Bremer Bay – Of Corten, Gyprock & Windows

Corten Cladding:

Monday 24th October 2016

Then time has finally arrived when we are able to free the corten steel from it’s packaging and begin the exterior cladding of the downstairs “Secret Men’s Business”.

We were instructed to talk to Matt (who came and measured the walls before pressing and cutting the cladding to size) before we started. Doing so cleared up a few queries Nino had and also resulted in a new flashing being sent to seal the join between the Fibre-Cement cladding boards above, and the corten steel.

The profile we had the corten pressed to is as below


The exterior was broken into 5 natural sections. Each section was defined by a window or a door as a boundary. So the first section was from the start of the wall to the beginning of the door, the second was from the other side of the door to the point of the house/end of the wall, and so on.


Section 1: To the door

The shadow line created by the profile needed to remain equal along the entire wall. But as the length of each section was different, and each section was to be made up of whole panels, the width of the panel was changed slightly for each section.


Section 2:  From door to point

i.e.section 1:  290mm, and for section 2:   295mm.  And while you could not pick the difference between the different panel widths you would have been able to if the shadow line was increased to make up for the greater section length. As I said, SIMPLE.


Installing the point

The panels are like a stainless steel colour if kept out of all weather, and start the rusting process as soon as they are exposed

Nino and Ash had to take careful note of which panels were for which section, and keep meticulous coursing measurements as they progressed so that the panels fitted exactly into the section they were cut for. Of course they did, and of course the result is absolutely magnificent. I realise it will not be to everyones taste but it is us they are trying to please, and I am absolutely pleased. After taking some time off to help install the last of the  windows  (Oh yes, and go fishing!! but no pics this time as no fish of consequence were caught.) Ash and Nino are now three quarters of the way through the process, and with a good system of installation in hand, it will not be long into next week before another part of our project is ticked off.

In last week’s entry it was intimated that Nino was a a wee bit shorter than what he thought he was. He was upset to read this and challenged us. Not to upset him further we didn’t tell him that Santa Clause wasn’t real either, but we did relent and told him that if he didn’t believe us he could measure himself against the yardstick. (Which Ash had made previously) We then apologized profusely and said of course he was right as always,  and that he indeed was over 2m tall. The smile was worth it! 😇


A Giant of a Man

Brad arrived from Mandurah on Thursday with most of the remaining glass to be fitted. He also had onboard the front door that he made to our Specs. and the bottom rail for the decking balustrade, some of which which he had to get curved…… of course.

The aluminium bottom rail has a 50mm channel into which we hope to put free-standing glass panels, so that no curved handrail is necessary. It will be fixed to the facia of the walkway and smaller front decks, the length of each pane of the glass  that slots into the channel will be 800mm wide,  so as to sit within the curve.

The big glass windows for both end rooms were fitted, with all hands required to lift and place the 130kg pieces into place from inside out. They were double glazed and butt jointed, so Brad had a task to cut the angle  so as the join was a perfect fit.


Nailed it!

The other end

Last of the butt joints

The front door has been placed & waiting for glassresized2000pimg_1634

As an aside I am impressed with the level of workmanship and detail that Nino and Ash have gone to, to make this place a bit special for us. I’m also sure it shows the pride they have in their finished work.

As an example, note the amount of work involved here to notch out each of these boards as they meet in the corner. Very neat, very tidy, great craftsmanship. So easy to have done it differently, …  and a lot quicker.resized2000pimg_1604

Gyprock continues to be fixed inside, the rooms become more defined and the house is beginning to taking on character.

Next week should see the finish of the Corten, and the final pieces of cladding fixed in the entry void and around the louvres above the bifold doors, now that they are installed and are a defining edge to fix to.

This entry was posted in Bremer Bay, Warmboard, Warmboard Australia, Warmboard S, Warmboard S Bremer Bay. Bookmark the permalink.

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