Introduction to the Battery Cast House

The Battery Cast House, also known by various names such as BRS Battery Cast, BRS Brecast, DSIR Edmonton, and others, is a unique type of system-built property that emerged in the 1960s. Designed by the Building Research Station (BRS), these houses were part of a broader movement to address the post-war housing shortage in the UK. This article delves into the intricate details of Battery Cast Houses, providing home buyers and investors with essential information to make informed decisions.

Historical Context and Manufacturers

Origins and Development

The Battery Cast House was developed in the 1960s, a period marked by a significant demand for affordable and quickly constructed housing solutions. The Building Research Station (BRS) played a pivotal role in the design and development of these properties. The system was primarily used for constructing 2-storey terraced houses, although it was also adapted for flats.

Manufacturers and Alternative Names

Several manufacturers were involved in the production of Battery Cast Houses, including Fram Construction, Fram Russell, and Harry Neal. These houses are also known by various alternative names, reflecting the different manufacturers and regional adaptations. Some of these names include:

• BRS Battery Cast
• BRS Brecast
• DSIR Edmonton
• BRS EDLO
• BRS Enfield
• Fram
• Fram BRS
• Woodley BRS

Typical Characteristics of Battery Cast Houses

Architectural Features

Battery Cast Houses are typically 2-storey terraced houses with a shallow or medium pitch gable roof. The roofs are usually covered with slates or flat roofs with bituminous felt or asphalt. The front and rear external walls can vary, featuring brick slips, vertical timber boarding, tile hanging, or precast (PC) panels. The gable walls are often constructed from brick, render, or ribbed storey-height PC panels.

Construction Details

Substructure

The specific details of the substructure are not well-documented, but it is generally assumed to be a standard concrete foundation typical of the era.

External Walls

The front and rear walls are constructed from storey-height timber frame panels, sheathed externally with timber boarding and clad with brick slips. These walls are lined with plasterboard on the interior, with insulation placed between the frame studs. The gable walls are made of brick, cavity, or storey-height PC panels.

Separating Walls and Partitions

Separating walls are constructed from storey-height PC panels, while internal partitions are made from timber studs lined with plasterboard.

Floors

The ground floor is typically concrete, while the first floor consists of PC slabs. In some variants, the first floor may be constructed from timber boarding on timber joists.

Ceilings and Roof

Ceilings are usually finished directly without additional cladding. The roof structure is made from timber, with large PC slabs and PC parapet panels.

Variants

There are several variants of Battery Cast Houses, including:

• Front and rear walls clad with vertical timber boarding or tile hanging.
• Front and rear walls of plain-faced storey-height PC panels or PC spandrel panels with timber frame panels above.
• Gable walls of rendered storey-height PC panels or ribbed PC panels.
• A wide range of panel sizes up to 6m x 2.6m x 200mm.
• Partitions of storey-height PC panels.
• First floor of timber boarding on timber joists.

Typical Hazards and Risks

Structural Concerns

One of the primary concerns with Battery Cast Houses is the durability of the reinforced concrete used in their construction. Over time, the steel reinforcement within the concrete can corrode, leading to structural weaknesses. This issue is particularly prevalent in properties that have not been adequately maintained or have been exposed to harsh environmental conditions.

Thermal Insulation and Energy Efficiency

The insulation between the frame studs in the external walls may not meet modern energy efficiency standards. As a result, these houses can be less energy-efficient, leading to higher heating costs and potential issues with dampness and condensation.

Asbestos

As with many properties built in the 1960s, there is a risk that asbestos-containing materials were used in the construction of Battery Cast Houses. Asbestos was commonly used for insulation and fireproofing, and its presence can pose significant health risks if disturbed.

Defective Premises Act

Battery Cast Houses are not specifically classified as defective under the Defective Premises Act. However, any structural issues or hazards identified during a survey would need to be addressed to ensure the property meets current safety standards.

Inspection and Assessment Guide

Pre-Inspection Preparation

Before conducting an inspection, it is essential to gather as much information as possible about the property. This includes reviewing any available documentation, such as previous survey reports, maintenance records, and building plans.

External Inspection

Roof

Inspect the roof for signs of damage or wear, such as missing or broken slates, cracks in the bituminous felt or asphalt, and any signs of water ingress. Pay particular attention to the condition of the timber structure and PC parapet panels.

Walls

Examine the external walls for any signs of cracking, bulging, or other structural issues. Check the condition of the brick slips, timber boarding, and PC panels. Look for any signs of dampness or water penetration, particularly around windows and doors.

Gable Walls

Inspect the gable walls for any signs of cracking or movement. Check the condition of the brick, render, or ribbed PC panels. Look for any signs of water ingress or dampness.

Internal Inspection

Floors

Check the condition of the ground and first floors. Look for any signs of cracking, movement, or dampness. Pay particular attention to the condition of the PC slabs and timber joists.

Walls and Partitions

Inspect the internal walls and partitions for any signs of cracking, movement, or dampness. Check the condition of the plasterboard and timber studs. Look for any signs of water ingress or condensation.

Ceilings

Examine the ceilings for any signs of cracking, movement, or dampness. Check the condition of the direct finish and look for any signs of water ingress.

Structural Integrity

Assess the overall structural integrity of the property. Look for any signs of movement, settlement, or other structural issues. Pay particular attention to the condition of the reinforced concrete and any signs of corrosion in the steel reinforcement.

Thermal Insulation and Energy Efficiency

Evaluate the thermal insulation and energy efficiency of the property. Check the condition of the insulation between the frame studs and look for any signs of dampness or condensation. Consider the potential for upgrading the insulation to meet modern energy efficiency standards.

Asbestos

If there is any suspicion that asbestos-containing materials may be present, it is essential to arrange for a professional asbestos survey. Do not disturb any materials that may contain asbestos, as this can release harmful fibres into the air.

Typical Defects in Battery Cast Houses

Corrosion of Steel Reinforcement

One of the most common defects in Battery Cast Houses is the corrosion of the steel reinforcement within the concrete. This can lead to structural weaknesses and, in severe cases, structural failure. Regular maintenance and inspection are essential to identify and address any signs of corrosion.

Cracking and Movement

Cracking and movement in the walls, floors, and ceilings can be indicative of structural issues. These defects can be caused by a variety of factors, including settlement, thermal movement, and moisture ingress. It is essential to identify the underlying cause of any cracking or movement and address it appropriately.

Dampness and Condensation

Dampness and condensation are common issues in Battery Cast Houses, particularly in properties with inadequate insulation or poor ventilation. These issues can lead to mould growth and other health hazards. Improving insulation and ventilation can help to mitigate these problems.

Asbestos-Containing Materials

As previously mentioned, the presence of asbestos-containing materials is a significant concern in properties built in the 1960s. It is essential to identify and safely manage any asbestos-containing materials to prevent exposure to harmful fibres.

Maintenance and Repair Recommendations

Regular Inspections

Regular inspections are essential to identify and address any defects or issues in Battery Cast Houses. It is recommended to have a professional surveyor conduct a thorough inspection at least once every five years.

Addressing Structural Issues

Any structural issues, such as corrosion of steel reinforcement or cracking and movement, should be addressed promptly. This may involve repairing or replacing damaged concrete, reinforcing weakened structures, and addressing any underlying causes of movement or settlement.

Improving Insulation and Energy Efficiency

Upgrading the insulation in the external walls, roof, and floors can significantly improve the energy efficiency of Battery Cast Houses. This can help to reduce heating costs and mitigate issues with dampness and condensation.

Managing Asbestos

If asbestos-containing materials are identified, it is essential to manage them safely. This may involve encapsulating or removing the asbestos, depending on its condition and location. Always use a professional asbestos removal contractor to carry out any work involving asbestos.

Preventative Maintenance

Regular maintenance, such as cleaning gutters, repairing roof leaks, and addressing any signs of dampness or water ingress, can help to prevent more significant issues from developing. It is essential to keep the property well-maintained to ensure its long-term durability and safety.

Conclusion

Battery Cast Houses are a unique and historically significant type of system-built property that emerged in the 1960s. While they offer a range of benefits, including quick construction and affordability, they also come with specific challenges and risks. By understanding the typical characteristics, hazards, and maintenance requirements of these properties, home buyers and investors can make informed decisions and ensure the long-term safety and durability of their investment.

At Flettons, we’re committed to safeguarding your investment. When considering a property purchase, trust our seasoned expertise to reveal any hidden threats. For a thorough building survey, get your instant quote through our quote calculator or reach out directly at 0203 691 0451. Your home’s safety is our top priority.

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