Farm and barn conversions to living accommodations come with very specific challenges. Surveying and contributing to the renovation of many of these buildings, here are the most typical problems that commonly need to be addressed:
All these problems often act in combination, causing severe damages to old barns and farm buildings. These problems need to be addressed individually, as they have different remedies. We are going to touch upon all these problems one-by-one below. Â
Rising damp is generally believed to be capillary action: the walls acting as a sponge wicking up liquid moisture from the ground making the walls wet. Although this is a good analogy to illustrate the concept of capillarity, real walls behave differently.
Most of the time there is very little liquid moisture present in a drained but damp topsoil. When the water table is lower than the base of the walls, moisture can only rise upward as evaporating vapours. The ongoing vapour movement results in moisture accumulation, leading to capillary action inside the capillaries through several stages, as shown below. Thus, most of the time, rising damp develops through indirect capillary action as a result of vapour accumulation - fundamentally being a vapour-driven phenomenon.Â
Obviously, in limited and specific circumstances direct capillary action can also be present in the walls (e.g. during flooding, extreme rainfall, water-saturated ground, extremely high water table etc.), making the development of rising damp much faster - its speed and rate of severity being determined by the quantity of water inflow.
The whole concept of rising damp is explained in much more detail on the rising damp page.
The reason why rising damp needs attention and must be addressed is the presence of ground salts rising damp draws up from the soil into the masonry. The real problem is not the water or humidity but the salts accompanying rising damp. Â
Contrary to common belief it's not moisture that damages the wall fabric or the plastering. It's the salts. High moisture content alone does not damage old buildings. Salts do.
Although water can cause damages to lime plasters through flooding, longstanding water ingress or frost, in the vast majority of cases, clean rainwater evaporates without a trace without causing any damages. Thus, dampness caused by clean fresh water is fully reversible.
The real problem, however, is when dampness is combined with minerals or salts. In the presence of salts everything changes. Salts are hard, solid minerals that in the presence of water temporarily go liquid. However, when humidity evaporates the salts re-crystallize and expand in volume 5-10 times. The crystallization or mechanical expansion of salt crystals is what makes old masonries or plasters crumble, salts being responsible for far more damages than water ingress and frost. This is a very important technical point that needs to be understood.
On real buildings the effect of salts can be very difficult to assess, as dissolved salts become invisible to the eye and touch, only dampness being obviously present. However, under controlled laboratory conditions the effect of salts can be easily demonstrated, measured and understood.
Here is a lab experiment: when two identical bricks - one salty, the other one not - have been subjected to high air humidity variations for an extended period of time, the salty brick has crumbled badly while the non-salty brick stayed completely intact in a high humidity environment.
So salts are the real problem, however it's water that carries them everywhere, contributing to their damaging effects.
Commonly, old buildings are replastered with lime plasters to keep the fabric breathable. This indeed checks the breathability aspect, however it does not address the problem of salts. Normal lime plasters are not salt resistant, thus they can easily be damaged by salts. As a result, the longevity of lime plastering is often much shorter than it could be.
However, there is a plastering solution that combines breathability, salt resistance and longevity of plastering in one robust, workable, tried-and-tested, building-friendly, traditional solution.
Dealing with high humidity and the destructive effect of salts requires special lime plasters. These are ancient plaster mixes initially used by the Phoenicians and Greeks, then rediscovered and perfected by the Romans throughout the centuries. Being outstanding architects and builders, the Romans have observed that adding to lime certain volcanic sands and ashes (also known as natural pozzolans - highly porous and breathable lava materials), these can significantly alter the properties of lime while retaining its breathability.
Through the skilful use of different types of volcanic sands and ashes, the Romans have created many types of lime mortars with outstanding properties - some of them becoming waterproof or able to set underwater, or becoming highly resistant to salts resisting seawater.
These volcanic lime mortars have been extensively used by the Romans in very demanding environments including sewers, ports, spas and aqueducts and they have survived for many centuries. They have also been widely used in Venice, as they perform extremely well in the humid and aggressive environment of the Venetian lagoon.
Traditional pozzolanic Roman mortars differ significantly from today’s modern NHL (Natural hydraulic lime) mortars.
NHL mortars - a mix of lime and clay - need to be fired at higher temperatures than normal (air) limes for the lime and clay to react. The higher firing temperatures and more heat partially closes off the pores of NHL plasters, reducing their breathability. Thus, NHL plasters trade-off breathability for improved water resistance.
Roman mortars use lime and volcanic materials. These are mixed at room temperature without heat as the volcanic sands and ashes have already been pre-burnt by the volcano. This keeps the pores structure open resulting in high breathability. The volcanic ingredients make the plaster highly resistant to dampness and salts, making these Roman mortars perform extremely well in damp and salty environments.
The commercially available material today is the Rinzaffo MGN lime plaster. It comes in 25 kg bags with all necessary ingredients pre-mixed, requiring only water. Once it hardens it becomes waterproof, extremely resistant to all salts (chlorides, nitrates, sulphates), yet thanks to its porous volcanic lava ingredients, it stays breathable allowing the wall fabric to breathe.
This plaster - depending on where it's used - performs several important functions:
This lime plaster is made exclusively of natural materials. It contains no chemicals nor additives. All prime materials as well as the final product is certified.
Thus, the Rinzaffo MGN plaster is a lime plaster that acts as breathable water and salt filter. Due to its small pores it blocks liquid water. Due to its open pore structure allows the wall fabric to breathe. Having no salt content of its own, it does not introduce salts into the masonry. Being waterproof, it becomes impervious to salt penetration and crystallization, resulting in an extremely long service life even in very demanding and damp environments (e.g. basements).
Using this Roman plaster as a base coat under the main plaster coat prevents the premature degradation of lime plastering, resulting in long-lasting lime plastering that can last for several decades in very damp and salty environments. Â
The energy efficiency of old buildings is a hot topic nowadays. Unlike new buildings which are designed and built with adequate insulation in mind, the retrofit insulation of old and listed buildings – especially the ones with solid walls – poses significant challenges, as the materials used in this regard must satisfy multiple (often conflicting) requirements:
The vast majority of insulating solutions on the marketplace, however, have been developed for newer buildings. They offer good thermal insulation, but modern materials – foam, plastic, metal foil, cement etc. – are non breathable, they trap moisture which can lead to future dampness problems.
Due to increasing energy costs, government pressure as well as the need for greater comfort, breathability is often sacrificed, leading to severe dampness problems in old building years or decades later.
Using breathable insulation materials in old buildings, such as lime thermal insulation, is very important for the long-term health and the integrity of the building fabric.Â
Due to the decayed, poor condition of many agricultural buildings, water ingress is a common problem.
Water ingress can take many forms, the most important ones being:
In such cases, due to their properties, regular lime plasters do not provide a robust enough, long-lasting solution. As a result, waterproofing jobs on old buildings are often performed with modern materials such as tanking slurries, bituminous tanking materials, plastic membranes, just to name a few. Although these perform well in keeping liquid water out, when used in older or listed buildings designed to breathe, they also come with important drawbacks or trade-offs.Â
Suitable lime alternatives exist which can replace modern Portland cement or plastic membranes, providing a robust long-term solution that also keeps the wall fabric breathable. Â
In order to protect old walls from driving rain, a common solution is the rendering of the wall fabric with a waterproof render.Â
The fabric of older buildings – typically the ones built before the 1930s – often contains a significant amount of moisture, which is kept in check by ongoing natural evaporation. In order to keep moisture levels low, the renders used for the waterproofing of old buildings must permit the evaporation of moisture, as such they must be breathable.
Because waterproofing and breathabilty are two opposing characteristics which are technically difficult and expensive to achieve, in practical waterproofing the concept of breathability is often overlooked or sacrificed. This oversight results in the gradual build-up of moisture inside the wall fabric, leading to (often long undetected) major dampness problems in older buildings.
Due to its widespread use and low cost, one of the most commonly used render materials today is cement – a material that promises good weather protection - however in older buildings it also comes with some notable drawbacks.
Some of the reasons why cement-based renders should not be used in older buildings are:
Lime-based breathable render alternatives exist that can solve all water penetration problems fully in a building-friendly way with no drawbacks, keeping the wall fabric breathable long-term. Â
As a result of the ongoing long-term decay of the old historic fabric, sometimes some structural consolidation of old walls or rebuilding the damaged masonry becomes necessary.
The structural consolidation of older walls and buildings is often done with cement-based mortars or concrete, for a number of reasons:
However, there is more to structural consolidation than just cement.
The Romans have developed lime-based alternatives, building some impressive buildings that have lasted hundreds of years using lime mortars. The Colosseum or the Pantheon in Rome are just some examples of Roman architecture fully built with lime about 2,000 years ago that still stand today.
So the right types of Roman limes are definitely suitable for all sorts of structural works, and they are breathable.
Here is how to resolve all the above problems in a building-friendly way. The solution of each of these problems is detailed on their individual solution pages given below:Â Â
For more information, please see below a list of technical pages, projects, image galleries and videos related to this solution.
Here are the typical recommended materials / products for this solution. Other plaster variations are possible as we have different types of main coats (normal or thermal) and finishes (smoother, grainier, coloured etc.) depending on your needs or application. Please get in touch to discuss additional options.
Here are some related pages with additional technical information, giving you a more in-depth understanding of this topic.
Here are some photos demonstrating this solution. Click on any image to open the photo gallery.
1600s timber-frame listed farmhouse undergoing full refurbishment from top to bottom addressing sympathetically many problems including: new roof, lime pointing, timber infill panels, thermal insulation, replastering, structural reinforcement with lime and lime floors – just to name the most important aspects of the project.Â
Here are some videos related to this solution. Please unmute the videos when playing them.
If you have any questions about a project, a problem, a solution, or any of our plasters - please get in touch.
We understand that each project is unique. Using the contact form below feel free to ask us any questions. Give us as much detail as you can about your project so we can get back to you with more relevant answers.Â
Here are some key application points about the application of each plaster, as well as links to the full application guides. Additional documents can be found on the individual plaster pages.Â
The plaster application video below explains the concept in detail.