Although our original drawings showed the windows sitting right under the soffits, we somehow ended up with a small gap above the top of the windows. We didn't really like the look of windows pushed up to the soffits so we were happy to leave them like that, however it did lead to a bit of an issue with the blockwork. The gap was too small to fit a conventional concrete lintel and too long for the span of a lintel trimmed to size with an angle grinder.
Since the timber frame was carrying the load, these gaps were of no structural importance, but something needed to be put in place in order to carry the render that would later be applied to the blockwork. An added complication was that nothing could be attached directly to the timber frame as it will move and settle over time at a different rate to the blockwork walls, which could lead to cracks in the render.
After much head-scratching, cups of tea, research on the internet and wildly conflicting advice from builders, Alan decided to bridge the gap using lengths of timber that he carefully cut to size and clad with Aquapanel (a kind of exterior waterproof plasterboard). As these couldn't be attached directly to the timber frame, he glued them to the top of the blockwork using heavy-duty adhesive.
The three top windows at the front of the house also needed doing, making eight in total.
Alan's Aquapanel sandwich (patent pending) in place.
We had a similar problem with the bedroom window at the back of the house. Again, this was originally designed to extend up into the soffits, however we changed it when ordering the timber frame as we realised that it might be impractical (where do you hang your curtains/blinds if your window goes up into the ceiling?)
Once again what seemed like a minor tweak threw up several problems. Alan spent weeks chasing suppliers who claimed they could manufacture a bespoke lintel only to be finally told that they couldn't make anything suitable after all. So the only practical solution was to make up a beefier version of what we done above the other windows.
After insulating the steel frame, Alan made up a timber framework to fit above the apex window.
This was then covered with OSB panels (left over from the timber frame).
We added a layer of breathable membrane (left over from the roofing) and then attached more timber battens...
...and more battens...
...and yet more battens.
We needed to build out quite far to match the depth of the blockwork.
Next up was a layer of plywood (left over from the flooring).
Another layer of membrane.
Finally the Aquapanel...
...fitted flush with the rest of the blockwork, ready for the render to be applied.
What a palaver. Next time we'll make do without any curtains!
Our site inspector looked suitably unimpressed by our efforts.
Looking less like a building site and more like a house. This is the view from the old disused railway bridge.
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