If you have condensation problems all you will need to do is insulate the underside of the roof, keep looking in skips it's amazing how much of the rigid stuff gets chucked away.
I insulated the underside of a tin roof many years ago and I got condensation between the insulation and the metal which ran to the edges and down the walls, its called interstital condensation and needs to be considered when you are insulating any surface. It might not be an issue for the OP but for me it made the workshop quite damp at certain times of year.
Right where were we. It was mid winter and I was digging a massive hole. At this point I was trying to get my head around the concrete side of things, although I have done a fair bit in the past it was never on this scale and to a required finish. I went through various scenarios, multiple mixers and mob handed, single mixer and dividing the pad up into smaller sections or get it mixed on site and pumped up.
The deciding factor was basically the time taken to shift the raw materials 40m and when laying it and trying to get a decent finish on the finished pad. I got a quote for mixed on site and it was about £1200 including the hire of the pump to get it to the back of the garden. Where I had previously knocked down the outbuildings that also needed concreting over.
Basically long story short I ended up booking it for late February - deadline set!
By now I was realising how much the recent material cost increase was having an effect. 18mm osb £50 a sheet for shuttering!!. I managed to find some at a salvage yard (old building site hoarding) for £16 and I managed to scavenge some pallets at work to make the stakes.
Sorry for the delay, at the moment every spare moment is being consumed by this garage!
Mid feb I had pretty much shifted all the dirt, I can’t remember exactly how much but one of the grab hire tickets was about 5 ton. I found going for grab hire better cost wise and easier in terms of not having to load a skip, only thing to watch is they will charge different for type of loads I.e. concrete was about £170 for the whole wagon and £350 for dirt!
I rehired the crusher as now I actually had access and I can only rave how good it was. Not as noisy as I thought and the quality of the what came out was really consistent (I went for type 1 grade) and it ate absolutely everything which was quite incredible and very satisfying to do. There was a brief downtime on the Saturday for a blocked filter but apart from that it didn’t miss a beat.
This is the side alley after I’d pulled up the base
What is technically know as a s*** load of concrete
Red beast about to work
This was the hoarding after being cut into strips for shuttering
The next weekend was mainly spent packing it down with a large whacked plate. It packed down really nicely with a good mix of fine and course.
I’d read a lot about putting a vapour barrier down. This only needed to be across the workshop area of the pad, although I did it I’m still not convinced it’s worth separating the hardcore from the concrete itself but time will tell. These style garages are apparently murder for being damp so I suppose every little will help if it does work.
I also managed to scab up some mesh that had a former life as some racking backing. At this point I was doing a couple of hours a night in the dark with some lights rigged up in order to meet the concrete deadline, this did also involve a slight ‘readjustment’ of the pad size after I’d checked the garage size for the first time in a year!
I did meet the deadline in the end and the guys were here for a morning pouring and floating the concrete. The concrete was mixed on site and pumped to the back of the garden. Having seen it done I’d be more encouraged to have a crack at it next time.
Sorry for the weird Photo below, strangely I didn’t get many photos of the finished pad, only where my boy is putting the pad to use with some biking.
Ok so with the pad down it was just the small matter of shifting 40 or so panels approx 30m to the back garden. As you can probably guess, these are heavy! I ended up making a extra long sack barrow (prob 2.2m long) and lifted one end at a time and then drag them up the garden. Doing it single handedly this is the only way to do it. Apart from a couple of trapped fingers it all went smoothly.
At this point I had also bought the roof sheets. Cost wise I couldn’t find anything cheaper than box profile sheet and found someone local who has the press tool and punts them out for about £18 a sheet.
As the garage had been sitting in my front garden for over a year the wooden apex frame front and back needed some remedial repair work but nothing too major. The panels were numbered kindly by the previous owner. I did attempt to organise them into a logical order but due to weight that soon went out the window, it’s not exactly like shuffling cards! In the end I got it so the window panels at the back and the narrower corner panels in each corner.
I should also mention that the garage came with a standard up and over double sheet door. I wasn’t really up for this as 1) it was a waste of space in terms of usable access into the garage (access will only be a single track in and out) 2) a larger area for heat and noise to escape from and 3) it was really ugly, we will be looking at it from our kitchen so it will have an affect. So in the image above you can see some wooden doors that I got from a demolition site in London for about £180 I think it was. They are incredibly well made and if I had to buy the material to make them would have cost treble. Only catch was that I was so pre occupied with the width (and the seller not being able to read a tape measure) I had completely over looked the height (I had wrongly assumed that all garage doors are a standard height) so basically they had to be shortened by 150mm, more on that later………
It’s only now looking back at the photos I realise how much has been done and also how much I have forgotten to post! In the photos above showing the panels piled up you can see that I had to build a retaining ‘wall’. I am certainly no brick layer and there is height difference between my garden and the rear neighbours of about 3 ft. I used concrete posts and gravel boards as a cheap and quick way of keeping their garden on their property and mine in mine! This area will be particularly difficult to access once the garage is up.
A date was coming up where my mrs and the kids were away for 3 days or so and I had earmarked this as an build date. In preparation I cleaned all panels as much as possible and splashed out on some new stainless bolts nut and washers for joining the panels and 60 tubes of adhesive.
I also made this out of some 18mm studding and scrap. The idea was to make some ‘hangers’ that would suspend some scaffold boards off the concrete fence posts. The threaded bar with the large cross on it could be wound in or out as and adjustable support that I could lean the concrete panel against while I got the bolts in.
I did the common sense thing of marking out a square corner at the rear and working out from there until it was self supporting. What surprised me about the assembly was that you’d think put two panels side by side stick the bolts in and tighten. In doing this what actually happens was that in tightening the panels wanted to curl in and it was a constant battle to try and keep the structure square straight and parallel. I added the adhesive to the sides and the bottom of the panels but in order to keep it square I was still left with quite large gaps between the panels.
I worked my way down until I could fit the trusses. Overall in 2.5 days I got the main structure up with all trusses in
Once I got the walls up it was a case of trying to get it waterproof. I stuck all of the box profile sheet on using the rubber washer tech screws. I left an inch over hang at the edge and there was a gap of 300mm each side of the apex. Using the big press brake at work I folded up some galv and made the centre panel. I will try and get a photo of this to try and explain better. It did save a fair bit of money not having to buy the centre section.
I had to shorten the doors, this was not something I was looking forward to as I can do a bit of wood work but certainly not a joiner and I really wanted to do the doors justice. The bottom edge was a tendon type joint, I managed to get it apart and in my mind I thought I could use a router to recreate the slot turns out this was not possible and I ended up with a mixture of chain drilling and chiselling the slot, the term wood butchery has never been more apt. In short I got them back together, they are strong, fit and are straight.
Because I now had a much smaller door way I bricked up the rest of the hole. As mentioned before I am definitely not a brickie but I got away with it as it’s straight and still standing! I’m hoping narrowing the doorway into the garage does not come back to haunt me in terms of access, the aim was to have far more usable space for activities.
I must also apologise for lack of quality photos, compared to some threads on here I know this one is severely lacking. I don’t own a smart phone or anything and have never been in the habit of photographing any work I do - all of this posting is being done on my mrs phone and iPad! I think the amount of questions I’m asking her in terms of how to do this maybe straining my marriage somewhat! All of that and I always seem to have my kids helping me so I’m trying to avoid putting any picture of them up for obvious reasons.