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Masterpiece marries timber with steel

Masterpiece marries timber with steel

By Ntsako Khosa
Working with different design elements pose many challenges, especially when clients specifically ask for symmetry. Bosazza Roofing and Timber Homes was asked to create this balance at an East London golf estate.

Bosazza Roofing and Timber Homes, a division of Cintsa Thatching CC, was called in to help design Olivewood Private Estate and Golf Course.

“In terms of design we were more involved in the practical elements including aesthetics of the exposed truss sections, stainless steel brackets, custom timber posts and finishes. The client’s requirements were a focus on balance between the mortar, metal and timber elements of the construction and consistent attention to detail to create clean finishes,” says Jonathan Bosazza, CEO of Bosazza Roofing.

Project scope included roofing and ceiling installation of the main house which spans 934m2 and summer kitchen that spans 145m2. Prior to installation, custom material preparation was the first step.

“We began by manufacturing all hardwood posts, loose rafters and stainless-steel brackets off-site. Once these were prepared all pre-fabricated trusses were erected and loose rafters positioned,” says Bosazza.

“The roofs were insulated with reflective sheeting applied throughout, before purlins were installed running horizontally to the rafters at a spacing of 900mm and 100mm thick bulk insulation laid in the cavities between the purlins,” says Bosazza.

Klip-Lok 406 concealed fix roof sheeting was applied to the roof. “The method of installation involved fixing the correct clips to individual purlins with stainless steel screws and applying the roof sheeting in sections, clipping each of the sheets together,” Bosazza explains.

Bosazza_003_Main.jpgSide elevation of the main house, summer kitchen and pergolas.Klip-Lok roof sheeting is fitted throughout the roofs.Double-storey open gallery with exposed rafters and hanging chandeliers.

Summer kitchen roof

Roofing of the summer kitchen opened the project. Situated behind the main residence this semi-outdoor kitchen and entertainment space provides a peaceful shelter and shade area, kitted out with modern cooking facilities including a braai and pizza oven.

The summer kitchen roof is constructed entirely of custom-made loose rafters. “We had to pay special attention to the behaviour of the raw material during the construction process and use temporary bracing to prevent warping and bending of the wood due to exposure to the sometimes-harsh coastal environment,” shares Bosazza.

Custom-made timber posts and laminated beams marry stainless steel brackets at roof height and create a clean and precise finish to this area.

Main house roof

The main house roof is a large and sprawling design. “Yet the resulting product has a deceivingly simple and concise look,” describes Bosazza. “Using the entrance and gallery as the central point the roof spans out almost symmetrically to the north and south ensconcing a wine cellar and guest suite to the north and dining, kitchen and master suite to the south. The roof is finished on the sea-facing side with low pitched verandas positioned under the lip of the main roof,” he says.

According to Bosazza, the most breath-taking element of the roof and house is the double storey entrance which opens in to the spectacularly light gallery where exposed rafters and hanging chandeliers take your breath away. The construction of this involved lifting two large metal I-beams to double story height and setting them into place.

“The beam profile is 305cm x 165cm, each beam is seven metres in length and weighed 287kg. Concrete plinths were in place to support the I-beams where they rested on the walls,” he adds. “The positioning of the loose rafters which were all custom-made laminated beams was an exact art – we worked closely with the engineers before the I-beams were manufactured to design and fit the rafter fixing plates in the correct positions. Once the I-beams were fitted the rafter beams, valley and jack rafters were all mitred on site. The I-beams were coated in marine epoxy before fitting and then boxed in with a timber framework and skimmed plasterboard before painting to finish.”

The ceilings in exposed rafter areas – found in the entrance and gallery, verandas and summer kitchen – are created from tongue and groove ceiling board applied to the top of the rafters. “In these areas special attention was paid to ensure that the joints between the boards were not visible. We also undertook the painting of all these sections to ensure the final finish represented our attention to detail and fine workmanship.”

A soft glow lighting effect was created with ceiling bulkheads located in the kitchen, dining and lounge areas as well as the wine and drinks rooms. “These bulkheads have light troughs to conceal the source of light which shines up onto the wall and ceiling,” says Bosazza.

Symmetry and precision in the rafters and beams of the gallery.Stainless steel brackets marry timber and mortar on the veranda eave ceilings.The roof design is almost symmetrical using the entrance as the centre point.Ceiling bulkheads create light troughs for a special lighting effect.

Making it work

Although Klip-Lok is generally selected for simple roof designs in large spans, this design is complex and involved many roof ridges, hips, valleys and gable ends. The various valley sections of the roofs were fitted according to Klip-Lok specifications, paying attention to where the roof sheeting ends and runs into the valleys; clips at these sections had to be custom cut so that all sections of the roof were clipped securely.

“Our system for applying the ridging sections was a further development of the method prescribed in the Klip-Lok specifications – to ensure a straight edge two strips of 1.6mm x 3.0mm galvanised metal are fixed to either side of the ridge by means of pop-rivet. The same fixings are used to fit the specified ridge sections to the roof over the metal strips,” he says.

The estate

This project is one of first private residences built on high-end Olivewood Private Estate and Golf Course in Chintsa, Eastern Cape, and the largest to date, the house sits on the side of the valley with a panoramic view of Chintsa river and beach.

In addition to the roofing and ceiling aspects of the project Bosazza Roofing also constructed two pergolas in the grounds of the house and custom wood and metal balustrades on the verandas and lower decks including Juliette balustrades on rear bedroom windows.

Photos by Bosazza Roofing and Timber Homes



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