Award Winning Project: Roofing of Residential Home, Olivewood Private Estate

Large Roof Installation - Corrugated Roof Sheeting - Eastern Cape
Large Roof Installation – Corrugated Roof Sheeting – Eastern Cape

Bosazza Roofing was contracted to install the roofs on the main house and Summer kitchen of this high profile project in the new Olivewood Private Estate & Golf Course, Chintsa; scope of works included installing the roofs, ceilings (including three exposed truss areas), eave ceilings, veranda’s, custom timber and steel balustrades and two pergola’s in the grounds of the property. The project duration was approximately 12 months and was completed in March 2018.

Large Roofing Project - North Elevation
Large Roofing Project – North Elevation
Large Roofing Project - South Elevation
Large Roofing Project – South Elevation

The Brief

To erect and install 1079m² of roofing on the main house and Summer Kitchen of this residential property including three feature areas with exposed trusses; installation of internal ceilings; veranda and eave ceilings; custom steel and timber balustrades and posts; construction of two pergolas.

The brief required marrying the three contrasting aesthetic elements of the home design – mortar, timber and steel – with a strong focus on elegancy, symmetry and fine quality finishes.

Large Roofing Project - Drone Photo - Site Map
Large Roofing Project – Drone Photo – Site Map

The drone image above gives a clear impression of the site with the main roof, veranda and entrance roofs as well as the Summer kitchen (the smaller building in the bottom right corner of this image).

Roofing of the Summer Kitchen

Roofing of the Summer Kitchen was the opening of the project; a 145m² semi-outdoor kitchen and entertainment space which provides a shelter and shade area, kitted out with modern cooking facilities including a braai and pizza oven.

Construction began off-site manufacturing custom stainless-steel brackets, timber posts, rafters and laminated beams.

The Summer Kitchen roof is constructed entirely of custom-made loose rafters. Special attention had to be paid to the behavior of the raw material during the construction process using temporary bracing to prevent warping of the wood due to exposure to the coastal environment.

Stainless-steel brackets were used in all exposed rafter areas throughout the roofs – brackets were installed at visible joins between the load-bearing timber lintels, ridge boards and main rafters as well as at the apex of the roofs.

Summer Kitchen - Roof Installation with Custom Timber and Steel Finishes
Summer Kitchen – Roof Installation with Custom Timber and Steel Finishes
Custom Timber and Steel Elements in Exposed Rafter Roof
Custom Timber and Steel Elements in Exposed Rafter Roof

Klip-Lok 406 concealed fix roof sheeting was chosen for the roof covering; installation involved fixing specified clips to purlins with stainless steel screws and applying the roof sheeting in sections, clipping each of the sheets together according to Klip-Lok specifications.

A challenge with the use of this product is that Klip-Lok in general is designed for use on large-scale roofs with simple designs; in contrast the roofs on this project were complex with lots of valleys and hips. To overcome this challenge, we worked very carefully with the Klip-Lok suppliers who inspected the roof installation to ensure that our methods were appropriate.

Main House Roof

Whilst the Summer Kitchen was being finished pre-fabricated roof trusses were being erected on the main house. Starting at the South elevation which would enclose living and dining areas on the ground floor and resident’s private suite on the first; working towards the centre of the building with its double story gallery and entrance; finishing with the north elevation ensconcing a wine cellar and guest suites. On the sea-facing side the roof is finished with low pitched verandas positioned under the lip of the main roof.

View of Sea-Facing Side of Property - Covered Verandas on First Floor Rooms
View of Sea-Facing Side of Property – Covered Verandas on First Floor Rooms

The Entrance & Gallery

The most breath-taking area of the house is the entrance and gallery where a double story covered entrance leads to the spacious reception room with spectacular high ceilings, exposed trusses, and chandeliers leads the eye to a wall of windows with unbeatable views of the Indian Ocean.

The Main Entrance - Double Story with Exposed Trusses and Custom Timber Posts
The Main Entrance – Double Story with Exposed Trusses and Custom Timber Posts

Features of the covered entrance include custom timber lintels and posts to hold the loose rafters and trusses. Nutec tongue and groove ceiling board (in a Scandinavian finish) was fixed to the outside of the rafters to form the ceiling as with all external ceilings.

The Gallery and Main Entrance - Double Story
The Gallery and Main Entrance – Double Story
Loose Rafters and Exposed Trusses - Spectacular Ceilings
Loose Rafters and Exposed Trusses – Spectacular Ceilings
Loose Rafters and Exposed Trusses - Spectacular Ceilings
Loose Rafters and Exposed Trusses – Spectacular Ceilings
Sea View from the Raised Walkway
Sea View from the Raised Walkway

Ceilings

Large expanses of open ceiling area were required to be totally smooth, with no joins visible between the sheets. The client specifically requested this finish on the eave ceilings and did not want the use of joining strips. The ceiling boards were fixed with concealed copper screws, where they met we took the time to hide the join – making it look like a continuation of the natural tongue and groove pattern. This detail required meticulous finishing and painting of the areas. Quality workmanship and attention to detail were vital to create a high-end product that the client was happy with.

Meticulous Finishes on the Ceilings with no Joining Strips of Visible Joins
Meticulous Finishes on the Ceilings with no Joining Strips of Visible Joins
Skimmed Ceilings with Down Lights in Master Bathroom
Skimmed Ceilings with Down Lights in Master Bathroom

Ceiling bulkheads with light troughs were fitted in various rooms on the ground floor to conceal the source of light which shines up onto the wall and ceiling providing a soft glow lighting effect.

Soft Lighting Effect - Ceiling Bulkheads
Soft Lighting Effect – Ceiling Bulkheads
Brick, Mortar and Glass - Harmony in Building Elements in the Wine Room
Brick, Mortar and Glass – Harmony in Building Elements in the Wine Room

Verandas

All first-floor bedrooms open onto covered verandas. The verandas combine timber, steel and mortar; 120x120mm hardwood timber roof posts hold laminated beam lintels which are fixed at all points with stainless steel shoes and brackets. Construction of the roofs was like that of the Summer Kitchen; erecting loose rafters, installing ceiling board, insulation & roof sheeting.

Covered Verandas with exposed rafters
Covered Verandas with exposed rafters

Pergolas

Two pergolas were constructed in the grounds of the house – one leading from the kitchen to the Summer Kitchen, the other on the North side of the house. The pergolas were constructed with custom timber posts made with an 80x80mm pine core, clad in 32mm grappa panels on all four sides. The posts were fixed to concrete foundations via chemical anchored stainless steel rods and stainless-steel base plates bolted to the concrete.

Custom Design Timber and Steel Pergola
Custom Design Timber and Steel Pergola
Stainless Steel Brackets used to Secure Pergolas
Stainless Steel Brackets used to Secure Pergolas

Custom timber and steel balustrades were also installed around the ground floor deck and pool area, the verandas and small Juliette balconies at the front of the house.

Custom made Timber and Steel Balustrades
Custom made Timber and Steel Balustrades

Award Winning Project

This project was entered into the annual ITC-SA Timber Engineered Awards 2018 and has been shortlisted for an award – we will be attending the awards presentation in Cape Town on Friday 27th July. Other key personnel on the project will also be recognized at the presentation including:

Lara Wilson McDade (LYT Architects)
Richard Bailey (Engineer)
Inyathi Truss (Fabricator)

UPDATE: 01-08-2018 Bosazza Roofing was awarded the Gold Award for Roofing at the 2018 Timber Engineered Product Awards for this project – click here to read our article about the awards presentation >

Media

The project was also featured in national roofing magazine SA Roofing – Issue #100 which you can view on line here.

Find out more about our roof construction services >

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