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Sutton Lodge Case Study – Natural Stone Build

The Challenge

The owners of Barnack Estates UK Ltd, Rob and Helen Facer, make the ideal couple to choose to oversee their natural stone self-build using Stamford Stone. The couple head up their own local commercial property development company, which means they run a building site like clockwork!

The couple were keen to build their new home on a site in Sutton, near Wansford. The build, a large stone, Georgian-fronted house took two attempts at gaining planning approval. Following a committee hearing against Peterborough City Council Planning Department’s initial rejection of the proposed plans, the plans were finally approved in December 2017.

 

Project Details

It took five months before the green light was given for the construction of the seven-bed, three-storey stone house with an orangery and triple garage to be built.

Initially Helen visited the Swaddywell showroom, near Helpston, to check out the wide range of sustainably sourced, Clipsham limestone for the new build. The showroom sits just a few miles from the proposed building plot.

Stamford Stone was awarded the contract to create the detailed architectural stone build drawings and subsequently supply and fit the external stone and some of the internal stone fixings.

Once the client had chosen the stone, they worked closely with the design team at Stamford Stone who drew detailed build plans incorporating stone from their two local quarry sites.

We chose to work with Stamford Stone primarily because of the excellent quality of their finished stone and the superb product and technical knowledge of their team. The design was obviously important to us, but we also needed guidance on the buildability of the house, which Stamford Stone provided.

Helen Facer

Local products, local teams

“The construction drawings we produce are far more complex as each piece of stone included in the build has to be identified and given its own design specification. Each piece is then quarried, cut, individually carved and then labelled. When the stone gets to site, the fitters use the labelling to piece together the stone exactly as per the build plans ultimately saving time and money on the build.”

“As a local business ourselves, we were keen to use local products and local teams in every aspect of the build. The Clipsham Ashlar stone we chose will, in time, age to a lovely pale honey colour and will stand for hundreds of years and just look better and better,” explains Helen.

“The fireplaces created by Stamford Stone are spectacular. The extra-large, bespoke fire surround based on the company’s ‘Barnack’ design is very fitting, given our company name!”.

Key building project

The Sutton Lodge build project is key to the Stamford Stone portfolio as it was a first in terms of taking the build right from the initial design concept stages through to supply, fit and completion. The clients handled all the internal works, working closely with Stamford Stone and their fixing team. The main external facade of Sutton Lodge was built using the Ashlar limestone, a prestigious, smooth stone which gives a very luxurious look. The gorgeous hues of the Clipsham Ashlar stone show up beautifully on the bespoke moulded columns that frame the main entrance to the property.

A team of expert stone masons work the cut stone using traditional methods and machinery to carve all the pieces. From the large cornerstones and window casements, to the ornate chimney pots and gate posts, each piece of stone has been worked to an exact size.

To the rear of the property sits a beautifully designed orangery, again built using Ashlar limestone. An extended wing to the back of the house has been built using the slightly rougher textured walling stone.

Moving mountains

Some of the largest pieces of stone in the build were used on the orangery exterior. At least six individual pieces measuring in at approximately 2m long X 40cm high X 30cm thick were used. Each piece weighs circa half a tonne! These mammoth stone pieces had to be manhandled into place using either slings and a crane or a clever piece of equipment called a ’single pin lewis’. The latter piece of equipment works by the process of drilling a hole in the top of the piece of stone and the single pin lewis is pushed into it. When a crane lifts the pin, the equipment acts like a pair of scissors and tries to open, cleverly holding the stone in place whilst it is lifted.

In addition to the main property, Stamford Stone also created the plans and supplied and built a sumptuous triple garage to the side of the main property. The additional structure complements the main house superbly. The roof, made from artificial Collyweston slate, is tapered and then runs flat. This design allows the installation of the dormer windows but restricts the overall roof height of the property. If the roof line carried on up to an apex, the property would be impossibly tall.

Making an entrance!

In addition to the exterior stone, Stamford Stone provided the beautiful, natural Walcot One Corner, Clipsham stone flooring which runs throughout the hallway. Continuing the stone theme internally creates a grand entrance that a house of this size and stature befits.

“The hall floor was the very first stone cut from the new Clipsham Bidwells Quarry and looks subtle but has impact upon entrance. It was a pleasure to work with all at Stamford Stone and Lee Muxlow and his team of experienced stone cutters had extremely high standards of finish,” explains Helen.

The house, set in 3.5 acres, comprises three reception rooms and seven en-suite bedrooms spanning across three floors.

Internally, Stamford Stone designed and fitted two grand stone fire surrounds. A bespoke ‘Barnack’ fireplace created in Greetham stone, Ancaster Hard White, has been created and installed in the drawing room. A second bespoke (Hambleton) design fire surround, using the same stone, was created for the entrance hall.

In order to complete the project, Lee Muxlow, Manager of the Stamford Stone fixing team, worked on site overseeing his team of fixers for over six months.

The whole project, from start to finish, was completed within a year. It was a large, private project. Clients, Helen and Rob are used to running building projects and so ran the site seamlessly.

Team work

In total, a team of approximately 50 people were involved with the stonework for this project: From the quarry team, to the cutters, stone masonry team to the designers and fixers.

Design brief

The build was limited as to its height. The planning department stated that the building should not be any higher than the adjoining buildings. After the initial rejection, the building footprint was moved back from the road. Within the design, the amount of steel required in the walls was minimised as it rusts and expands.

It’s been a lovely project to work on. Being local, the whole team has been able to watch the build progress from start to finish. We’ve all gained a great sense of pride in having a part in the creation of such a grand and beautiful building which will be admired for centuries to come.

Laura Green, Director Stamford Stone