Welsh self builders Evans and Evans are stuck on thin joint technology with Durox System
Although not related, Andrew Evans and David Evans have one thing in common; they are both self-builders that have formed their own bond with Tarmac Topblock's Durox System, using thin joint technology to construct their new six and seven bedroom properties on neighbouring plots in South Wales.
Foundations for the two properties in Rehoboth Road and Five Roads were laid in November 2005 after David sold plot three to Andrew in August 2005. With his first development on a neighbouring plot constructed using a timber frame kit, Andrew had planned to use a similar method of construction for his new seven-bedroom property. These plans were dramatically changed when Andrew discovered a significant rise in the cost of using the proposed timber frame kit. It was at this point Andrew decided to research alternative construction methods, discovering the Durox System, using thin joint technology.
Andrew explained: "I had bought the first plot off David in 2001, building a timber frame house on it, which I then sold. A few years later, when it came to planning for my second build and the construction in the neighbouring plot of David's property, we were going to opt for two timber frame kits, erected by the supplier. However, when I looked at the cost increase for the kit I had previously used, I was shocked, to say the least. Realising the effect this would have on the build and my profit margin, I decided to approach the local Jewson Builders' merchant to see if there were any other options available. They put me in touch with the local representative for Tarmac Topblock, Gary Davies, who was kind enough to spend some time with me to explain how the Durox System worked. Garry then introduced me to one of the local contractors that had been using the system successfully for a number of years.
After talking to these three contacts and having seen the demonstration of the Durox System on Tarmac Topblock's very helpful DVD, I priced up the cost of the build work for both of the properties and realised that there were significant savings to be made. Not only could we save on the cost of materials, we could also save on the cost of labour, as the Durox System was so easy to use, we could build the houses ourselves. After persuading David to opt for this method of construction we ordered the Durox blocks."
Commenting on the change of construction method from timber frame to Durox System, David Evans said: "Not having done a lot of brick or block work before, I was intrigued when Andrew told me the blocks would be glued together with a thin joint mortar instead of using the traditional method. It was Andrew's enthusiasm and the fact that he said he would give me a hand with the build that persuaded me to go for the Durox System. At first I was going to get a local contractor to build the property for me, but he was unavailable at the time, due to his heavy workload commitment. Then, after talking with Gary Davies about concerns that I had with using the system, I decided to have a go at it, with Andrew's help of course. We purchased an electric driven circular saw between us, to cut the blocks to shape. Initially, we wanted to buy a band saw, but the circular saw opportunity came up at a good price, so we opted for that. We also purchased a high quality self-levelling laser level, which we both used to ensure the buildings' corners were always at the same level.
To ease myself into this new method of construction, I started on Andrew's garage, while he continued work on the main house. I was also dubious about the system when it came to installing the wiring, as having rewired my first house at the age of 14, some 42 years ago, I have always preferred wiring timber frame houses, as it is far easier to chase wiring into a timber structure than one made of concrete blocks. However with the Durox System, since the blocks are lightweight aircrete, cutting holes and chasing channels for both the wiring and plumbing is much easier than using dense concrete blocks. This ease of cutting was also a benefit when it came to cutting the angles for the gable ends, which was accomplished with a hand saw, after the blocks had set."
"In addition to the main benefits of time reduction and ease of handling, by opting for the Durox System, David and Andrew were able to take advantage of using items like concrete lintels in the main fabrication of the build, and accessories like helical ties for positioning insulation," added Gary Davies, Tarmac Topblock territory manager.
David commented: "As a self-builder you always look at ways of making a saving, but when you add it up with the extra time it takes you to do simple things like mixing mortar, it pays to invest in the right equipment. I can honestly say that by listening to Gary's advice, particularly when it came to getting a powered mixer, we have saved days of unnecessary work and the adage of 'getting the right tool for the job' certainly holds true."
Having completed his first self build project in 1991 as part of a group of 13 builders working on an 18-month project, Andrew always wanted to take on another self-build project. He realised his opportunity to do exactly that in 2001 by purchasing a plot from David. Seeing the potential at the Rehoboth Road site to develop a four property cul-de-sac become a reality, Andrew has now set his sights on making a living from build projects using the Durox System.
Andrew said: "If I manage to build one house a year, I will make a comfortable living doing something that I really enjoy. When you are a self-builder you always expect to have to call in the cavalry to help you with some major part of the build, particularly if you are using what is seen to be a traditional method of construction. The Durox System eliminates this issue. Due to the lightweight of the blocks, I am able to carry them up the scaffolding to build the walls without any assistance, so in other words, I am able to do the work as a lone worker, reducing potential labour costs dramatically. I just couldn’t have achieved this using concrete blocks.
As a lover of innovation, and having first hand experience in the car industry as to how it can help to cut manufacturing times, I am constantly amazed how in general potential buyers and the construction industry often shun it. As I learnt from my first build, buyers want traditional solid wall buildings and are reluctant to see the benefits of things like under-floor heating, since they are always looking for the negative 'what if it breaks' scenario. This is why I haven't got a bad word to say about the Durox System. As a modern method of construction it gives most buyers what they are looking for and its innovation helps me to reduce build time and cost. I just don't understand why the industry and other self-builders are not waking up to its benefits and jumping on it !"
Backing up Andrews comments, David said: "From a financial point of view, the Durox system has introduced a method of construction that I am confident in working with. I have been amazed with what can be achieved with the blockwork and have had bricklayers, who have visited the site, comment on how well the construction of both Andrew's and my development has progressed. Being able to do the construction ourselves has saved us a considerable amount of money. This saving has enabled me to devote all of my time to this project and allowed me to use some of these savings to include a reasonable salary for my time. Comparing the Durox System build with the timber frame option and even taking into account the delays for the foundations, I have saved nearly £8,000 on the build and ended up with a solid wall property, that will ultimately be a preferred choice for most buyers when I come to sell the property."
Keen to differentiate their developments from other new build properties on the market, both David and Andrew are planning to add those extra touches to the six and seven bedroom houses that will make them stand out from the competition. David: "Since I have an electronics background, I am investigating the latest in home automation technology in order to incorporate a system into the house design. The system I am looking at will control items such as whole house temperature, audio/visual equipment, curtains, lights, security system, etc. Buyers of the property will therefore benefit from a truly modern living environment. Eventually I would like to set up workshops to teach others how to take advantage of this technology."
With work on the two houses due to finish in November 2006 and construction of a four bedroom dorma bungalow, built by Andrew with the Durox System, due to commence in early 2007, there is plenty of work to be done before David and Andrew can enjoy the fruits of their labour.
