Garage/Workshop conversion
Garage-workshop conversion
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HOME PAGEPHASE 1. Back door removal & window replacement. PHASE 2. Construction of a stud framework supporting eight joists. PHASE 3. Plasterboard ceiling construction. PHASE 4. Partition construction with relocated door.

PHASE 5. Construction of mezzanine floor.
(This page)

PHASE 6. Installation of wall insulation & OSB sheathing. PHASE 7. Electrical re-wiring.
Garage/Workshop conversion
Garage/workshop conversion
FITTING OUT PROJECTS WOOD-TURNING
PROJECTS
APPENDIX 1. Measurements & materials.

Phase 5. Installing Ceiling Insulation & Chipboard Mezzanine Floor.


Synopsis of Work for Installing Ceiling Insulation & Chipboard Mezzanine Floor.
The first step was to pack rock wool insulation on top of the ceiling plasterboards between the joists. The chipboard flooring was then cut to size and screwed to the top of the joists ensuring that the tongue and groove joints were fully engaged and that lengthwise, the boards abutted together above a joist thus ensuring that the joints were fully supported.

2nd August 2015
Loft insulation purchased.

Details of Loft Insulation installation.

Loft insulation purchased 2nd August 2015 Loft Insulation Purchased. 2nd August 2015

Two rolls of 'Rock Wool' insulation were purchased. These are made from recycled glass. This product comes partially cut into three widths of 400mm which is ideal for the 405mm joist spacing adopted for this project.

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Loft insulation 2nd August 2015 Loft Insulation Unpacked, 2nd August 2015

A roll of 100mm thick insulation. The partial cuts are clearly visible with options for either cutting in half to give two rolls of 600mm width, or making two cuts giving three rolls of 400mm width. The 400mm width option was the preferred one for this project.

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Loft insulation 2nd August 2015 Cut to Size, 2nd August 2015

The best course of action before using the insulation in the confines of the loft, is to use some scissors to completely cut through the partial cuts so that three separate rolls of the correct width are ready for use - as shown in this photograph.

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Loft insulation 2nd August 2015 Installation, 2nd August 2015

Work in progress installing the loft insulation between the joists. Work carried out in tandem with chipboard floor installation. The unfixed sheets of chipboard flooring provide useful temporary supports whilst the insulation is unrolled in position.

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Loft insulation completed 3rd August 2015 Completion, 3rd August 2015

Loft insulation completed and work well under way in installing the overlying chipboard flooring (See details below).

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Loft Insulation completed. 3rd August 2015.


Details of Chipboard Floor Installation.

Work commenced 2nd August 2015 in tandem with installation of partition studwork. Using 10 boards of flooring grade tongue & groove chipboard, 2,400mm x 600mm x 18mm. Each board weighs about 17.3kg.

Chipboard flooring dimensions. Chipboard Flooring Dimensions.

Estimated that ten boards required, delivered on the 20th July 2015.

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Cutting the boards to size. Cutting to Size.

After marking out, the boards were easily cut to size using a hand-saw. The boards are just manageable to move by one fit adult but two people make handling much easier.

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Cutting the boards to size. Installation, 2nd August 2015.

This was very similar to the installation of the plasterboards. The positions of the underlying joists were marked out in pencil on the boards and then the same wooden template was used to mark the positions of the screws at 150mm intervals (this worked out at 4 screws across the boards for each joist). Screws were 4mm diameter, 45mm long. Where two boards join, it is essential that the joint is above a joist (as for the plasterboard sheets), and also essential that the tongue & groove is also on the joint.

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Completed mezzanine floor. Installing the Last Board. 4th August 2015.

The last narrow row of boards were difficult to install because of the constraints of the tongue & groove contacts with the other boards on one side and the garage wall on the other. It was found that the easiest way to fit them was to slide the boards in from the open (garage door end) of the loft, tapping them gently into place using a wooden mallet.

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Cutting the boards to size. Completed Mezzanine Floor, 4th August 2015.

Photograph of the completed chipboard floor (bottom) compared to the floor as envisaged in the Sketchup design (top).

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Mezzanine Floor completed 4th August 2015.


Replacing & Moving Collar Ties.

To improve access and storage capacity of the mezzanine floor, three of the collar ties (spanning the rafters across the garage above the mezzanine floor), needed either replacing or moving. Two were replaced with lower (& longer) ones, to improve access & capacity, whilst a third, immediately in front of the mezzanine floor, was moved forwards by one rafter to improve ladder access.

It's important to replace and not just remove the collar ties as they are an important structural element of the roof.

Replacing & moving collar ties. Replacing & Moving Collar Ties.

This sketch plan shows which two collar ties were removed (pale brown), after the replacement ties (pale green) had been bolted in place. It also shows the front collar tie (pale brown, right of sketch), was moved and replaced (shown in dark green), one rafter forward. This was to improve ladder access to the mezzanine floor.

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Replacing & moving collar ties. Replacing & Moving Collar Ties. 4th August 2015.

This photograph shows the two collar ties to be replaced and, at the front, the collar tie to be moved.

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Replacing & moving collar ties. Replacement Collar Tie Details. 17th August 2015.

Photograph of one end of a replacement Collar Tie (45mm x 95mm). The joists were cut to the correct size and pre-drilled (with one 12mm diameter hole at each end), to take M12 coach bolts. Bolting was the preferred option rather than nailing.

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Replacing & moving collar ties. Fixing a Replacement Collar Tie, 17th August 2015.

The new collar tie is temporarily held in place with a clamp. Note that the original collar tie is still in place (nailed to the rafter), and was only removed after the new collar tie had been bolted in place.

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Replacing & moving collar ties. Drilling a Fixing Hole, 17th August 2015.

With the new collar tie temporarily clamped in place, a 12mm hole was drilled through the rafter using the 12mm pre-drilled hole in the replacement collar tie as a template.

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Replacing & moving collar ties. Bolting in Place. 17th August 2015.

Replacement collar tie bolted in place. The old (higher) collar tie, nailed in place, can now be removed.

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Two new collar ties bolted in place. Completed, 19th August 2015.

Two new collar ties bolted in place and the old ties removed.

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Existing Collar Tie Moved Forward. Moving an Existing Collar Tie, 29th August 2015.

Collar tie moved forward by one pair of rafters and fixed in position by two M12 coach bolts. This gave much improved ladder access to the Mezzanine floor.

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Ceiling insulation and mezzanine floor, completed 29th August 2015.


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