Barn Conversion Repairs Retain Original Materials

Before a disused and dilapidated farm building in Wellington, Somerset, could be converted into a modern private residence some serious structural faults needed to be rectified. These were overcome using a combination of concealed stainless steel remedial systems from structural repair specialist, Helifix Ltd, which had the added benefit of retaining the building’s original construction materials and appearance.

Originally used to house cattle, the barn had suffered over time from general decay and structural deterioration. The first floor timbers were rotten, the walls had lost lateral support and were bowing and leaning and, due to a former adjacent soak-away, the gable end had rotated and separated from the main structure causing large vertical cracks in the stonework some 30mm wide.


The repair scheme, undertaken by Approved Installer, ASRS Ltd, consisted of wrapping the entire building at various levels in HeliBar stainless steel reinforcing bars bonded into channelled-out mortar beds. These tied the stonework together, stitched cracks and formed masonry beams that reinforced the structure and spread the loads. Additional shorter length bars were used to stitch individual cracks.

BowTies were installed through clearance holes in the 400mm thick stone walls and driven in to the joists of the repaired first floor before being bonded into the masonry to stabilise the bowing walls. To reconnect the separated internal and external walls, grouted CemTies were installed while DryFix remedial ties were driven vertically into the stonework to secure the arch lintels over doorways and two newly created window openings.

All the Helifix repair products were fully concealed upon installation, restoring full structural integrity to the building without major taking down and rebuilding. The original stonework and appearance was retained while contract times and costs were reduced, making the barn fit for final conversion and habitation.