JEFFREY TITMUS : RESTORATION WORKS :
www.hertsrestoration.co.uk
Historic building consultancy
RE: BEAUMONT WORKS. AL1 5HT: E.H.I.D 163464
CONDITIONS OVERVIEW/PROCESS REVIEW 2014
Sept 2011, instructed by owners Michelle Murray/Steelcraft Construction to carry out a
conditions survey report of the buildings comprising Beaumont Works, a combination of late
Victorian industrial factory structures built between 1900 -1903. The site was listed in the 1970’s
as part of the national re-listing program. The main listing features being the ornate detailing of
brick and terracotta façade and entrance ways to coped Dutch gables fronting Sutton Road St.
Albans. Construction is typical of industrial era solid brick masonry supporting ‘Northern
Light/Saw Tooth’ roof covering of Welsh slate and wired glass panels supported by a
combination of mild steel, cast and wrought iron trusses.
The original 5 bay footprint fronting was extended and added to with additional 2 storey bays to
the left and right flank elevations (N+S) around 1911, continuing in the same vernacular. A dual
pitch building was later added to the rear of the right flank 2 storey bay. Evidence (OS map1924
+ 37) of later additions to the rear have since been demolished.
The structures were constructed for Mr. J. Nicholson, a water proof clothing manufacturer who
had relocated from Lancashire and his ‘N’ & ‘C’ initials/logo are displayed on each of the ornate
gable facades’.
Survey Overview/2011:
The main structures are common of late Victorian industrial/factory constructional design
techniques; solid masonry supporting ‘northern light/saw tooth’ roofs utilizing the natural light
source. Combination of the then preferred mild steel, cast and wrought iron truss designed to
prevent internal thrust stress/spread to the supporting walls required in large work production
space. Common materials used comprised of locally sourced soft dark red facing brick, wired
glass panels (northern light), Welsh slate, with integral formed cast iron valley box gutters. The
main aesthetic/design focus being the fronting to Sutton Road; coped Dutch gables, bay entrance
way door-cases of Terra-cotta tile dressing, faience, break-front cornice with glazed tiles.
Gauged arches with key stones over timber mullion casements.
Built for the manufacture of waterproof clothing (Nicholson & Co.), expansion of production in
the early 1900’s allowed the additional 2 storey bays to north and south aspects, Coach Mews
and Hedley Road, following the original design for ‘northern light’ source.
C18+19> industrial structures were generally over engineered being function specific. Innovative
in design and evolving technical knowledge, these structures were built to last. Adaptation,
conversion and usage has enabled them a significant place in our urban landscapes. However,
maintenance of these working structures provides unique logistical issues with regard to safe
access within today’s health and safety regulations. Inherently and specifically in material and
design; the layout of the ‘saw-tooth’ roof configuration and linked combination of glass, cast
iron and slate within the 'saw-tooth' roof design. All materials have a lifespan. Individually units
can be repaired and or replaced. However within the ‘saw-tooth’ configuration, safe access for
maintenance operations are challenges today not envisaged when originally designed.
The Beaumont Works structures have missed the major overhaul periods usual for the lifecycle
of an industrial building. Extensive replacement and improvements are now a priority.
Beaumont Works was purchased in 1970 by the present owners and was part of the re-listing
program the following year. Maintenance of the structures up to that date comprised mainly of
individual localized repairs of the slate/glass roof coverings, and part replacement to the Hedley
Road pitched elevation irrespective of the potential additional weight loading and aesthetics. The
profiled formed cast iron valley box gutters have been repair coated in asphalt and bitumen. The
corroded and leaking glazing bars and rotted fibre seals to the glass panels have been covered
with plastic adhesive flashings. The large 2 storey bay slate roof pitch to the north is entirely
covered in multi-layered bitumen paints, with extensive nail fatigue to the remaining slated
slopes. ‘Short-term’ attempts at weathering have inevitably and consistently failed and the
substructure of structural softwood timbers and soffits, wrought and cast iron truss members now
suffering irreparable damage.
The present owners have instructed us to provide a conditions report with subsequent
recommendations.
The summary appraisal of which comprised the replacement of the roof coverings and associated
fabric within listed building regulations for which listed building consent was obtained. With
specific consideration to the unique constructional and design layout of these structures,
specialist design engineers for the access/temporary works and specialist contractors for the
supply and installation of the traditional materials required were sourced and subsequently
recommended to tender stage.
Process/Proposed Roof-Reinstatement Options: (Ref: App/Documents/Photo Identification)
Surveys were commissioned to ascertain the feasibility of such an undertaking, considering that
the works units were to remain fully occupied as leased to individual, on-going and thriving
businesses. Material and method specifications were proposed to satisfy listed building consent
planning requirements.
Access Scaffolding of historic structures must be totally independent with neither ties nor
loading to the existing fabric. Temporary roof support or interventions through to within the
working units were totally unacceptable
In discussions with engaged specialist access company Layer (GDR) it became clear that the
undertaking would need to be 3 phased due to the structures span size and configuration.
Specialist access design engineers (48.3) proposed and calculated Phase 1 (drwg STS P1-6), a
system to entertain Unit 1*Body-limits Gym, the 2 storey bay North (Coach Mews), spanning
south to the third valley box gutter at Unit 2* Caxton Blinds. Approximately 40m x 40m a
maximum temporary roof capacity. From this temporary roof covering internal suspended work
platforms where designed to service the internal pitched slate elevations and glazing works.
Additional kentledge loading/bearing requirement was calculated to support the original working
design. A unique feature of the Layer (GDR) system is the on-ground bay-erection and crane lift
to gable end bay linking of the sections that make up the roll-out roof covering system on full
length eaves casters N + S.
The northern eave scaffold being exclusive to firm ground (Coach Mews), with the southern and
west eave scaffold needing to bridge span the structure 30m from Sutton Road through to the
rear car park. The ‘bridging’ eave scaffold S (W>E) required support on designed full length
steel members (drwg STC 20-25) again with additional kentledge and ground bearing capacity at
either base. Mobile crane lifts of the rear car park assembly of full-length steel member bridging
sections and the southern rolling roof eaves caster construction into position S. Scaffold base
axial point leg loads and mobile crane travel loads were calculated to quantify ground bearing
capacity.(STC C 1259addA)
Scaffolding calculation, steel works design and crane load calculations were reviewed and
confirmed.(revSTC Calc C.1259A(v2.1) drwg STC 1259 1-6revA)drwg STC 1259 20-25A)
A second below ground survey was carried out following discovery during decommission of a
collapsed underground storage (heating oil) tank cover of other redundant services, voids and
poor surface conditions to the rear car park abutting and part beneath the structure Unit 1.
Leaking utilities/drainage systems, ground/surface water catch pits, poor compaction and
honeycomb voids to concrete/tarmac, with a history of repetitive pot-hole repairs were located
directly within the main rear works area. Solution-finding, trial-pit/core drill calculations and
reports are with consulting engineers Gyoury Self who are to devise and provide material
specification for instating temporary works foundations to construction purposes prior to any
proposed roof refurbishment schedules.
Internally and throughout the occupied/working units (Body-limits Gym 1*+ 2*part Caxton
Blinds), Phase One required internal safety scaffold crash decks and sealed working
platforms/ceilings, to be positioned spanning full width at wall/roof plate/ceiling height, with
temporary lighting and heating to be required for the duration of the works.
It became clear following the temporary works tender quotations that the ‘logistical costs’ alone
of Phase 1, with the units fully occupied, and subsequently Phases 2 and 3, rendered the funding
of the proposal unfeasible. Phase 2 (encompassing the remaining span Unit 2 third valley gutter
through to Hedley Road ( S.), a mirror image of the Phase 1 design, with a separate design for
the required unit works of Phase 3.
Costs of implementing the traditional fabric/material replacement were a mere percentage of the
safe access and logistics of the temporary works proposals.
Emergency repairs and attempts at localised weatherproofing of the structures with the latest
‘hi-tech’ materials are on-going but are temporary, costly and symptomatic without any real
confidence of long-term success (and have indeed consistently failed).
Attempts at weatherproofing Units
The Internal degradation of the substructures (Baltic) softwood timbers (rafters and soffits), iron
trusses have now become vulnerable. The ‘northern light’ glazing panes regularly slip due to the
rotting of the original fibre seals and fixings with further water ingress. Similarly with the coated
slate elevations, the t&g timber boarded soffit and softwood timber rafters are now remaining
permanently wet and decay due to trapped rainwaters.
Regarding the internal working environments; Heat loss and wasteful energy consumption,
remains unsustainable within the present deteriorating conditions. A proposal to coincide with
total refurbishment could include new ground-source energy, water recycling, efficient lighting
division, thermal efficient glazing and wall and roof insulations all within the structures historic
context. It has been suggested that a change of use proposal represents a unique opportunity to
sensitively convert this former industrial building to a use that will secure funding its future.
Summary of surveys carried out @ Beaumont Works; 2012/13/14:
The solid masonry structural walls of mainly English bond, part Flemish bond facing brick are in
good condition, with no major deflections, degradation or historic decay. Similarly, the internal
solid concrete floors that run throughout with substantial suspended timber floor members to the
2 storey units. Fenestration, part original timber mullion and part replacement are also in good
condition and functional. No opening up or investigation of foundations was carried out nor
deemed necessary. High level inspections were carried out via, ladder and mobile hoist.
All problems of degradation stem from water ingress via most roof slope coverings, slate and
glass, the integral shared valley box gutters, rainwater disposal systems and rear location
underground systems and services.
Although presently structurally sound, the water ingress and disposal systems are an immediate
priority in the preservation of these historic structures.
1/Elevation/Roof slope; ‘northern light’ 120xNo.Wired glass panels in lapped rows. Eaves to
ridge. Upper glazed slope discharge via pvc rainwater gutter & downpipes to lower glazed slope,
and discharge to rectangular cast iron formed section and downpipe to underground. Vertical
brickwork has water and salt staining as a result. Stepped lead flashing to Dutch gable abutment.
Slate verge condition to rear gable. Water ingress via corroded glazing bar seals and flashings.
Elevation 2/Roof slope; Originally Welsh grey/black slate covered in multi-layered bituminous
paints/coatings.
Original angular clay tiles slate ridge also coated. Bitumen painted stepped lead flashing to
Dutch gable end abutment. Decayed softwood timber fillet to end rafter verge condition to rear
gable. Half round pvc rainwater guttering and downpipe discharge to horizontal zinc formed
valley box gutter (1) abutment with Unit 2>.
Cast iron formed ‘ogee’ gutter and downpipe to front elevation Sutton Road and pvc hopper
outlet to rear to underground. Water ingress and trapped rainwaters sealed within roof layers.
Elevation 3/Roof slope; ‘northern light’ 120xNo. Wired glass panels in lapped rows,3xNo. raised
to vent panels.
Slate top eaves and angular clay ridge with ventilation stack/pipe. Stepped lead flashing to Dutch
gable end. Slate verge condition to rear gable. Rainwater discharge directly to abutment/shared
valley box gutter with Unit 1 with downpipe to underground. Water ingress due to fatigued
valley box gutter membranes and glass panel seals.
Elevation 4/Roof slope; Forward section, original footprint, Welsh grey/black slate, rear section
of concrete interlocking tiles to rear gable. Angular clay ridge tiles. Slate section discharges
directly to shared valley box gutter (2) Bitumen coated stepped lead flashing to Dutch gable end
abutment. Concrete tile section discharges via pvc half round gutter and downpipe to
underground. Water ingress via slate-tingle nail fatigue repairs and ridge vent coated inserts.
Elevations 6/8/10 Slate roof slopes, 5/7/9/11 Single Wired glass slopes comprise original
footprint configuration.
Elevations 11+12 have been extended during the site expansion and addition of the 2 storey
structures N + S and prior to the dual pitch building elevations 15-18 at the rear.
Elevations 12 + 14 roof slopes have been re-laid in concrete tiles with rotted under-felting
probably 1970.
The formed cast iron Valley box gutters Nos 3>6 have been coated in asphalt and bitumen,
discharge via the formed cast iron gutter outlets to the front elevation Sutton road and to rear
hopper and downpipes to underground. Valley gutter 6 rear discharges internally through Unit 5
via sealed pipe to underground. Water ingress via fatigued valley membrane surface fractures.
Elevations 13/16+18 Double row of wired glass panels, with raised venting panels and with
narrow slated verge sections. Consistently and dangerously loose full length glass panel slip due
to corroding seals and metal fixings.
Original 5 bay Dutch gable, 1 through 5 ridge lines have zinc formed flue/vent stack inserts, now
coated, with leaks through to units.
Wired glass panels to slopes 11/13/16+18 have vent panels and slipping full length glass units
with subsequent ingress.
Conclussions:
1/ Water ingress via slate and glass roof coverings; box valley gutters, abutment up-stands and
flashings at verticals, flue/vent stack inserts and poor verge conditions, corroded glass panel
seals and slipping units are all an immediate priority.
2/ Rear and car park ground conditions; surfaces, subsurface voids and underground service
conditions generally are a major hazard to any refurbishment proposals and an immediate
priority. Past development and demolition have created a subsurface to the rear with potential
here for serious collapse under any increase/pressure or implied loads.
Complete new rear ground conditions, including foundations, services and surfaces need
reestablishing prior to any unit refurbishment works schedule.
Acknowledgements: Surveys/Designs:
Paul McConville Roof Associates; Adam Neat Roofglaze Ltd; 4.83 Scaffold Design Engineers
BenBeaumont/Gavin Dempsey; P+N Consultants and Design P. Somani Ceng. MI SructE; Nick
Archer Gyoury Self Consulting Eng AMI StructE; Plowman Craven & KND underground
surveys Ltd.
J. Titmus. 32. Field Road. Oxhey. Hertfordshire. WD19 4DR Tel/Fax 01923 250247
S.P.A.B. I.H.B.C. ICOMOS. VSA. AECB. Historic Building Surveys Planning Specifications Project Management Drawing Service
BEAUMONT WORKS SITE
Site layout looking N /\
Site Layout viewed S /\ Underground services survey overlay (Drwgs KND+ Plowman Craven)
PHASE ONE
Site Layout N /\ Scaffold base overlay (Drwg 48.3 STC1259 1)
Site Layout S /\ Scaffold axial leg load overlay underground services (Drwg KND+48.3)
WATERPROOF COATING TO SLATE ELEVATIONS
PREVIOUS ATTEMPS AT WATERPROOFING SLATE
TRAPED MOISTURES WITHIN SURFACE LAYERS
SPECIALIST CONTRACTORS 2012
TENDER QUOTATIONS OBTAINED 2012 (AVERAGED)
ROOFGLAZE LTD
MC.CONVILLE SLATE ROOFING
TRAD SCFFOLDING LTD
MACLEAN GROUNDWORKS
RAINCLEAR RAINWATER GOODS
PHASE ONE: UNIT 1’BODY LIMTS GYM’ + UNIT 2 ‘CAXTON BLINDS’ (3rd VALLEY BOX GUTTER)
ALL TEMPORARY WORKS SCAFFOLD ACCESS/ LOGISTICS £350,000.
RESINSTATEMENT TRADITIONAL WELSH SLATE (PENRYN) £75,000.
REINSTATEMENT GLAZING £80,000
REAR CAR PARK GROUND WORKS INC TEMPORARY WORKS FOUNDATIONS £145,000.
INTERNAL UNITS TEMPORARY WORKS £ 55,000.
RAINCLEAR CAST IRON RAINWATER GOODS AND GUTTERS £ 35,000.
(2015 COSTINGS TO BE @ PRO-RATA % INCREASE)
WINTER 2013
REF: EXTERNAL DOCUMENT LIST:
KND SITE PLAN AND UNDERGROUND SURVEY
PLOWMAN CRAVEN UNDERGROUND SURVEY
48.3 SCAFFOLD DESIGN CALCS + STC 1259 Rev (1-6)
48.3 SCAFFOLD STEEL WORKS STC 1259 (20-25)
48.3 AXIAL LOAD OVERLAY (AddA)
J. Titmus. 32. Field Road. Oxhey. Hertfordshire. WD19 4DR Tel/Fax 01923 250247 [email protected]
Historic Building Surveys Planning Specifications Project Management Drawing Service
2 STOREY TRUSS CONFIGURATIONS SINGLE STOREY TRUSS CONFIGURATION
TRUSS TO WALL HOUSING TRUSS LINKAGE CAST/WROUGHT IRON
S/W TIMBER BOARDING/RAFTER/PURLIN CAST T-BAR WROUGHT TENSION ROD
MILD STEEL GLAZING BARS
REAR VIEW OF EXTENDED BAYS 1 + 5 c1911 @ TIME OF 2 STOREY BAY ADDITIONS N. + S.
PROPOSED LAYER (GDR) ROLLING TEMPORARY ROOF COVER AND ACCESS SCAFFOLD DESIGN
FRONT ELEVATION SUTON ROAD / PROPOSED PHASED WORKS
FRONT ELEVATION PROPOSED PHASED WORKS>SOUTH
FRONT ELEVATION PROPOSED PHASED WORKS>NORTH
J. Titmus. 32. Field Road. Oxhey. Hertfordshire. WD19 4DR Tel/Fax 01923 250247 [email protected]
S.P.A.B. I.H.B.C. ICOMOS. VSA. AECB.
Historic Building Recording Surveys Specification Schedules Planning Applications Project Management Drawing
Services.