Flasher

This last week I have been finishing off the roof flashing. I spent time cutting up gal steel off cuts left over from the construction phase of the project. I have pieces of corner section, ridge capping etc. I cut them into narrow strips and then folded them into the pieces that I needed for each specific place.After the brickies finished the walls, there was a gap between the steel shed and the new brick veneer wall that needed to be covered.


In one spot on the wall where the corner meets the verandah. I had to cut and fold a special section that is folded in 5 different directions.


That was a very satisfying little job. I’m pleased that it worked out well. I have no idea how much that would have cost me to get a plumber to do these jobs. But it wouldn’t be cheap.

I also needed to cover the electrical conduit brnging the power into the workshop.



This conduit needed to be protected from sunlight, but also mechanical damage.


I have finally finished the capping on the roof between the new brickwork and the steel shed.
All done, now back to the acid cleaning of the brickwork. I had to finish the steel capping before I could afford to pull down the scaffolding. Without the scaffolding, I wouldn’t be able to reach the central capping safely. Every job has to be done in its own specific sequence.

I’ll be pleased to remove the scaffold, so that I can finally see the arched wall and window in its complete form.

Frog up, or frog down?

The brickies have finished. However, there is still a lot to do to clean it all up. I still need to scrub it all down, fettle it, then acid wash the surface and water blast it, but even at this stage it looks great to me.

I asked Bill, one of our brickies, if there was a rule about laying bricks with the frog up or the frog down, as I had noticed while securing the brick ties to the shed frame, that some of the bricks were laid either way. Bill explained to me that he was taught by the English Master Bricklayer Dave Smith from Leeds in Yorkshire to lay bricks frog down, so he lays bricks frog down unless there is a reason not to, such as the need to get a particular face out, or if the brick is warped and won’t sit flat any other way.

At this point, I should explain to those not familiar with bricks, that old fashioned sand stock or modern day dry pressed bricks have an indentation in one of the broad, flat faces. This has a few functions, but mostly to provide a ‘key’ to allow the mortar ‘grip’ the brick and lock it into the wall.

Modern extruded bricks have a lot of holes all the way through them, so don’t require a ‘frog’, the extrusions provide the texture for the cement to grip the brick. BTW, Bill told me that he refuses to work on jobs that specify extruded bricks. He said that they aren’t ‘real’ bricks, just rubbish.

So a frog is an indentation in the brick. In old, hand made, sandstock bricks like ours, the bricks were made one at at time in wooden mould, also hand made on site and not always exactly the same as the other moulds that were being used, so there is plenty of variation in the size and shape of the bricks, but particularly in the size and shape of the ‘frog’ indentation.

We have diamonds and ovals, but mostly a huge range of rectangular shapes.

It appears that each brick maker seemed to make his own mould and chose what ever piece of wood was available at the time to add to the mould to make the ‘frog’ indentation in the brick. There is a huge variation. I have read that as each frog was different, the shape of the frog in the brick was a way of counting up the tally of each individuals daily output, as the brick makers were paid per brick produced.

You can see above, many of the various shapes of the frog, these varied from long, narrow and deep, made by using a squarish baton of wood in the bottom of the mould or ‘Stock’, to very wide and shallow, with tapered edges. Warwick Gemmell in his book ‘And so we graft from six til six’ – Brick makers of New South Wales. states;

Having a wooden piece in the bottom of the mould also had the beneficial effect of pushing or ‘kicking’ the clay slop out to the corners of the mould. It is important to fill the corners of the mould to get a well shaped, square edged brick. Having a ‘kick’ in the bottom of the mould made this easier to achieve by kicking the soft clay out to the edges and allowed the brick maker to work faster with less ‘seconds’.

So where does the word ‘frog’ come from in brick making? The the OED vol 6. P208/6 quotes it’s first use in print in 1876. But gives no indication of it’s origin. In a book called “Des Brykes”, I read that fancy brick work in many old English stately homes was done by imported Dutch bricklayers, as the techniques of sophisticated and decorative brickwork were well advanced in Holland at that time. The Oxford Dictionary also quotes on the same page that Dutchmen were called ‘frogs’ as a term of derision in 1652.

Could it be that immigrant Dutch brick workers introduced the frog into English brick making? It just might be possible, because the ‘Kicker’ piece in the bottom of the mould is also the same word in Dutch (kikker) that means frog!

Just speculation, but food for thought?

A very Good Friday

Janine and I have been particularly busy today cleaning up the brickwork left as it was by our wonderful brickies, Gordon and Bill after they finished up their 4 day week on Thursday. They got the verandah wall all done, right up to the roof. That only leaves the top of the gable wall to be completed. If anyone needs a couple of very skilled and experienced brick layers to do a great job, contact me and I’ll pass their details. They only work a 4 day week, as with them both being well over 70, they can do that. We don’t want to wear them out.

What was particularly good about their working style is the number of times that they asked me what I wanted done here or there. What was I expecting. What did I think about this problem… How should the Sussex bond variation be interpreted and implemented here? etc etc. They’re always consulting and prepared to be flexible. Although I’m very tired from being the brickies labourer to two brickies. Constantly on the go, making mortar, or cutting special shapes on the brick saw, but mostly passing mud and bricks up onto the scaffold, I’m really glad the end of the day, and particularly now that this wall section is complete. We can stand back and appreciate the final ‘look’ of the project so far. And it looks great! Better than I imagined 12 months ago when I drew up the plans and started to get quotes on this crazy idea of buying 5 different ‘off-the-plan’ kit-form farm sheds of all different sizes, heights and shapes, and then bolting tham all together, to make something a little bit different and more interesting. It’s worked!

Today is Good Friday and everything is closed for some obscure ancient pagan reason, so we are working hard at home as usual. As the brickies have finished the verandah wall, we can start to fettle it and begin to wash it down with dilute hydrochloric acid and scrubbing brushes. I’m using a 0.5 norm muriatic acid from a big hardware chain. I’m diluting it to a 10% titration just strong enough to react with the lime in the mortar to dissolve the white ‘blush’ and occasional streak of smeared excess mortar from the brick face, but not strong enough to cause any damage to our skin if spilt. We are wearing long rubber work gloves and goggles, just in case.

We spent most of the day from 9.00 am to 7.00 pm. on the cleaning of the wall. We first went over the entire wall, every brick, brick by brick, scrubbing it down with acid, then follow this up with another going over with the water blaster gadget. The wall looks better, but not quite good enough or clean enough. There were still a few smudges here and there when we came back from lunch and got a fresh look at the surface.

We decide to go over it again with the dilute acid wash and scrubbing brushes. We follow this up again with the high pressure water blaster. Our supposedly, high pressure, water blaster is just a toy, We bought it very cheaply over 20 years ago and have hardly used it, as it’s not very powerful, but it does blow off just enough of the lime gunge without damaging any of the bricks or the environment. It turns out to be just perfect for this job. I wish that I had owned it 35 years ago when I had to wash all the brick work on the old school extension. I did all of that acid scrub and water rinse off by hand from buckets carried up onto the scaffold. It’s amazing how fast a bucket of water can get emptied by hand using a sponge. I spent more time climbing up and down the scaffold, than I did washing bricks.

But that was then and this is now. We have just had a massive down pour of rain last week, so we have an excess of water in the dams, as they are still over-flowing with the seepage from the saturated soil. So water supply is no problem for us this week. I can leave the pump on for an hour while I wash everything. The electric pump runs directly off the solar panels, it’s a sunny day, so we are just using up some of our excess solar-electric power as well.

The water is over-flowing from the dam, so If I don’t use it up in this way, it just flows out of the dam and out into the already saturated soil farther down the hill and into the ‘key-line’ system of dams that we have built over our 45 years years of living here. The water flows from one dam down into the next. We have 4 dams on the property, before the water leaves us and flows down the hill and into our neighbours dam.

We did the second acid scrub and water blast rinse, then stood back and had a good overall look. It looked better and was worth the extra few hours of work. Once the bricks were cleaned, it was time to dismantle the scaffolding piece by piece, removing all the planks and ply sheeting and stacking them all away for re-use again later. The planks and ply will be used as bench tops and tables in the pottery in a few months time when we get to that stage. They were 2nd hand when we got them given to us, as they came from a house that was demolished in Tahmoor. We had to de-nail them before we could use them as scaffolding, they will need to be heavily cleaned to remove all the spilt lime mortar before they can be used again. I will have to wash them and scrub them to remove all the sand before I can plane the surface without damaging the planer blades.

Once all the steel scaffold frames were removed and stacked on the ute, we could remove the plastic sheeting that I had stapled onto the timber windows to keep them clean. Only then could we get to see the outcome. The wall looks great. The Sussex brick bond variation that Gordon and Bill have created for us looks perfectly matched to the Old School building. It also matches the tone and hue of the old rusted galvanised iron sheeting that I used on the wall above the verandah.

I used almost 4 litres of acid to get this wall cleaned. I can see that I’ll use another 4 litres on the gable wall next week when that wall gets finished.

I’m starting to get a bit excited now as things are beginning to come together. The rest of this long weekend will be spent in the garden as everything is growing it’s head off and has been left somewhat neglected for a while now.

A well constructed arch is a beautiful thing

When the weekend comes around, we spend time playing catch-up. There are so many jobs that don’t get proper attention during the week, just a cursory glance. I get stuck in and pick tomatoes, Zucchinis, pumpkins, etc.

Janine has been doing all the garden harvesting during the week while I’m flat out being builders labourer to our wonderful, sensitive and highly skilled, couple of brick layers.

Saturday is the time for washing, sorting and chopping all the sub-prime tomatoes. The best ones are put aside for the weeks lunch time salads. All the rest are chopped up and boiled down into passata, starting with frying brown onions in good olive oil, then adding a knob of peeled and chopped garlic. This batch, I’m adding lots of capsicums and chilli, as well as the usual bay leaves, a sprig of thyme, some sage leaves, and loads of sweet basil. The sweet basil is trying to go to seed just now, so I have to continuously pay attention to pick off the flowering heads, with a couple of leaves. Back in the kitchen, I strip all the useful leaves from the somewhat woody stalks and florets. I eventually get about 3 hands full of leaves and my hands smell divine for an hour.

I usually bring the chopped fruit to the boil and then continue for an hour longer on a low simmer. Once the vegetables and herbs are well and truely reduced to pulp, I put the pan aside and let it cool. Later, I come back to it and pass the boiled pulp through a moulii sieve to extract most of the stalks, herbs, seeds and skins. I choose not to use the very fine screen in the moulii. I usually use the medium screen. This lets a few tomatoes seeds through, but it also passes some of the herbage. I like the rougher texture. It somehow feels more honest and real.

This time, I also add 2 teaspoons of salt to the pan, just for that little extra savoury hit. I generally avoid salt in my cooking, but tomatoes and eggs, both really comer alive with just a little of the poison. I do this because salt is in everything that you buy, and in excess, it isn’t good for you. As nearly all processed foods are loaded with the stuff. I think that it’s best to keep my consumption of self-inflicted salt as low as possible. The result of this self-imposed restriction, is that Janine and I both have blood pressure that is at the lower end of normal. 110 over 60.

The resultant puree is again brought to the boil to reduce it by about 1/3 and then bottled. My 5 litres of original chopped fruit, is reduced to 2.75 litres of tomato sugo or passata.

This stuff is magic. It’s so hard to describe a combination of aroma and taste, but trust me it is amazing. This ritual of making tomato sauce every summer is the closest that I come to having a religion.

We chopped up one of our big greenish grey, glaucous ‘Queensland Blue’ pumpkins and Janine made pumpkin soup that will last for a day or two. Even feeding our two brickies.

We have been supporting our brick laying brothers by mixing lime mortar, stacking bricks up onto the high scaffold, passing up queen closers and snap headers to them and generally being helpful and supportive in whatever inept way that we can, whilst staying mostly out of their way. It can be a bit dangerous working below a scaffold, with occasion objects falling down at times. The odd trowel, but mostly brick spalls.

I had to go into town and buy us two safety helmets to keep us safe. Appropriately identified as belonging to the King and Peasant.

The work on the southern facade progresses this week with the home-made double story scaffold including safety rail. The arch is now completed, fitting the two keystones that close the archs. A ‘keystone’ is the last brick that fits in the arch, joining both sides of the span securely. The key stone is no more important than any other brick in the arch, every brick is equally important, it’s just the last one to be placed. Once the arch is secure, the wall is closed over the top, requiring me to cut a few special tapered ‘wedge’ bricks to bring the coursed brickwork back to level over the arch.

A well constructed arch is a beautiful thing. I built over 300 kilns over the course of my kiln building career. With the assistance of my good friend Warren, who was my right hand man for over 25 years, we prided ourselves in creating perfect arches in our brick lined pottery kilns. I know the whereabouts of some of these early kilns, and they are still working well after a very long life of untold firings over 30 years and more.

A well constructed arch is a beautiful thing!

We have spent two days on it and there is still the best part of a day to go the get the gable facade complete. It will require another small centre section of extra scaffold to allow the ridge to be reached comfortably and safely.

As the rain has started to set in, and is forecast for the remainder of the week, we finish the day by wrapping the new brickwork with its soft, freshly laid, mortar joints and covering it with black plastic to stop the rain from washing the joints out over night. If we are lucky, the rain will be very light or hold off for another day so that we can get the wall finished.

If the rain persists, we will be working under the verandah area and try to finish off the front wall around the door and windows instead.

Bonded

We have spent the last week working with our heritage bricklayers. The job progresses slowly and steadily. I spent the first half of the week working on the southern high arch window end wall.

Mid week I had to build a scaffold to allow the brickies to get higher.

On Thursday I got some help from our son Geordie and my good friend Colin the builder who came over for a couple of hour to help me erect the wooden arch former so as to facilitate support the arch bricks over the arch. I built the frame, but couldn’t hold it up safely while I secured it in place without help.

The brick work proceeded up the wall pretty quickly, so Colin and I spent Friday afternoon building the scaffolding up to the second level and securing it to make it very stable, then creating a safe ty rail around the top to make it safe for the brickies while they work up there next week.

While we worked on the end wall, the brickies worked under the verandah to keep the job moving along.

I secure the brick veneer wall to the corrugated ironed steel rail wall by using what are called ‘brick ties’. These are specially designed steel brackets that are screwed to the steel wall and are embedded into the cement mortar.

These are sold in boxes of 150 units. I am placing these ties on every 2nd brick, on every 3rd course of brick work. We are about half way through the job and we have used almost 4 boxes so far. I can see us using about 1,000 of these in total. Tragically for me, these things are made to secure the brickwork to a timber frame, so the hole in the tie to allow the nail or screw through is made too small for the big roofing screws that I’m using. So I have to spend half an hour a day drilling out the holes from 4 mm. to 6.5 mm.

To prevent any bricks being dropped onto the glass panes, I have screwed plywood panels onto the arch formwork supports and then covered the plywood with black builders plastic to keep it from getting wet in the rain that is forecast this coming week.

It’s all very tedious and takes so much time, but is so very necessary, as replacing a broken pane would take a longer time and cost more.

In chatting to Bill, one of the bricklayers, it turns out that he was taught by a master bricklayer, Dave Smith, who came from Leeds in Yorkshire. I tell him that my father was born in Leeds. Bill likes this bit of news and spends our next few ‘smoko’ breaks telling me all about his good ‘mate’ Dave. He even rings Dave up to tell him about the job, about our ‘Sussex bond’ variations, and about our Yorkshire/Leeds connection.

It also turns out that Bills brother Gordon, our other brickie, knows a lot of our friends here in the Highlands, as Gordon lived here for a decade in the 80’s. We discuss our connections and it turns out that we must have met 35 years ago, or if not, at least been at the same ‘open house’ music concerts.

It’s a small world. We are bonded by more than just bricks and mortar. We have the Sussex bond, the Leeds bond and the Open House music bond.

Navvie, Hoddie, and Gaffer’s Best Boy

It has been a busy week, with 3 of the 5 sparkies turning up early on Monday morning. I also had my friend Ross turn up to help strip down some of my burnt bits and pieces, to see if we could salvage any of it. It was all put aside and wrapped up under a big plastic tarp to help preserve what was left of it.That kept me busy all day, running between the gaffers doing the electrics and Ross pulling gear boxes apart. Ross is a pretty impressive guy, he seems to know an awful lot about all sorts of things. He started out as a Telecom technician, but quickly moved into electronics and then heavy earth moving equipment. It was Ross who turned up just after the curfew was lifted here post fire, last December ‘19. He brought me his bob cat to borrow for a few weeks to help me in the cleaning up. That made me cry! It was invaluable to me and got me started well on my way to recovery. Being able to shift burnt trees and building materials around to clean up the huge mess gave me hope.
I would look at a blackened piece of twisted metal and see trouble and difficulty. Ross would look and see possibilities. “We can straighten that, get the oxy torch”. and “I have an old 3 phase motor about that size that will fit in there” etc. “I can take that bent shaft home and straighten it in the hydraulic press on ‘V’ blocks”. I started to feel a little confident that some things are recoverable and not just scrap.


I had to split my time between the two sets of action, being best boy to the Gaffer. A gaffer is an electrician, and the Best Boy is his main assistant. I was asked to make large metal brackets for the 40mm conduits going up the outside wall. Cutting, folding and spot welding sheet metal cable covers to protect the exposed conduits towards ground level. I was busy all day. 
On Tuesday Ross worked at home and only two sparkies turned up. I spent the day hoisting 3 phase cables through the upper portals and ‘tophats’ to get the power around the building. That involved geting up and down the tall 3 metre step ladders all day. A good work-out.
Wednesday I had my friend Len here to help me clean bricks. Janine finished all the full sized bricks on Monday with our friends Rai and Fran. I had to miss that last bit of brick cleaning, doing the last 80 bricks. Len and I started on the 1,000 broken bricks that I will use for the ‘fake’ headers and queen closers in the Sussex wall bond veneer. If I can use the broken bricks to cut up for all the small pieces needed to fill the bond pattern, then I will have enough full bricks to do the job.


As well as Len, I had one lone sparkie here, I was needed to help him pass the heavy copper cables through the wall cavity from room to room. When I wasn’t needed inside, I helped Len outside the verandah chipping the bricks. My main job in the afternoon was to fit 25mm conduit down the portals and pass the power cables down through it to where the power points will be. I had to try and stay one step ahead of Ian the sparkie, I’m saddled with the job of fitting the wiring in place in the conduits and securing it all with saddles, as Ian came behind screwing on the fittings and connecting all the wires up.



After lunch, a brickie turned up to see our job. He was recommended by a friend. Gordon is a semi-retired ‘heritage’ brick layer. Perfect!He looked at our bricks and at the job as I explained what we want. We looked at the old school classroom, then the 1980’s addition that we did. Gordon understood exactly what I was saying and offered pertinent comments as we went about the particular bond and the quality of the mortar. Do we want it pointed, raked, or struck flush? He agreed to come and do our job, and even said that he could start on Monday! We are happy about that. He even has a brother, also a brickie, who will come and help out on the 2nd week.
I now need to get 4 tonnes of off-white brickie’s loam, 6 bags of lime and 12 of off-white cement to make lime-compo mortar. I also have only 3 days to cut and shape the 7 sandstone window sills. particularly the two large ones that are needed under the big arch window for the first course. No pressure!I won’t have much time to do this while I’m being the brickies labourer or donkey. Every trade has a nick-name. Sparkie, Brickie and Donkey or Hoddie, even Navvie, But there are also Carpenters as Chippies and painters are apparently called Smudgers.
So starting next week, I’ll be a Navvie or Hoddie for two weeks as well as the Gaffers Best Boy!That is – if it all goes to plan. This is the 5th brickie to check out our job. We’ll see on Monday morning at 7.00 am!

8,000 bricks

We have been working pretty consistently on the brick cleaning job for four weeks now, chipping, scraping and scutching away at our pile of sandstock bricks. We want to get the job done as soon as possible, but we don’t want to ruin our health in the process. We have had 3 brick layers say that they were interested, but then pull out when they realised that the job was a bit demanding of their skills.
The old School building where we live was built in 1893, when Queen Victoria was on the throne. Janine came across the the contract to build our school in the government’s Department of Education archives. One of the interesting things that she found was that the contract called for the brickwork to be laid in ‘Flemish Bond’. Flemish bond is a style or pattern of brick laying that was used for public buildings at the time and is quite distinctive. It produces a wall that is double brick thickness and incorporates a lot of ‘header’ bricks to tie the two parallel courses of ‘stretchers’ together. 
A header brick is laid at right angles to the normal two rows of parallel ‘stretcher’ bricks, across the the two to link them, and because you only see the skinny end of the brick, or the ‘head’ of the brick, it is called a ‘header’. Whereas the bricks laid so that you can see the long edge exposed is called a stretcher for obvious reasons. There are also ‘queen closers’ used at the end of each course and a repeating, but alternating pattern of bricks of stretchers and headers in the order of two stretches to one header. A queen closer is laid as the ‘pen-ult’ or in this instance, the ‘brick-ult’ piece , second from the end of the course, such that you only see one quarter of a brick. This off-sets the pattern by a quarter for each course.

Got that?

There’ll be a test later!

It’s a little bit complicated, but once you get your head around it, it’s dead easy. To complicate things a little bit more. When we wanted to add a house onto the derelict single room Old School classroom that we bought. We were forced to do the addition in single skin brick veneer construction, because the local council wouldn’t allow double brick construction. This was due to the fact that the village was affected by the near-by coal mine, and therefore mine subsidence. Double brick was deemed to be too heavy and fragile for a mining subsidence area. It would probably crack.
‘Mining subsidence’ is when the coal mine goes under ground and takes out 4 to 6 metres of coal from under everything. All the land on top slowly drops down by that amount to fill in the gap underneath, this is called subsidence. It causes buildings to crack as the ground shifts, stretches, cracks, drops and deforms in an unpredictable way. Double brick buildings are the most vulnerable.
The mining industry has convinced the government that mining is so good for the economy, that to protect the coal mining industry, the owners of buildings like ours should have to insure the mining company against being sued if their mining effort causes our building to crack due to subsidence. They do this by insisting that no building that is likely to crack is allowed to be built, so no double brick buildings, no two story buildings etc. If you do want to add on an extension to a building like ours, then it can only be in single brick veneer. They also insist that we had to get a massive engineered concrete slab and/or footings done at our own expense to protect them. We had to pay to insure the coal mine again loss. while they creamed off all the profits to the overseas owners, ruined the environment, drained the local lake of all its water through subsidence cracking and added untold carbon into the atmosphere!
The outcome of all this was that we added on to the Old School building in brick veneer construction, so we had to ‘fake’ the look of Flemish bond pattern brickwork using half bricks instead of headers and quarter bricks instead of queen closers. It worked and we did it that way. No un-informed person knows the difference at a quick glance. To do this extension of our house, we needed a lot of similar sandstock bricks.
We acquired these bricks back in the 70’s when we bought the old Mittagong Railway station. We saw that the 2nd railway building. The southern one, it was being demolished by a big excavator. This had been the dormitory for the change of shift for the steam train crews. As there are no more steam trains. This two story building was now superfluous to requirements. I don’t think that it could happen today, as there would probably be a heritage order on it.
We saw it being demolished and approached the Station Master to ask what was going to happen to all the bricks. He told us that they were all going to the tip! The site had to be cleared by Wednesday for the track crew to come in and start to widen and raise the platform to be ready for the introduction of the new XPT trains.
I said that we would finish the demolition and remove all the bricks and other building rubbish for them for no cost. He told me that there was no time, and any way, there would have to be a contract and money would have to change hands to make it all legal, and as it was already Friday and the paper work/contract couldn’t be organised in that time frame, there was no chance.
I countered that I would pay him a deposit now in cash and that the contract could follow. He countered that he couldn’t touch money. He was a Station Master, not an accountant. It would all have to go through head office in Goulburn, and that would take time.
I responded that If I drew a bank cheque from the commonwealth Bank in favour of ‘State Rail’, and put it in the mail here in Mittagong, the Manager of State Rail business in Goulburn could open the mail on Monday morning at 9.00 am. and have the equivalent of cash in hand, there and then, so we could start work and the contract could follow.
If I defaulted, then nothing lost, the bricks could still go to the tip on Wednesday. I could see him wavering. I was winning him over. He replied that we hadn’t agreed on a figure for this fine heritage quality, 2 story, brick building yet.
I said OK, let’s haggle. I offered $10… he was shocked. It put him back a bit. He explained to me that a fine 2 story sand stock building like this, made with heritage, hand-made bricks was worth a lot more than that, and what did I take him for? He said try again.
OK I said, then I will offer $100! 
He said done! 
He put out his hand to shake on the deal. It was as good as ours. All we had to do was finish demolishing the building, roughly clean the 8,000 bricks, then find 20 pallets, stack them on those pallets, then put together a team of workers and find a brick truck to move them to our place in 2 days!
We rushed to the bank and then posted the cheque with just minutes to spare, as the bank closed at 3pm on Fridays in those days. Then the real work began. I had to ring around and call in on friends, to get half a dozen blokes to help me. I got two friends who were very handy on the tools and available, then a young local ‘out-of-worker’ guy and his mate that I didn’t know, and that was it. The best I could do at short notice!
Janine was a bit conflicted, as Geordie has just been born and she was a nursing mother. Luckily we had some older friends. One of them was the local plumber, Joe. He had employed me when we first arrived here in the village. He sometimes needed a labourer, digging trenches, ladder work and under floor work, all the things that he was starting to find difficult at his age of possible 60+? I’m guessing, he was recently retired at 60. But he had come out of retirement to take on his son-in-law, Rob, as an apprentice, to give Rob a trade. The things fathers do!
Joe offered us the services of Rob for the next week to help out. Joe would pay Rob’s wage as usual. The things neighbours do! We knew Rob and his wife well, as they also lived in the village and I had helped Joe to build Rob’s house, digging footings, casting the concrete slab, doing roofing and plumbing etc.
We also had a friend in the owner of the local Saw Mill in Mittagong, Mr Blatch. He was very supportive. He said that I could ‘borrow’ a dozen of his pallets to stack the bricks on each day as we worked. That would make them easier to move back to our house on the brick truck.
The next big challenge was to find someone to move the bricks for us. I asked around and was tipped off about a driver of a brick truck from Bowral Brickworks. As a contractor, he owned his own crane truck and was used to moving pallets of bricks with his ‘HiAb’ crane. I called in at his house on the Sunday. He wasn’t too keen, but as it was a Sunday, his wife was there and over-heard my spiel, talking to him at the front door. She stepped in and told me that her husband would be happy to come each afternoon and collect whatever bricks we had stacked on the pallets that day, then drive them to Balmoral and unload the pallets in our drive way, after work. This was great news. He wasn’t cheap, in-fact, that was the most expensive part of the process. I got the feeling that she not only wore the pants, but also had her hands firmly in the pockets, as she did the accounts.
We were all set, with the bricks removed every afternoon, we didn’t have to worry about someone stealing all the bricks overnight. It does happen! One of my pottery students from years ago, told me that he called them ‘Midnight-spares’. That was how he built his pottery shed! Or so he told me.
Rob, Col, Willie and the others turned up on Monday morning. Mr Blatch sent one of his men up with the first half dozen pallets. We called out to the Station Master in his office and he stuck his head out and gave us the thumbs-up. We started levering the bricks loose from the walls, carrying them over to the side of the road and stacking them on the pallets.

Rob helped us with the demolition on the first day, but after that he stayed at our house each day to unload the pallets and re-stack the bricks along the drive way with Janine. It all went pretty smoothly for 2 days, until the 2 lazy young guys I had hired got into an unprovoked argument with some of the railway track workers. I had to step in and break up the fight. I sacked them. I didn’t need that problem at all and they were the laziest workers. At 20+ years old, they were still kids. At 32 myself, I was only just becoming adult.
So the 3 of us finished the demolition. Wednesday came and went and no railway people showed up to take the remaining bricks to the tip. So we kept on working. By Friday we had all the bricks removed along with all the bearers and joists, even the huge stone footings, we prised them all out. All that was left were the broken bricks and rubble.
I went on the Saturday morning to return the pallets to the saw mill and asked Mr Blatch if I could hire his two 3 tonne tip trucks for the day to collect all the broken bricks as well. I knew that as I would have to build in brick veneer, I would be needing a lot of halves and quarters to make the fake ‘Flemish bond’ pattern, and it would be a waste to cut up full bricks when here were all these broken bricks for the taking.
Mr Blatch agreed, he even sent one of his workers up with the other truck to help throw the broken bricks into the other truck. We worked at it for the next 4 hours and got both trucks full of the rubble by just after closing time at the mill. Mr Blatch and his off-sider, drove the trucks to our house and tipped out the two loads. The off-sider drove home, but Mr Blatch stayed on, he wanted to get a pot for his wife. 
We showed him around the show room in the pottery, he chose a big expensive bowl. I said, please take it as a gift for all your support, but he wouldn’t hear of it. He insisted in paying for it. He said that it was really gratifying for him to see a young couple get off their arse and show some initiative. He wanted to support us in our endeavour. So not only couldn’t we pay for the use of the pallets, the use of his worker on Saturday, the use of the two trucks, but was was going to buy the most expensive pot in the showroom. Before he left, he gave Geordie one of the brand new and shiny golden dollar coins. He was a beautiful amazing man!
So this is how we came by 8,000 hand made sandstock bricks and 2,000 halves. All we needed now was a brickie that knew how to lay a veneer version of Flemish bond. It turned out to be much harder than we thought.

When it came to building our home back in 1984, I asked every bricklayer that I came across if they could lay Flemish bond, every one of them said yes, no problem. $500 dollars a thousand! But when I quizzed them on how they would do it, it became obvious that they had no idea what was involved. They were just going to lay old fashioned, Humpty-Dumpty, cartoon-style, stretcher bond. They didn’t even know what I was talking about. Every young guy was the same.
One day, a lady came to the pottery to buy some pots and her husband soon lost interest and wandered off to look at the Old School, I saw him looking with some interest at the brickwork and I asked him what he was looking at. I told him that this was built in 1893 and that it was Flemish bond, a little known old fashioned style of brickwork. He told me that it wasn’t Flemish bond at all, that he was a retired brickie and that this was a little bit different from standard Flemish. 
He seemed very well informed, so I asked him what he would charge to build our house in a replica ‘not-quite-Flemish’ veneer bond? He replied straight away that he couldn’t quote on a job like this as it was very fiddly work, and it would have to be priced by the hour as it would be slow work to get a good result.  I replied. “That is the correct answer! I want you to do the job, as you clearly understand what is involved.”
The brickie’s name was Denis, he was an Englishman and told me that he was semi retired and only did little jobs these days, BBQ’s, small retaining walls, back door steps, etc. I told him my predicament in not being able to find a skilled brickie who knew Flemish bond. If he was semi-retired, I was prepared to have him come just a few days a week, just a few hours a day if necessary, whatever it took to get him to come and do the job. I would be his labourer, mixing the mortar and passing the bricks etc. he eventually agreed and we started the job. 
Denis explained to me that our brick work wasn’t true Flemish bond, there were subtle differences. He would copy the brick bond pattern exactly as we had it, but in single skin veneer. I looked into brick bond patterns and educated myself in the history of brickwork. I went to the State library and read a very old book from England about the influences on British brickwork from Holland. I think that it was called “Des Brykes”. I also found a very old book on brickwork in a 2nd hand bookshop called simply “brickwork’, tragically, I have since lent it to someone and never got it back. These books explained to me the subtle differences and developments in brickwork bonds. i learnt that our bond pattern is called ‘Sussex garden wall bond’. As the original contract to build the Old School specified ‘Flemish bond’, I assume that the local brickie that won the tender for our school, back in 1893, came from Sussex, or was trained by someone who came from from there!
Denis was a really nice old guy, 60-ish (that somehow sounds quite young to me now!) and very careful and highly skilled. He took his time, we worked from 9 to 3 with half an hour off for lunch, just 3 days a week. It took a few months to get up to window sill height all around the house. I had done most of the preparatory brickwork from the below ground level, up to floor level, with the help of my brother-in-law, John. He showed me all the basics and got me started, setting up the levels and squaring the site. I would have been lost without John’s experience, guidance and knowledge.
We had to stop at window height, as I had to make all the windows and make all the sandstone window sills, but first I had to learn a bit about blacksmithing, to make all the tools to cut and shape the stones for the sills. Stone masons tools were very hard to come by in those days before the internet and had to be posted out from England from a specialist supplier, and the cost was astronomical  There was no Bunnings in those days! Come to think of it, Bumings still don’t carry stone masons tools! So I made my own. I needed a pitching tool, a broad chisel and a set of gads. I though that this would be the minimum set, as I already had a couple of small cold chisels, a bolster and a heavy hammer. Not a complete or proper set, but it would do. I forged out the tools from some heavy, left over, concrete ‘rio bar, that was from the footings of the house.
Years ago, I worked at the National Arts School with a lovely old guy – another 60 year old, called Alan. He had been a stonemason amongst other things in his life. I met him when he was the Ceramics Dept, Technical officer at the old East Sydney Tech, now the National Art School, when I was a student there in 1971/2. Alan agreed to come and give me a lesson on how to cut stone and I invited a few friends along who were also interested.
As I’m completely untrained and had virtually no idea of how to go about blacksmithing. I got a few books on the subject, some had to be posted out from England, and I taught myself by reading and trial and error – mostly error. I eventually got a set of stone sills carved out. I cut and shaped 17 window sills in a few months, and then made all the windows for the house over the rest of the year. We also had to clean the rest of the sandstock bricks. It took quite a while. Fortunately we had some friends visiting from the Wales. Sally Seymour and her daughter Annie, plus her two children. We all got stuck in and made a good dent on the pile. They were fabulously hard working visitors!
When I rang Dennis the brickie again after a years break, he told me that he was even older now, a year on, and that he wasn’t that keen on doing all the rest of the job on scaffolding at height. He didn’t own any scaffolding and I would have to hire some. That was another expense that I wasn’t prepared for. If the first third of the house took 6 months working on the ground, then I could image that the upper 2/3 would take a year. I decided to look for some 2nd hand scaffolding.
Before the internet, the way to find things that were for sale was through ‘The Trading Post’ paper. It wasn’t a newspaper. It only carried adds for 2nd hand stuff. I found some used scaffolding from a guy who had bought the scaffolding from another guy who had bought it 2nd hand from ….. It was well loved, and a bit bent! I paid a few hundred dollars for it, and this was a fraction of what it would have cost to rent for a year.
Dennis returned to see what I had done, but suggested that he couldn’t do it all himself. He asked if I minded if he brought in a friend, another local brickie, Theo, to help him get the job done. I was delighted, if it meant the job would be completed sooner. Then I could get on with other things. It just so happened that they came back during the Art School vacation, so I could dedicate myself to full time brickie’s labourer. It took a massive amount of energy to labour for two brickies up on scaffolding. 
I had to cart the bricks around the site in a wheel barrow and pass them up onto the scaffolding and stack them at their feet, two stacks, one at each end, then mix the mortar in a barrow with a ‘larry’- like tool that I made from a garden hoe. I then had to shovel it up above my head onto mortar boards at their feet. I was exhausted at the end of each day, but the job went very quickly and they were finished by the end of the month. I was so pleased and they did a beautiful job.
I now know what is involved in laying pseudo Flemish bond brick work. Actually, Sussex garden wall bond veneer brickwork. So now I’m looking for a brickie who knows a little about other bonding patterns other than straight stretcher bond. Someone who is inquisitive and creative. Someone who is prepared to do something different. It is turning out to be rather hard. All the young guys just want to lay straight long walls with no gaps, no window or doors, and all at ground level. Fast easy money.
I was given the number of a guy by the concreters who cast our slab. His mate is a brickie and he assured me that he knew all about Flemish bond. I rang him and he told me he was an ‘master’ brick layer. I sent him a photo of our Old School to see the brickwork pattern involved and a copy of the plans for the new pottery.He called be back almost straight away. He asked me if that is an arch in the end wall? I told him, yes it is. He said forget it I don’t do arches! What sort of ‘Master brickie’ can’t lay and arch?
The next chance was with an old Scottish guy who even came out here to look at the job. He was positive and very nice and helpful. He asked me to ring him once I had all the bricks cleaned. I rang him a couple of weeks ago and told him we were approaching the end of the brick cleaning. He didn’t reply. I texted him again a week later. Still no answer. Finally on my 3rd attempt, he replied that he couldn’t be doing our job.
The third brickie was working on a job in the north end of our village. I stopped and asked him if he could do our job, and did he know Flemish bond? He told me that he did and that he couldn’t quote on it. It would have to be piece work @ $1.70 per brick. I agreed, and he told me that he was currently working on a big job and would do ours next, in two months time. Great! But then an email came last week to say he didn’t want to leave it till near the time to let us down, so he was telling me now that he wouldn’t be coming.
The fourth brickie I contacted said he knew Flemish and understood what I meant by pseudo Flemish veneer, made with halves and quarters to mimic the style. I sent him the photos and plans and he said yes! He could do the job in two weeks. He said that it would have to be done on piece work – a good sign that the knew what was involved, and that he would charge $1.70 per piece plus 10%GST, or $1.87 per brick or part there of! A bit pricey, but I agreed, as I’m running out of options. 
So now we have to wait and see if he shows up or pulls out like all the rest. Every tradie that I talk to is flat-out busy, sparkies, brickies, plumbers and chippies. We appear to be in a building boom here, so no one wants to do a small or slightly difficult or unusual job, and they want $100+ per hour. That’s approaching the quarter of a million dollars a year! I’m in the wrong trade. Our sparkies are starting work at 4.00 am in the morning and working through until 8.00 pm at night on a big factory job. I can only get them intermittently on occasional days. Wrong trade indeed!
If I can’t get a brickie to turn up. I’ll just do it myself, but the brickwork will have to wait for a few years, until I get the pottery up and running and get the PowerHouse commission finished. The brick veneer face is not essential. It’s just that we have all the bricks on site and need to use them up. They are the perfect match with the other half of the bricks used on the house and a brick face on the west will be very heat resistant in the next fire. The building is clad in corrugated iron already and is sealed and weather proof, so the brick work can wait if needs be. Sussex garden wall bond veneer, is an aesthetic luxury, but one I want to ‘finish’ off the project.

Eventually!

The Old Feed Mill striped bare

I returned to the old feed mill today to finish stripping all of the old grey weathered galvanised iron sheeting off the sheds. I was joined by my son Geordie and we finished the job of taking the walls off in intermittent rain. I’m so glad that Andy and I took the roof off yesterday when it was mostly dry. I wouldn’t have gone up there today. Far too slippery in the wet.

We loaded the truck with another full load that flattened the springs. Another good tonne of steel. This load was mostly all the long 5.3 metre long sheets. Altogether we collected over 150 sheets of old corrugated iron, totalling over 530 linear metres of roofing.

Not too bad for 2 days work! I shudder to think what this would cost new. of course I couldn’t be buying any of it new! I’d find something different to scrounge and re-cycle, or up-cycle, as it’s so trendy to say these days.

I’m very lucky to find such lovely old weathered, matt grey and slightly rusty material. It’s just what I really like. Most of these sheets will line the walls of my metal working workshop, which is over 4 metres tall, just right. Some of the other rooms will benefit also with the kiln room and the gallery getting a wall or two also. I’ll have to wait and see how far it all goes, as there are always losses in cutting the sheets to fit the size of spaces required.

It’s important to me to use these old recycled materials in this new shed. It would look awful if it was all shiny and ‘off-the-shelf’ new. This shed needs the sabi wabi feeling that this weathered old iron will give it. It needs softening and ageing in this way to make it ‘fit’ in this creative and sustainable environment that we envisage for ourselves here in our new post-fire future.

In the evening Janine makes a fabulous dinner of garden veg with a little bit of feta. She was watching A TV show about cheese making and the presenter explained that this was a local recipe from Greece. She thought that it sounded interesting, so wrote down what she remembered after the show. So there is immediately a little bit of interpretation and creative adjustment going on. Whatever was originally intended doesn’t really matter, as this works aa treat.

Spinach, capsicum, zucchini, onion, garlic, and potato slices baked in the oven in a tomato passata sauce. We just happen to have all these ingredients in the garden and a bottle of home made passata in the fridge just now. The only thing that is purchased is the feta cheese.

It was totally yummy, and absolutely local with the exception of the feta cheese, mostly zero kilometres of carbon debt, just 30 metres of travel carbon debt, expended on foot.

Janine also made red grape jelly jam.

And we picked our first apple from the the new trees in the new orchard. It’s a beauty!

A busy day of getting on with all this self reliance stuff.

The Old Feed Mill Factory

Today I spent the day demolishing the old feed Mill factory sheds in Moss Vale. I had known about the sheds needing to be demolished to make way for a new steel fabrication factory. The owner had offered me all the roofing iron for free if I took it all apart. I looked at the site a month ago, but wasn’t ready for the iron until now. The Old Feed Mill has been on that site for a very long time. I was told by one person that their father went there as a kid with his father and his father is now over 80! The original feed mill was built and run by the Hirsh family. This shed appears to be a more modern building. It doesn’t look to be 80 years old, possibly dating back to the 50’s or 60’s. The current owners, who bought the company in 1992, finally closed up in 2017. I know this because the last message was still scrawled up on the black board at the entrance.


The pottery rebuild has got close to the stage of lining the sheds. The electricians have started wiring the building, but will still be another few weeks before they finish, as they are doing my job in their ‘spare’ time in between doing a huge factory installation in Mittagong. so I only get them when they have ‘spare’ days.Once the electricians have all the wiring installed in the walls, I can then start to put the insulation batts in the wall cavity and then line the buildings. The iron from the old feed mill will do nicely as a fire proof lining material. The shed will be steel framed, steel lined and steel clad, with fibreglass insulation. Not too much to burn there.I would have left it for another couple of weeks until the electrics were done, but I got a call asking me if I still wanted the metal, because if I didn’t, there are plenty of others who do. So I had to move now.


I asked my friend Andy to help me on this one, as I thought that it was just a bit too big for me alone. also, working on ladders at heights and on high roofs, it’s best to have a friend there just in case. I’m a decade past the age when I should have stopped doing this kind of work, but nobody told the bush fire that.


We started at 8.00am and hammered, ground, levered, screwed and bludgeoned our way across the two roofs prising off the old rusted nails and screws, then throwing down the liberated sheeting to the ground in a rather messy pile. It all went to plan – almost, except for the rather strong gusty winds that picked up, just after we started, we had to time the picking up and carry the loose sheets to the edge of the roof and throwing them off to coincide with lulls in the gusts. It could have ended badly if a severe gust of wind hit me with a full sheet in my hands at that height. Long sheets of iron act like a sail or even spinnaker.


We finished taking the roof off by 2.30 and then spent an hour cleaning up the mess on the ground and loading some of the iron onto the ute. We got about half of it on. 104 sheets on the ute, which was a really full load for the one tonne ute, but I made it home OK with out being booked. Andy had more sheets on his trailer. We stacked them all in a corner of the new workshop. They can wait there until the sparkies are finished.



We finished stacking the first load of 100 sheets in the shed around 5 pm. A big day for an old guy.
I’ll be going back tomorrow to take the walls off and bring the 2nd half of the load back home. That’ll keep me off the streets for a while. I’ll certainly sleep well tonight.
I know that I shouldn’t really be doing all this ladder work and roof work at my age, but I gave the Work Fairy a month to get it done for me, and she never showed up. Fictional and imaginary friends are just So unreliable! There is nothing much that a passionate and committed human can’t do – given time.

All this self reliance is hard work!

Still on the tools

We have been working on the tools, brick cleaning for the past 3 weeks now. Last week, my wrists began to ache, so I stopped and had a 3 day break to let them rest. Our friends Rei and Fran called in on Monday to give us a hand and I did my share, but that night my wrists swelled up and ached, so I realise that I have reached my limit on brick cleaning. I’ll need to have a few weeks off now to let them recover. We got 2,200 bricks cleaned, so we are about 2/3 of the way through the job, an average of around 100 bricks a day. Not too bad, but obviously too much for my ageing body – at this time of great anxiety and stress.

Instead of brick cleaning, I finished off the claywater/greywater drainage system, digging the trench from the pottery studio to the seepage trench by hand using a crow bar and shovel. Interestingly, this didn’t hurt my wrists the way that chipping away at lime mortar does?


Once the sewerage line was completed, I turned my attention to the LP Gas line. We hadn’t fired our LP gas kiln for the past decade, as we were trying to minimise our use of fossil fuels. But the gas bottles still have gas in them and I’m planning to build another solar electric kiln using gas reduction at stone ware temps.
There are so many services that need to be buried all around the building, I’m trying to get these done, I’ve finished the storm water and guttering, so all that remains to be dug in and buried is the fresh tank water supply to the sink. This has to come all the way around the building from the 2 big rain water tanks next to the barn. I want to get all this done so that I can finish the ground works around the building and start to clean up the site. 
The LP Gas line comes from the 2 big gas bottles past the studio and around into the court yard then up and over the verandah and into the kiln room. I’m really proud that I have been able to achieve this complex installation using only two tools, a coil bender and an expander.

With this minimal tool set, I have been able to make all the elbows and joiner parts necessary for the job from simple copper pipe. I’m using thick class B pipe and 5% silver solder for all the welds, as required by the Australian Standards. The only parts that I will need to buy are the 2 end threads to screw on the LP Gas connection fittings. 
Miraculously, my ancient 1950’s oxy set and the 2 gas bottles survived the fire because I wheeled them out side into the paddock and wrapped them in a piece of 1/2” ceramic fibre blanket. The fire raged past and over them and didn’t even melt the plastic hoses, such is the insulating value of ceramic fibre in the short term. It saved me too!


I’m not real fast, It has taken me 2 days for this job, but I don’t charge myself anything for my time. One of our past pottery students is a plumber and he has agreed to come and test my line and certify it if it passes, then connect the kiln for us. I saved myself a lot of digging by using the existing stormwater trenching for nearly all of the underground work.
Another of our past students, Tony, a retired builder came and installed the glass french doors. These were donated to us by another ex-student Geoffrey and his wife Sue. They bought the doors 2nd hand and Geoffrey cleaned them back, reglazed and puttied them, then undercoated them. Only to realise that they didn’t really suit what they had in mind and found them to be excess to their requirements, so donated them to us. Tony did a wonderful job of installing them, which required moving one of the studs and me making a new steel header beam and then some new steel door jambs out of 3mm thick gal steel plate, so as to save using a wooden door jamb to save the extra space. This was the only way we could fit them in. They look great and let lots of light into the building. We are really pleased!


I also finished the back verandah with the help of my friend Warren last Sunday. I had made up all the parts to make a new ‘portal frame’ to finish the job that the builders said couldn’t be done. I used the off cuts from the 3mm thick gal steel plate that bought for the french door jambs, and cut out and folded the parts for the frame myself, using the guillotine and pan break, watched over by the always attentive chickens, Gladys and Edna. 


The back verandah is now complete and weather proof.
The brickie that we originally had come out ond look at the job, has now said that he can’t do it. A shame, but I have been in touch with a couple of younger guys who are interested. One says that he can start in 4 weeks, so the pressure is on to get the last 1200 bricks cleaned in 4 weeks! We’ll see what we can do. That’s 50 a day, 25 bricks each. It may be possible? 10 before breakfast, 10 before lunch, and 5 before dinner. We have a few weekend working bee’s organised, so that will take some of the load off our wrists.