Cob Construction Work

Internal and External Restoration work undertaken to Georgian 1830s property. A1 complete builders instructed to remove concrete Render from all External stone walks and replace with Lime & remove gypsum plaster from internal walls and also replace with Lime.

Barn conversion with a new extension.

A1 Complete Builders was awarded this contract due to our experience in conversions and cob renovation work. The project consists of a new block and beam floor, for the new kitchen and dining room area and a complete restoration of the existing cob barn. The client is one of our previous happy customers who lives in St Allen.

Phase 1: To be completed by end 2019

Phase 2: Will commence mid 2020

A1 have been instructed to undertake renovation works on Polsue Cottage at Point near Devoran. Removal of sand and cement from cob walls and re-plaster using the correct material (lime plaster)

This project is two cottages, ‘Upalong and Downalong‘ owned by the same family for 3 generations.

We are completely gutting the properties and upgrading all electrics, heating, insulation, damp proof floorings and new kitchens and bathrooms.

Lime plastering to walls and new upgraded ceilings throughout.

All Exterior walls have been Sand Blasted to remove old flaking paint enabling us to get back to a sound surface in order to repaint using Beeks Breathable paint. All interior and exterior to be painted.

All work carried out under a J.C.T Contract and overseen by Cockram Surveyors.

We have been instructed to renovate this charming Cob Cottage in Trencreek, Newquay. 

Sand and Cement applied over the years and now severe damp problems and render blown and cracked in various areas. Once the cement based render was removed it was evident that most wood lintels were rotten and had to be replaced, again once the moisture is locked in wood will decay and rot eventually also causing the cob to collapse.

Various areas needed some T.L.C and cob stitching together and a mesh over lay to prevent further cracking.

St Astier N.H.L 2 mixed with C.L.S 28 in first scatt and C.L.S 30 for dubbing coats followed by C.L.S 33 for top coat.

This beautiful stone and cob built terrace house located in Campfield Road, Truro was built in 1816 and sold to Paul Row in 1825. Paul subsequently gave his name to the whole row. [Pauls Row]

At some stage in its glorious life a builder has applied sand and cement render to the façade and as we now know this material is not compatible and does not adhere to the substrate, in time blowing, cracking and falling off.

We have been instructed by our clients to remove the old render and replace with lime render, St Astiers  N.H.L 2.

Duration of time on site, four weeks.

A1 Complete Builders Won the Contract to Renovate A 300 Year Old Cob Thatched Cottage in Feock.

Our clients own the thatched cottage adjoining this and have done substantial works over the years but now face a challenge in restoring this property to its former glory but very sympathetically.

The property has been empty now for some six years and had only two night storage heaters in place. There is no kitchen just a couple of cupboards and a Belfast sink and no bathroom. The old and new extensions will now benefit from a new heating system to include under floor heating and the installation of two wood burning stoves backed up by a boiler system.

This cob cottage will also benefit from four new living areas once the four extensions are built around this old frail Cottage. Extensions to include a single story lobby/bathroom, a two story lounge down and bedroom above, another single story kitchen extension and finally a two story dining room down and bedroom above.

All wood windows and doors purpose made by D.J. Newman Joinery although the cob cottage is listed and the existing windows will remain in place and have an overhaul, new sash cords etc.

The cob itself is very frail and in poor condition in various areas this will need stitching together with 6 – 12 mm stainless steel helifix bars other areas will need to be carefully taken down and rebuilt with cob blocks in particular the cottage had a cob extension tacked on the end but it was not tied into the thatched section and is causing concern as to its stability.

Cornish Lime Company will supply all materials needed to undertake the cob restoration works to include lime plastering all internal and external walls using C.L.S 28,30 and 33 grade mixed with hair and 3.5 St Astiers Lime allowing this historical cob cottage to breathe and live on.

Most of the internal doors will be oak ledge n brace, floor finishing will be a mixture of ceramic floor tiles, carpets and oak plank floor boards. The cob cottage floor is a completely different set up as it needs to breath and once the floor has been dug out and reduced we will lay a Geotextile with 150 mm recycled foam glass insulation and a 150 mm limecrete slab with underfloor heating pipes laid before laying the finish floor surface A 75 mm lime/sand screed.

Duration of time on site: 4 Months

This was once two gorgeous Cob Cottages but now converted into one. Built we believe around 1750, (goes to show how well Cob lasts) , A1 Complete Builders have been instructed to remove the sand and cement render – put on by a local builder.

In this case we have one section of the cottage rebuilt in concrete blocks and two thirds still in cob, where the two different materials meet we have applied mesh to stop any cracking in the future.

There is also a lot of cob damaged due to lumps of concrete or cement render been applied in the past, we must be very careful when  removing this material as it pulls the cob out with it.We have purchased cob blocks to make these repairs as lime render would only crack.

We have also been instructed to replace all windows with double glazed wood sashes along with the replacement of all window lintels which at present is a mixture of concrete and rotten wood. Truro Saw Mills have supplied us with Solid Oak.

A1 also has most of the internal walls on the Ground floor to lime render along with some small alterations.

Duration of time on site: 8 weeks

We have here a typical example of what water will do when entering a cob wall, This particular problem was through water constantly running of the roof as there was no guttering.

In time it washed out the Cob and caused a crack that then had to be stitched together with Helifix Stainless Steel Twist bars and then lime rendered.

Once dry a etching fluid was applied to the wall and then a fixative followed by two coats of Beeckosil breathable paint.

This former coach house over the years has had various works undertaken by various builders but done with cement render. Unfortunately not suitable for this general construction as it is of stone and cob.

A1 Complete Builders removed all cement render from all walls external to the property and some internal also.

We have restored the sides and rear of the property back to its former glory and applied Lime Putty Render to allow this beautiful property to BREATH once again but as you can see the front of the property revealed all stone and no cob. The clients then decided to keep this appearance and asked A1 to Point with Lime Mortar.

At present A1 is still at Gwarnick Mill undertaking various internal and external work, to include fitting of an oak decking area and replacement of old floor boards etc.

Duration of time on site: 12 months