see some of the insulation taping.

The installation of the mesh means that we are fulfilling the bushfire regulations by not having any gaps smaller than 2mm which may allow the entrance of embers in the event of a bushfire.

Then we installed the ridge cap on the roof. First lengths of insulation were taped to the ridge cap, and the roof was swept clean.

Then the ridge cap was screwed to the roof. There were two lengths of ridge cap, each 5.5 metres long.

With roof length of 10 metres and an overhang of about 35mm on each end, that gives plenty of overlap in the middle. After the screws were done, they were all covered in silicone to ensure waterproofing.

 Another job was installing bushfire mesh in the verandah gutter. This mesh has about 7mm squares which will greatly reduce the amount of leaf litter which gets stuck in the gutter. This helps reduce bushfire risk at the same time as helping ensure cleaner water, and means that we have to get up and clean the gutters much less often.

I also finished the screws on the decking. We had bought some screws from the store which is 1 ½ hours drive away, but it turned out that either they didn’t give me the 140 screws which I asked for, or that despite my many calculations and recounts, 140 still wasn’t enough. So I went back to the store and bought a bunch more, but when I checked them, it turned out that they had sold me the wrong screws – they were too short.

So third trip to buy screws for the decking WHICH SHOULD HAVE BEEN SUPPLIED BY THE KIT HOME COMPANY IN THE FIRST PLACE, we are advised that we have been given the wrong screws from the kit home company all along. We were shown a pack of the same kind of screws which says on the back ‘Not Recommended for Fixing Wood Decking to Metal Joists’. Which is exactly what we are using it for. Apparently because of the way that wood and metal expand and contract at different rates with change of temperature, that creates a tendency for the screws to shear and break. It turns out that the correct type of screws are only available in very large packs which cost hundreds of dollars, so we figured that we may as well finish the job with the same screws we have been using all along.

Next step is to put the windows and walls on. It has been raining for the last week, so the country lore that the rainy season starts on Australia Day might be true.

Thursday, 4 January 2018

Second Side of Roof Finished

     Finally our first day of decent weather, and the boys finished off the second side of the roof.

     We still have to turn up the end of the sheets at the top, and put in some kind of bushfire protection under the ridge cap when we put that on to seal the gaps, but it's looking pretty amazing.

Monday, 1 January 2018


Significant progress has been made on the roof during the christmas holidays, due to the wonderful help of visiting family. Thanks so much guys!

Since the last post I spent several mornings putting up the 10 fascia brackets. First one end, then the other, then a string-line between them to make sure all the ones in the middle are in a straight line.

I found this a difficult and annoying job as the brackets tended to move while I was trying to drill the screws in, despite the clamp holding it in place. I learned as I went though, and the later brackets were done much more quickly than the first.

After this was done, the boys put up the first gutter which was a bit tricky as it bends very easily. Some supports were taped to it and then it was lifted up with rope and the use of two ladders. The gutter is attached with the use of suspension clips and gutter straps.

Then the boys put the fascia board on. This was done in two halves with the middle joined by an extra support piece, riveted together, the same as the fascia board on the other side of the house. Then the gutter was put up using the same method as the first side with supports and ropes.

Next the roof was started. First the insulation was cut to length and taped into place, and then a roof sheet was placed over the top and screwed in. The same was repeated for the other side.

Also the roof strapping was tensioned up while working up in the roof. Here you can see the underneath with the roof strapping, the insulation which is 135cm wide, and two sheets of Colorbond – each 84cm wide.

A couple more days of dodging rain and the bottom side of the house is nearing completion. Christmas day we had 70mm of rain in only a couple of hours, so it seems the wet season has come early!!!

Thursday, 14 December 2017

Verandah Downpipe

This morning we put up the downpipe for the verandah gutter. First I assembled all the tools we would need. Most of them were handtools except for the cordless drill.

Then I drilled the top of the downpipe where it attached to the downspout and riveted the holes together.

Then at the bottom we needed a piece to join the gap between the decking and the verandah post, and push it outwards a little so that it would end up at the perfect spot for the water to flow into the 100 litre tank which we will place underneath it. This piece of metal was a left-over piece from building other parts of the house, and just happened to be the perfect size. It was trimmed a little at the ends to ensure it had a flat surface for the downpipe to press against. We were provided with downpipe brackets which we used for the outside join, and cut a short length of strapping which was left over from strapping the frame of the house. After these were screwed on, the structure was very solid and stable.

After that was finished, I climbed up onto the verandah roof and put silicone over all of the roofing screws. I also washed out the gutter as it was full of metal filings from attaching the screws. We won’t put the 100 litre water tank under the downpipe quite yet, as I want to wait until we have some rain to wash the roof and the gutter clean. No rain is forecast for the next week, so we might be waiting a little while.

Tuesday, 12 December 2017

Verandah Roof Finished

First we assembled the gutter for the verandah, this was relatively straight forward as we had done exactly the same thing for the house verandahs previously. For the stop ends, holes were drilled through and then riveted together.

Then for the downspout, a rectangular hole was cut in the gutter, the spout put in place and then holes drilled and riveted together.

To finish the whole thing off, silicone was spread over all the joins. Here is our collection of tools for this job.

Then I spent an afternoon and two mornings screwing in the gutter brackets. First one was put at the top end, and then another put at the bottom end with a 20mm fall. Then a string line was stretched between those two, and the other brackets screwed in to follow the string line.

After leaving the silicone to cure, we put the gutter up into the brackets, this was easier than I expected – since the gutter is slightly over 6 metres long it is a little difficult to handle while standing up a ladder, but one of our best 'tools' is an old broom which we found at the tip. I used the broom to push the gutter to click into each bracket while Josh held it up, and then he folded down the clips over the top.

We decided that it would be worth the effort of putting insulation underneath the roof sheeting, so we cut up one of the rolls which was provided with the kit home into sections which fit the width of the verandah. By lucky coincidence our 180cm level was exactly the right length so I used that as my measuring stick.

This is the paperwork that came with the insulation, which I suppose we will have to show to the council when it comes time for approval that we met the energy requirements for Basix.

Then we joined the pieces with rolls of insulation tape. This is a special type of tape which is a cross between gaffa tape and alfoil. This photo is looking up at the underneath of the roof after the insulation was placed on the top.

We were provided with 8 sheets of colorbond which were 187cm long and 85cm wide, so we laid them on the ground to measure how much we should overlap them to achieve our 6 metres for the verandah size. They are laid upside-down in the photo, showing the underneath colour. By the time I took the pic, we had already taken away a piece to put on the roof.

This is the colour of the top of the sheets, it is known as Slate Grey. This is the first time we have actually seen the colour, and it is actually a lot darker than I was expecting.

Then Josh got up on the roof and laid the sheeting, screwing it in as he went. The perfect length was achieved by overlapping the last sheet a little more than the rest, luckily avoiding the need to cut a few centimetres off the end. The metal roof in the sun was VERY HOT, so I am glad that we put the insulation up, as it will keep it a lot cooler under the verandah. Even the blue framing metal is cool to the touch compared to the Slate Grey roof.

I can't believe that we finished the whole thing in one day! It is actually very difficult to photograph, as by the time I am far enough away to see the roof there are small trees which block the view. I went up on the roof this morning and finished screwing the middles of the sheets, and the next thing that needs doing is to put silicone over the screws. After that we need to attach the downpipe to the gutter, and into a small tank.

Finished Deck Roof

Just a quick tease of a photo of the finished deck roof which we started and finished yesterday.

I would do a longer post but I want to get down there and finish screwing it in before it gets too hot this morning!