Vertical window goodness

Pretty

Yesterday I finished the "parging coat" (first coat) of mud render on the inside of the east wall. I took my time and enjoyed sculpting the curves.  To all the people who gave opinions on whether this window should be vertical or horizontal, you were right: vertical.

Hepburn render mix dries

I'm really pleased with how the new render mix is drying on the walls.  The photo above shows the worst of the cracking - that is, hardly any, especially compared with my first attempt.  The cracks and bumps are small enough to be covered in the next coat of render.  

Shrinkage gap

There is a shrinkage gap at the top of the walls, and it looks ugly where the wall joins the off-cuts of wood that prop up the ceiling, so I decided to take a bit of time yesterday to patch the walls and try (where possible) to cover the wood and bring the mud up to the ceiling.

Ready to start work

When we made the core of the walls, we put in some dodgy formwork to create a sloped window reveal.  It made a really neat surface, but there wasn't going to be enough room for the window to open inwards once I'd put on some thick render. So I had to attack the wall with a hacksaw and scissors.  Again.

Prepared curve

While I was at it I put a few bits of bamboo in at ceiling height above the window reveal.  When the first coat of render dries the ends of those bits will be securely buried, so I'll use them to hold some render upside down in that spot.

Patches on old panels, new panel nearly completed

It wasn't long before I became completely enchanted with the light playing on the curve of the window.  I wish the mud could stay shiny and dark forever. Look at the difference in colour between wet and dry!  I'm definitely going to experiment with some oxides to give the walls some colour.

Formwork and heat

Thrilling, yes?

Today at least we did some building.  Behold, five pieces of formwork.

We achieved that much in the shade before it got too hot to stand, then gave up and drove to Melbourne.  We left Clydesdale mid-morning when it was already 35 degrees inside the house and something really really stupid outside.

The four small boxes are made from laminated chip-board and MDF, which we pulled out of a rubbish skip in Yarraville a few years back.  It used to be someone's kitchen cupboards. Anyone doing mud work should get themselves some of this stuff, because it's easy to cut and join, nothing sticks to it and it's free.

Hippy New Year

Before - shaggy walls adorned only by TJ and his measuring tape

Too tired to type much.  It's 10pm, still over 30 degrees and we spent most of the day building.

East wall interior - 1st batch of mud render

I spent the day rendering the inside of the shed, where even without doors and windows, the mud walls keep the temperature stable.

Curve

It never fails to surprise me the difference render makes to the wall, and how easy it is to make lovely shapes.  I curved the window sill to stop people using it as a shelf for the pleasant aesthetic.

The other great thing about the first coat of render is that it forgives all sins.  The first coat is bulked up with sugar cane mulch so I can use it to fill all the holes and gaps in the wall, and smooth out the shaggy bits at the top where we shoved straw into the wall by hand.

Lunch break

I think this is the last full day of render I will do.  It's tough work, pushing the mix into the wall all day.  I think half days are a better idea if I'm going to last two weeks.

End of day - nearly four panels done

Rocking the north wall

Window seat rocks

Rocks, as it turns out, are heavier than I remember.  I had left the largest, prettiest rocks for the north wall, and some of them were so big I couldn't even move them, let alone lift them.  Thank goodness for TJ.  

3D jigsaw puzzle

It was tough work in full sun and we were wilted by lunchtime but we got it done. 

I should point out that none of these rocks come from the bush.  They were all left close to the house by the previous owners and we think they originally came from the house excavation.  Even so, rocks are an important element for biodiversity so we checked carefully and didn't leave anyone homeless.

I wasn't kidding about the scorpions

When it was too hot to work outside I had a bit of a play with the sub-soil I got from my brother's place.  I started with a basic sediment test, which had some surprising results.

Sediment test - our mud (left) versus Hepburn mud (right)

I tested it against our our own soil, hoping to get some idea if it had more or less clay - I was looking for more clay.  That's our soil on the left, which has settled into three or four distinct layers - sand and grit at the bottom, then a wide band of silt/clay topped with a narrow band of pure clay.  Then there's a layer of muddy water on top and some floating organic matter.

The Hepburn soil on the right behaved very differently.  Other than a tiny layer of clean water on the top, it all remained in a thick suspension for hours.  I think it has so much clay, nothing has settled out of it.

As soon as it was cool enough to move again, we went down to the dairy and got some cow manure so we could make a test-batch of render with the Hepburn soil.  I tried it out on the gaps in the east wall where choughs had eaten the render.

New mud patches

The test-batch of render was very sticky and great to work with - 100% easier.  I also used the sugar cane mulch instead of chaff, to make it less edible (!) and that also works just fine.  Anything this good has to come with a catch, so I predict that this high-clay mix will crack a lot when it dries.  But honestly, I don't care, so long as it goes on easily and stays on.  I can fill cracks in the next layer.

Rendering around the local rocks shows very clearly that this is not the local soil.  The red-brown walls harmonised with the landscape, because they were made of the same stuff.  But I can cope with the colour.

 Tomorrow I'll do some more render if I get up early enough, but it's going to get stupidly hot so we'll go back to town for a couple of days.

Summer mudding

space creature examines hole in floor

We are here for two weeks for summer break, so I hope to show a bit of progress every day or two.  We have some ambition to get the fourth wall up, the internal wall up, the sub-floor prepared and the first three walls rendered so that when we go home it will look like a proper building.

The main thing holding us back is the heat.  Today will be about 35 degrees, and the following two days will likely push 40 degrees up on our ridge.  There are only a few useful hours for outdoor work when it's that hot.

My job for today is to find some rocks, lift them up and apologise to the scorpions that live under them, move them into place on the footings then move them a few more times until they look pretty.  It's 8.30am and the sun is already a great big orange thing, so I decided to blog about it over a coffee instead of getting straight out there.

TJ is going to finish digging holes in the floor for a bit of concrete work - a small slab for a wood stove and stirrups for the base of all the joinery, because we can't let any wood touch the floor (termite country).

New pile o' dirt

Rendering the east wall taught me that our own pile of dirt, which was excavated from the footings trench, doesn't have enough clay in it.  The render has set brilliantly, but it was very difficult to apply to the wall.  But my brother who lives nearby has a pile of dirt he doesn't have immediate plans for, so we brought some home in his trailer and I'll test that out in the next day or two.

I grossed out my niece M by shaking some of that dirt pile in a jar of water to settle the sand to the bottom, then rubbing the top layer on my teeth.  This is how I test for clay - clay and silt look the same to me, but silt is gritty.  This stuff felt smooth.  So, here's hoping.

Now BIRDS are eating the mud shed?!

You remember my beautiful east wall render, worked smooth and snug around the lovely natural stone?

Well, white-winged choughs are eating it.

Goddamn it.

I really, really, REALLY need to stop making this house out of gingerbread.

It's my own fault.  I'm too lazy to chop up straw into tiny pieces for the render, so I buy bags of chaff.  Chaff is pre-chopped bits of straw meant for animal feed, with some oat seeds in it.

But here's the thing.  Chaff makes for a lovely render.  If you think of mud render being like a concrete mix, chaff is the aggregate.  It gives the clay something to bind.  Without it, the clay will bind to itself and crack when it shrinks.  Chaff also makes a bucket of clay go a lot further, and a lot lighter. It also helps smooth out the bumps in the wall ready for the top coat.  A $20 bag of of chaff will do a whole wall.

Spot the cracks? Nor can I.

The only draw-back is IT'S SODDING EDIBLE.

Back in winter there was a mouse plague, so mice were prising the seeds out of the render and eating them.  It was kind of cute, and soon enough small carnivorous marsupials called Tuans moved in and ate all the mice (hooray! Tuans are endangered - if humans had more sense we'd set up nesting boxes all over Melbourne).

I don't know what to do about the Choughs.  They stand on the ground, attacking the shed with their beaks.  I didn't even know they ate seeds.  Maybe they're just curious? They are glorious creatures that live in big family packs and make an unearthly whistling crying sound.

White-winged Choughs, from the fabulous Natural Newstead website

Perhaps they will stop when I do the next coat of render, since that will enclose the chaff in a layer of mud and manure?

I don't want to chop up my own straw bits, because it's a health hazard (dust and spores) and straw has seeds in it anyhow.

I'm thinking of trying some of that chopped up sugar cane mulch you buy in shrink-wrapped bales.  It costs more than chaff, but it should be seed-free. Perhaps the shed will be attacked by Sugar Gliders and wattle-birds now.

The great water tank migration

Brrrm, brrrrm, brrrrm

We have a water tank now.  You have no idea how hard it is to get one of these things from the industrial area where it is made to a place in the middle of nowhere where we live.

They don't deliver to the middle of nowhere.  Well they do, but you have to pay for a truck and two workers, each way.  So TJ hired a trailer and I borrowed some old tyres to protect the tank from the edge of the trailer and he drove it at about 20km/hr on a major freeway on a windy day, listening to the gentle sound of every other vehicle beeping him.  On its side and empty, this thing was a huge sail trying to make the trailer go in a different direction from the car.  I'm really glad I wasn't there.

Last weekend, we found some old treated pine logs and used them as rollers under the tank to move it across the landscape.  It was nice to find a use for the Logs That Will Not Die - you can't build with them, cut them or burn them because they are contaminated with arsenic for all eternity, but you can roll a tank over them.  We inched that baby over the ground, laying ply from the formwork over rocks, to get to the new tank stand.

I never did blog the tank stand.

Check out the form work! That was some serious maths.

The tank stand took us about two whole days to make out of concrete, back in winter or early spring. Just as we screeded off the top (I have all the concrete lingo now) it started pelting with rain.  We covered it as soon as we could, but as us concrete experts know (trust me, over the years I've made one thing out of concrete), you can't go back and smooth it out again or the cement will rise out of the mix and it will crack.  Thus, something as ephemeral as a raindrop is immortalised for eternity.

"Greeeeg the stop sign ..."

Luckily, we have now removed the formwork and covered that mess in a water tank that fits to within a few millimetres. Here's the finished product.  Very rural.

Just add water