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Weak Mortar In Taylor Wimpey New Homes

The great weak mix mortar scandal – Part Three

My first article highlighted the weak mortar scandal and the reasons why the industry has now widely adopted factory manufactured ‘just add water’ mortar, along with technical reasons which might explain why incidence of weak mortar in new homes is increasing. My second article I followed up on “Britain’s crumbling new homes” on the BBC2 Victoria Derbyshire programme on 6 December 2018.

So in this part three article, I will expand on last week’s BBC Victoria Derbyshire story featuring 130 homes built using an incorrect M2.5 weak mix mortar on the Taylor Wimpey ‘Kingsmeadow’ development at Kittlegairy in Peebles and the seven homeowners’ 2-year battle with Taylor Wimpey. Weak Mortar Taylor Wimpey development Peebles

In 2008, Taylor Wimpey started building houses in Kittlegairy, Peebles,  approved by Scottish Borders Council with designation (iii) prescribed mix mortar specified. That is mortar with a cement content of 14% – 17% and deemed equivalent to an M4 factory produced design mix mortar. Unbeknown and undeclared to Scottish Borders Council, Taylor Wimpey, for reasons as yet unknown, used a Tarmac silo M2.5 design mix which had a cement content 6% less than that approved and under HALF the cement content required (M6 or 1:3-4) to meet the NHBC warranty standard for areas of severe exposure, in which this development is located.

Tarmac Silo Design Mix Mortar

Sheila ChalmersPeebles homeowner Sheila Chalmers first contacted me for advice in October 2017 and featured on the programme. She told me: “In 2008, the Tarmac Mortar Specification Sheet (as supplied by Taylor Wimpey) stated that their M2.5 mix was the equivalent strength of (iii). This has changed since (I do not know when) with Tarmac’s current literature saying that their M4 is now the equivalent of (iii).” Tarmac also state on their website: The mix proportions of Tarmac dry silo mortar conform to values specified in the following table when tested by the methods prescribed in BS EN 1015 and BS 4551.

Tarmac recently confirmed to me that their PDF data sheet (April 2007)  sent to homeowners by Taylor Wimpey is genuine. Perhaps Taylor Wimpey used this data sheet when considering which design mix was required to match the specified designation (iii) equivalent mortar?
Taylor Wimpey attempts at concealing the issue

Sheila told me that around 2011/12 and unknown to the rest of the estate at that time, a house had started to show signs accredited to weak mortar, this being raised with Taylor Wimpey, the NHBC and the Scottish Borders Council. It was discovered that an undeclared change from prescribed mix mortar to design mix mortar had taken place. Sheila said “It was all kept very quiet with Scottish Borders choosing to not alert home owners that their houses may start to fail over the coming years.” Peebles site plan showing extent of homes Taylor Wimpey built using incorrect M2.5 mortarIn the years that followed, houses started to empty, with people literally disappearing overnight – Taylor Wimpey were buying back houses. Sheila indicated that “probably around 10 or 12 houses but it was still being kept hushed up. People were signing gagging orders and therefore kept quiet. Taylor Wimpey’s solution at the beginning of this, was to buy back the homes and silence the homeowners with non-disclosure agreements” Apparently some of the homeowners recently confirmed that Tradecast the repointing contractor, had been put under “severe pressure” by Taylor Wimpey and were instructed not to acknowledge any issues when challenged by homeowners. “In the early days, Taylor Wimpey were wanting Tradecast to park off-site and take taxis onto the estate in order to keep the problem quiet”

On 28 September 2016, four years after the mortar started to crumble on the first home,  Taylor Wimpey wrote to home owners admitting “some of the homes” did not meet the requirements of the NHBC. It outlined a 20-year extension warranty cover for mortar on every home on the development. Apparently then, if any homeowner was concerned, Taylor Wimpey would inspect with their engineer. Shelia told me that “as would be expected most did, with the majority being informed that there was nothing wrong with their houses, this despite owners now “scratch testing” their own mortar and seeing it crumbling away.” More owners began having their own mortar tests done with a wide variety of results, from between designation (i) 30% cement, to below (iv) less than 10% cement

Sheila said that Scottish Borders Council were coming under increasing heavy pressure from concerned homeowners and, after several families provided their structural results to the Council, it was forced to arrange its own structural assessment which carried out by Harley Haddow, on a random selection of houses within the development on 17 May 2018 . The Harley Haddon report had similar findings as the owners’ structural reports and giving a 10-year timeframe “the mortar will weather, will subsequently weaken and will undoubtedly result in failure” for the properties built with M2.5 mortar.

Harley Haddow’s report, shared with Taylor Wimpey, ultimately resulted in Taylor Wimpey letter on 19 September 2018 to all houses built with M2.5 mortar. It advised homeowners, despite Taylor Wimpey’s original rejection of repair works in many cases, that it has now finally agreed to carry out repointing works if the homeowner requested. The company still maintains that “only some houses in phase one have a durability issue and a significant number of houses where no issues have been identified.”
Weak mortar at Taylor Wimpey development in PeeblesSo despite Taylor Wimpey stating in their 2016 letter “we are fully committed to carrying out the works that are needed for the remaining affected homes as soon as possible” nevertheless, over three years later, homebuyers like Sheila have had a long battle with Taylor Wimpey to arrive at such an undertaking. Sheila says that “we felt that at that time if there was a problem, Taylor Wimpey would step up and rectify the problem no questions asked.”  The repointing Taylor Wimpey has finally agreed to “falls way short of what we should all be getting, ie, knock down and rebuild of our properties.”

“…the repointing of joints on walls where purposeful demolition and reconstruction should have happened”
Jo Churchill MP for Bury St Edmonds House of Commons debate (13 Dec 2017)

Even in statements for the BBC Victoria Derbyshire programme last week, Taylor Wimpey maintain that raking out and repointing with M6 mortar, which they have now finally agreed to carry out for Sheila during this summer, is still considered by them not to be necessary for Sheila’s home. This despite independent laboratory analysis of the mortar her home was built revealing as low as 8% cement content. It is interesting to note that Taylor Wimpey used Alastair Dick from David R Murray Consulting Engineers the same consultants that produced some of the engineering plans who have been involved in the project all along, can hardly be considered independent. When Sheila spoke to Mr Dick a couple of weeks ago, he told her “he was now relieved that Taylor Wimpey had agreed to repoint all the houses.” Sheila said, “you’ve knocked mine back several times” he told her “… there was a lot of pressure on them before the agreement was put in place.”
Independent mortar test resultsHowever, Taylor Wimpey told the BBC that the tests Sheila and her neighbours used were “not appropriate.” It said “The weaker mortar used on some of the houses is of sufficient strength to meet structural requirements… but it may present as less durable under prevailing exposure conditions”   “May”?

The good news is the internal mortar with 13% cement content just under the lower end of the 14% for M4 mix so could possibly be structurally sound. However the cement content of the remainder of the external walls falls below even M2.5. Of particular concern is the mortar used below ground which should have been a 1:3 mix as it is often saturated and subject to the actions of freeze thaw, even more likely in this area.

The 25mm deep raking out of mortar joints and repointing works will only improve durability and does not address the issue of the potentially weakened bond with the wall ties, reducing the stability and integrity of the cavity wall, which could in certain conditions, result in external walls becoming unstable and dangerous on exposed elevations. However, it is interesting to note that wall tie pull out tests, arranged by Taylor Wimpey and witnessed by Harley Haddow, found a pull out of 1KN or more, greater than the anticipated tension loads of 0.6KN and “the tensile capacity had not been demonstrably compromised by the bedding mortar’s friability. “

It is unimaginable, the extreme anxiety, worry and mental anguish that at times, must have been almost unbearable and detrimental to health, suffered by Sheila and her neighbours. This coupled with the expensive legal fees (around £350 an hour), structural survey fees and the cost of mortar testing which basically forced Sheila’s household into debts totalling £16,000, all caused by Taylor Wimpeys’ intransigence and the NHBC’s ongoing denial of what I believe, is a wholly valid warranty claim, over the last 24 months. Sheila told me “this could have all been avoided if Taylor Wimpey had admitted it instead of trying to bat this away and lie through their teeth. They knew all along when they built this bodged Estate but were quite happy to lie to us and say all is well, forcing us to spend huge sums (I am not the only one) to prove it. Legally, they don’t even have to reimburse our fees despite us proving all this.” Although Taylor Wimpey has told the BBC they will now do so.

Pete and Jill Hall have "garage built with sand"Sheila’s neighbours three doors away, Pete and Jill Hall also had a 2-year fight on their hands with Taylor Wimpey. They too had independent testing of their weak mortar, which in the worst case showed their garage had such a small cement content it could be considered to be built with virtually wet sand! After a heated meeting with Taylor Wimpey’s solicitors, Dentons UKMEA LLP, during which the Halls outlined the only options they would accept either: 1) Buy back the house, 2) Demolish it entirely and re build as it should have been or 3) Carry out works required to bring it to the standard it should be; much to their astonishment they received a letter from Taylor Wimpey’s solicitor. It said they were considering reporting the Halls under “Proceeds of crime legislation” with allegations of “clear and specific threats linked to demands of money and offering to conceal information if such money was paid and other demands met” Not quite as Taylor Wimpey claim “we always aim to do the right thing for our customers?” Now two years on, Taylor Wimpey has made an offer to the Halls. Jill told the BBC “It falls short of where we think a proper full repair should be but they [Taylor Wimpey] have basically turned round and said it’s that or nothing….I would never buy a new house again”

Notwithstanding the site-wide weak mortar, apparently this development also had other “workmanship” issues. As noted in Harley Haddow’s report: they “found examples of what we consider poor overall site quality control, over and above that of the mortar.” This including: poor restraint strapping details, homes with garden rooms where foundations are misaligned, missing wind posts in some house types and external DPCs below ground level. Shelia says “and the list goes on with regards to boilers and heating systems supplied.”

What about the NHBC? “Protecting homeowners”?

Shelia asked the NHBC reinspect her house and yet again it rejected her warranty claim saying that despite obvious gaps and holes in mortar joints there is no evidence of physical damage. At that time Sheila tells me the NHBC were made aware that M2.5 mortar had been used and not the M6 required for severe exposure areas and required in the NHBC warranty standards, but still “they would not budge”. Even the NHBC’s own inspector report concluded that the mortar class used throughout this development “indicates it may not be suitable to provide adequate durability”
NHBC Inspector's weak mortar report Peebles

“Once mortar deteriorates it will compromise the rest of the brickwork.” BDA

The final response from the NHBC:

Sheila’s home is now outside the 10-year warranty (by 5 months) and as far as the NHBC are concerned “that’s end of the matter”. The NHBC said:

“I should advise you that this is unlikely to change our view on liability. Section 3 of the Buildmark policy provides cover for actual physical damage to the home that was caused by a defect in a part of the property listed in the policy document if the cost of repair is more than the minimum claim value. Regardless of whether, or not it is identified that there is a defect with regard to the specification and/or preparation of the mortar mix this item is not covered by the policy in the absence of actual physical damage to the home.

The construction is now 10 years old and during this time the mortar can be considered to have generally performed, given that there is little sign of erosion to date to indicate any failure within the compressive strength of bedding material used and/or impair the structural integrity of the load bearing walls. As such, the criteria that is required for a valid claim under the terms of the policy has not been met.”

This, despite three separate independent Structural Engineers reports concluding: in the longer term (beyond 10 years) the mortar will weather, will subsequently weaken and will undoubtedly result in failure.”
Are NHBC worried about the high costs of remedial works?
So much for the NHBC:
“Preventing problems before they happen and being on hand when they do” Their own technical materials requirement R3 in the warranty standards states: “All materials products and building systems shall be suitable for their intended purpose”  That is having a life of at least 60 years.”

In my opinion, the NHBC are behaving abysmally regarding the issue of weak mix mortar. It is a serious issue which the NHBC have been aware of for many years. As far as I am aware there is no research being carried out to discover why it is on the increase. The NHBC has not revised its standards to prohibit the use cement substitutes such as GGBS and PFA or to require regular ongoing site testing of mortar used.

NHBC Technical Newsletter July 2000 Issue 20:

The consequences of getting it wrong are well known to NHBC. At the least it may mean raking out all joints and repointing and at worst it can be removing the outer leaf and rebuilding. The problem is that too little cement is added to the mix to ensure that the strength is achieved and, perhaps more importantly, the hardened mortar is durable.”

In addition, the NHBC’s Technical Extra Issue 11 in September 2013  (Page 22) specifically warns against using M2.5 design mix factory mortars.
NHBC have known about issues with M2.5 mortar for yearsThe NHBC spent a total of £94.6million on remedial works on warranty claims in the 12 months to 31 March 2018, around 11,000 claims a year. Around £28 million for claims made during the first two years. Superstructures (walls including render/floors/roof) accounted for around 38% of the total cost of claims in 2015/16. The NHBC has reserves of £462million and additional investment assets totalling £1,560million. This non-profit distributing organisation, can well afford to do right by those new homeowners with weak mix mortar policyholders.
Repointing works to 130 Taylor Wimpey new homes at PeeblesTaylor Wimpey is currently repointing 130 homes in the M2.5 area of the development, but not those built using M4 mortar. Taylor Wimpey said they “sincerely apologise to the homeowners affected… we are fully committed to resolving matters” They claim “this is a localised issue and falls short of the high standards we uphold. We are committed to carrying out the works that are needed to the remaining homes as soon as possible” However, Taylor Wimpey’s latest letter advises that it considers it is not under any obligation to undertake this work and it is committed to complete all repointing work within three years! Sources on site, tell me their contractor Tradecast is aiming to complete repointing works on 90 houses by the end of this year and surprisingly, some homeowners being unwilling to have the work done at all.

Sheila has raised a formal complaint against the NHBC through their complaints team.

The NHBC’s 86-year old ‘go-to’ “mortar expert” Barry Haseltine stated in his report:

“I recall that, up to 2012, Tarmac were concerned that achieving a strength of 4N/mm2 would require them to use more cement than they would have done in a prescribed mortar of the equivalent designation, (iii). I suspect that the designation (iii), M4, was used throughout; however from what I can see of the mortar quality in photographs taken by the Claims Investigator, there is nothing that I can call damage within the NHBC definition of the word. The house is structurally sound and should remain so for a normal life. There is no need for any remedial work.” 

Barry Haseltine basing the statements in his report from NHBC photographs and never visited Sheila’s home and inspected it himself.

The NHBC would appear to base their rejection of the M2.5 mortar when M6 is required purely on the basis it hasn’t (as yet) structurally failed in the last 10 years!

Taylor Wimpey Annual Report 2018 (27 February 2019)

This specifically makes reference to Sheila’s development although again, plays down just how potentially serious and expensive it could be for its shareholders.

“We acknowledge concerns raised by some of our customers in connection to mortar durability on a development in Peebles, Scotland. While a significant number of houses on the development are unaffected, a robust technical solution, supported by an appointed structural engineer and the NHBC, to fix the durability of the mortar has been identified and homes are being remediated as soon as possible”

This despite the company knowing about the weak mortar issue in 2011 and all homes built using a mortar not considered sufficiently durable for the severe exposure location of this development!

It would appear that Taylor Wimpey also have structural failings on their 2013 development ‘The Chariots’ in Andover.  As I understand it, the roofs to 75 homes are being removed, work which will take 2 months per house to complete.Taylor Wimpey extensive remedials at The Chariots Andover

Taylor Wimpey 30-year weak mortar warranty

In their letter dated 28 September 2016, Taylor Wimpey undertook to provide a total of 30-year warranty up to 31 December 2045, for “issues specifically caused by mortar quality” for EVERY home on their ‘Kingsmeadow’ development in Peebles. This does not include what it refers to as “fair wear and tear” but “defective mortar which has failed to maintain its strength and durability” It would appear the mortar warranty is only for the external mortar which can be seen. Amazingly, Taylor Wimpey also said  it “takes such concerns seriously and stand by the quality of our construction.”

No integrity. Taylor Wimpey CEO Pete Redfern should apologise to Peebels homeowners in person.Obviously in 2045 everyone will have departed this mortal coil and CEO Pete Redfern will no doubt be keeping ex-Persimmon CEO Jeff Fairburn company, stoking the fires of hell. It will be interesting to see whether the correct mortar (M6) is used on the adjacent development land. I very much doubt any works will begin until long after the current repointing works are finished.

For those wishing to take legal action against their housebuilder, the case of Halvorson v Persimmon Homes 2018 (Scotland) is case law which determined that all NHBC warranty standards form part of the contract and non-compliance of any guidance or recommendations could be judged as a breach of contract.

A sea-change of behaviour is required

It is time the tin-eared, corporate bean counters running the nation’s plc housebuilders did the right thing right away and stopped trying to minimise what are huge issues like weak mortar. First with denial, then the great cover up, using non-disclosure agreements limit their exposure. Finally, as on this Peebles development, when a weak mortar issue became widely known, threatening, intimidating and mentally torturing its own customers for two years before finally agreeing to undertake repointing works to all 130 houses. This has got to stop!

This whole industry lacks moral integrity. It says one thing, then does the opposite,  frequently exposed lying and cheating its own customers, concealing the extent of defective homes and quietly carrying on with apparent impunity from this weak government. James Brokenshire promised a new homes ombudsman but has yet to deliverIt is to be hoped that the current Housing Secretary James Brokenshire is good on his word and legislates for the statutory new homes ombudsman which in his words: “will champion home buyers, protect their interests and hold developers to account.” as a matter of urgency, a government priority, rather than as current, “when parliamentary time allows.” Make time!

Until government acts, new homeowners like Sheila and her neighbours will be left wondering,  in the words of the Pet Shop Boys,
“How I’m gonna get through  ……….what have I, what have I, what have I done to deserve this.”

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Weak mortar – Britain’s crumbling new homes

The great weak mortar scandal – Part Two

Following my first article  exposing the weak mortar scandal, many more new homebuyers have contacted me. It would appear this issue is both widespread and serious. Whatever causes their mortar to crumble, sometimes in under a year, both housebuilders and warranty providers are doing everything they can to limit their costs and keep weak mortar issues quiet, out of the public gaze.weak mortarThe NHBC provide warranty policies for around 80% of all new homes built in the UK. Defective superstructures, which include external walls, is their most common cause of claims accounting for 41% of all claims in the year to 31 March 2017, costing the NHBC £27.2million. Weak mortar cannot be considered as minor snagging, this is the rectification of serious defects often affecting the structural integrity of the home. It cannot be explained away by the industry as a few “isolated cases” either.

Are NHBC Warranty Standards “Raising Standards – Protecting homeowners”?

The NHBC Warranty Standards are in general, recommendations or guidance as a means of compliance, with just five absolute Technical Requirements (in red) these are mandatory and must be met by the builder
Regarding weak mortar, two stand out. R2 Design Requirement;
“Design and specification shall provide satisfactory performance”
and R3 Materials Requirement; “All materials products and building systems shall be suitable for their intended purpose”  That is having “a life of at least 60 years.”NHBC Technical Requirements - Chapter 2.1If Performance Standards (in black bold) are followed, the Technical Standard for that particular work will be met. The NHBC are quick to highlight to buyers that the remainder of the warranty standards are just Guidance on how the Performance Standards may be met and surprisingly, are not mandatory. The NHBC have stated that “failure to follow that guidance does not constitute a non-compliance” [with warranty standards]

With regard to mortar, the Performance Standard is 6.1.14 “Mortar shall be of the mix proportions necessary to achieve adequate strength and durability and be suitable for the type of masonry…”
The Guidance table then state various mix proportions which enable the Performance Standard to be met, using Portland or sulfate resisting cement. No mention is made of cement replacement material such as GGBS. Clearly mortar with an insufficient cement mix proportion, namely less than that stated in the NHBC Standards “guidance” table (from BS EN 1996-1-1), will not meet the “adequate” performance standard required. It is certain that mortar which is crumbling and falling out of joints is not suitable for its intended purpose neither is it of “satisfactory performance”.Mortar mix designations
So what are the NHBC responses when new homeowners who make a claim under the warranty for crumbling mortar?
“We can never guarantee that a property will be defect free”
“The mortar was tested with a flat blade screwdriver [dragged over the surface] and examined for defects”
“I am advised that the cement/lime/aggregate ratios provided in our Standards are guidance only”
“We remain of the opinion……….. to rake out to a depth of 25mm and repoint are [sic] an acceptable method of repair”
“Where issues relating to mortar are concerned, we predominantly rely upon visual assessment of the performance of the mortar to determine our opinion on whether the mortar complies with our Standards.”
“It is the problem associated with exposure and weathering which is the main factor when determining remedial works required”
“Repointing the external walls of your home will ensure our Technical Requirements are met”
“Jenkins and Potter Consulting Engineers [Barry Haseltine] were tasked with providing an independent opinion on the durability and strength of the mortar to your home and provide any necessary recommendations for repair.”
“Under our standards the builder must ensure the Technical Standards are met. Mr Haseltine remains of the opinion that repointing works recommended, if carried out using a specialist contractor, will ensure the durability of the external walls and will also meet NHBC Technical Requirement R3.“
This does not necessarily make the weak mortar behind the repointing “suitable for its intended purpose”

“I am advised that the overall strength of the brickwork comes from the compressive weight of the brickwork and mortar”
The builder is responsible for putting right anything covered by Buildmark that isn’t built to the NHBC requirements. If we don’t consider that the resolution service is appropriate, or if you don’t accept the findings in our report, we may advise you to consider another form of dispute resolution. Bear in mind that your concerns were raised during the builder warranty period (first 2 years), so any action you take will need to be against the builder and not us.”
“You have the right to refer your complaint to the Financial Ombudsman Service (FOS)…. Some aspects of our Resolution service do not form part of our insurance regulated services”

Indeed they do not as the FOS have confirmed to me:
“Generally during the first few years of the policy the cover they provide isn’t an insurance product. And isn’t something we can look in to. “We can’t investigate when NHBC are acting to mediate under their resolution service. But if the resolution report isn’t complied with (deadlines for work are missed for example) the insurance element kicks in and we can then investigate.”

Mortars of Mass Degradation – Prescribed or Design mix?

A “prescribed mix” is one where the mortar is made in pre determined proportions, the properties of which are assumed from the stated proportions (recipe concept). A “design mix” is a mortar whose composition and manufacturing method is chosen by the producer in order to achieve specified properties a compressive strength (Performance concept) The M number being the expected compressive strength in 28 days so an M4 design mix mortar should attain a strength of 4n/mm2. Mortars are given a designation ranging from (i) highest cement content to (iv) lowest under BS EN 1996-1-1.

Mortar manufacturers can now infer the mix proportions of their mortar from compressive strength. BS EN 998-2 states the relationship between compressive strength and mix proportions for a limited range of strengths and mortar compositions in Table 2.

“Whichever type of mortar, in terms of its constituent materials, is chosen, its durability will be enhanced
as the cement content is increased”
BDA

NHBC “leading mortar expert” Barry Haseltine (85)

When a buyer makes a claim under the NHBC warranty eventually the NHBC normally dispatch their “leading mortar expert” Barry Haseltine (85) to the home. Having seen more than one of his reports, I was surprised by the similarity, with identical ‘cut and paste’ paragraphs, despite being at opposite ends of the country, different housebuilders, different mortar suppliers and different mix analysis results. Haseltine alludes to the fact that the mix proportions in the NHBC Standards mix are “a recommendation” and have not been revised since the use of factory produced ‘design’ mortar, covered by BS EN 998-2 in 2010, became more widespread. Haseltine also stated in letters and reports:
 “an M4 design mortar is the same as a 1 : 5-6 cement : sand mix.“

“an average batch volume proportion of 1:7.4 from which it is indicated that the mortar can be taken to agree with the designed mix and so there can be no complaint about it”

Yet in this case, of the 18 samples tested, by five different UKAS accredited testing laboratories, ranged from a best 1:7 to worst 1:9.6. In addition, the mix proportions from the manufacturer’s batch records fall well below the “guidance” mix table in NHBC Standards for M4 mortar, that would be deemed to meet Performance standard 6.1.14 and in turn, the NHBC mandatory Technical Requirements R2 and especially R3. When confronted by indisputable multiple evidence of insufficient cement.
Haseltine says:
it was very common for laboratories not to reach the same results as others. Although I am not a chemist, I believe it is not possible to find more soluble silica, the basis for cement content, than is there but it is possible not to find all that is there.”

“A cement content of 8.5% equates to a volume mix of 1: 9.3; looking at all the test results in my table… I conclude that the mortar mix can be considered to be a designation (iv) on the basis of mix proportions, one must remember that this mortar was a designed M4 mix so mix proportions are not a valid means of checking compliance”

A designation (iv) being a mix ratio of 1:7, equivalent to M2. The cement : sand ratio of 1: 9.3 is even weaker than this and in any case is not the designed M4, designation (iii) required and specified!

No samples were tested from mortar supplied to the site so there cannot be any allegation that the strength of the mortar that was supplied was incorrect. Factory Product Control (FCP) tests do not have to be related to any particular delivery of mortar”

“I would recommend M6 mortar for the repointing”

M6 is 1 : 3-4 cement : sand that is a minimum 25% cement content by volume. This for a new home constructed with mortar proven by laboratory testing, to have just 13% cement content.

Incorrect mortar specified at the design stage

Severe exposure areasThe mortar specified at the outset is often not as required by warranty standards for the level of exposure on certain developments. In geographical areas with ‘very severe’ and ‘severe’ exposure, new homes should be built using a mortar as designation (ii) – M6 which is an equivalent mix of 1:3 to 1:4 cement : sand. The Brick Development Association and Ibstock go further stating that in these areas, the cement used should be sulfate resisting cement (SRC). So mortar required to be M6 due to exposure, when M4 has been specified and used, clearly does not meet the NHBC mandatory technical requirements R2 or R3.

Insufficient cement

It is well known that the greater the cement content, the stronger the compressive strength of the mortar will be. It is relatively simple to take mortar samples from a wall and have them analysed in a laboratory. In most cases when buyers report crumbling mortar, these have proved the mortar has far less cement than is stated in NHBC warranty standards and in Table 2 found in the National Annex provided in BS EN 998-2:2010. In one case, laboratory analysis of samples found the mortar had just 36% of the cement (1:11) required in an area with severe exposure (1:4).

Testing weak mortar

There is no agreed UK or European Standard test method available for assessing the quality of questionable mortar, in-situ. However, when mortar samples have been taken and in one instance analysed by three accredited test houses they were found to contain far less cement (being in the range 1:7.5 to 1:10.5) than that required of a prescribed class (iii) mortar and has been classified as class range (iv) to (v). This casts doubt on the bond of wall ties that require a minimum of class (iv) mortar.

“Once mortar deteriorates it will compromise the
rest
of the brickwork.” BDA

Wall Ties

A weak mix mortar as opposed to say a purely durability issue due to weathering, can have serious structural implications. (The NHBC tend to use the word “erosion” specifically excluded under the Buildmark warranty) In any mortar proved by laboratory analysis to be a mix with a cement content of less than 16% (1:6 – designation (iii) M4), the bond to the wall ties should be considered as inadequate, meaning the brickwork outer wall could potentially fall away from the house in severe stormy weather.

The NHBC’s go-to “mortar expert” concludes the request for testing using a screw pull-out test which records the helical wall tie pull-out force from a 20mm to 30mm depth, 6mm diameter hole within mortar, is “unwarranted”. He says “the results would be very dubious” due to vibration, concluding: “the wall ties are entirely adequate and no work is required to justify them.” but fails to grasp it is the integrity of the actual composite cavity wall that has been compromised by weak mortar, creating an inadequate bond with the wall ties, not the strength the actual wall ties. He appears to completely overlook that it is the performance of the overall structure in adverse weather conditions, especially in severe and very severe exposure areas, that has the potential of structural collapse and in the worst case, even loss of life. Furthermore an unconnected report by Tarmac regarding weak mortar in a Persimmon home stated we are concerned about the fixity of the cavity ties into the outer leaf, which if not suitable will result in the cavity masonry wall mot acting as a composite structure when considering lateral wind loading. A 100mm thick brick single skin wall will be structurally inadequate when enduring high wind loading”

Erosion

The NHBC and their resident mortar expert make frequent use to the term “erosion” in letters to homeowners and reports. Could it be because erosion is not covered by the NHBC Buildmark warranty; “mortar erosion which does not impair the structural stability or protection from the weather” is specifically excluded. So in years 3 to 10, if the matter has not been addressed by the housebuilder, the NHBC can reject a claim and say it was caused by erosion.
Mortar Erosion not covered by NHBC Buildmark Warranty
Cement substitutes:
Ground Granulated Blast furnace Slag (GGBS) and Pulverised Fuel Ash (PFA)
GGBS is a by-product from the production of iron. PFA is a by-product of burning pulverised coal in power stations. GGBS hydration mechanism is more complex and the rate of strength development is slower than that of Ordinary Portland Cement (OPC). Graham True of GFT Materials Consultancy says in his excellent article “What is happening to masonry mortar” that National Annex NA1 guidance based on best UK practice, including limitations on the use of replacing traditional OPC with GGBS or PFA ash, is restricted to specific levels namely 6–35%. One mortar supplier has stated that the National Annex guidance in BS EN 998-2 is just that – ‘guidance’ not ‘mandatory’ – and therefore can be ignored! Graham says: ”On investigation it transpires that GGBS additions are being incorporated at levels well above the recommended limits of 35%, up to 50% and more, of the total cementitious content.”

Even Barry Haseltine, the NHBC’s go-to 85-year old “mortar expert” acknowledged in at least one of his many reports that: “For the last 20 years or so, cement has become a complicated subject compared with the relative simplicity that existed when we had Ordinary Portland Cement and a small number of specialist mixtures for example masonry cement. It is a regrettable fact that mortar has become a potential problem with regard to durability in recent years, probably linked to the use of cements that have considerable proportions of additions which reduce the active cement in the mixes.”

Graham True says: “There has been, and probably will continue to be, issues related to the performance specification of mortar since it currently differs fundamentally from past UK practice but in addition so does the incorporation of high levels of cement replacements, in particular GGBS

Sulfate attack

It is well known that where there is a high risk of saturation and in [very severe/severe] exposed areas, even with an M6 design mix, sulphate resisting cement should be used. Simply put, sulfate attack encompasses a series of chemical and physical interactions that occur between hardened cement paste and sulfates. The soluble sulfate salts within a high proportion of clay bricks react with a constituent (Tricalcium Aluminate) of the Ordinary Portland Cement within the mortar forming calcium Sulfoaluminate (Ettringite). So when sulfate present in bricks is dissolved due to driving rain and saturates brickwork in severe exposed areas, the sulphates present will cause mortar to degrade. For anyone interested in the chemistry.

Importantly for new homeowners with failing mortar, the normal 25mm rake out and repointing with M6 mortar will not have any lasting longevity if sulfates are present in the bricks. In investigations by Tarmac which supplied mortar to Persimmon site in Leeds found “sulfate levels higher than would be normally expected” believing that “the mortar has been subject to sulphate attack and cement degradation over a long period” However, it should be noted that it is in the mortar supplier’s own best interests to find alternative explanations to failing mortar other than incorrect mix proportions.

Use of Non Disclosure Agreements (NDAs)“Gagging orders”

Weak mortar is the housebuilding industry’s dirty secret and it is doing everything it can to ensure it is kept quiet. It has become almost standard operating procedure for housebuilders and warranty providers to require the homeowner to sign a legally-binding non-disclosure agreement (NDA) also referred to as a ‘gagging order’ as part of any compensation settlement, especially when buying the home in question. One buyer on a Taylor Wimpey estate in Peebles Scotland tells me: “over the course of the following few years, houses started to empty with folk just literally disappearing overnight – Taylor Wimpey were buying back houses, probably around 10-12 houses but it was still being kept hushed up.
A plc housebuilder's 'Gagging Order'People were signing gagging orders and therefore kept quiet. Taylor Wimpey sent out letters saying there were a few houses that had mortar issues and scaffolding was to be erected for repair works but not to be alarmed as they were isolated cases.”

I am also aware that the NHBC often require buyers to sign NDA’s perhaps because the last thing either housebuilders or the NHBC need is everyone on the development becoming aware of weak mortar issues in their home and making a similar claim. The Home Builders Federation chief Stewart Baseley said on BBC national radio
I’m a great believer in transparency”  yet the industry he represents, promotes and defends, is anything but transparent.

New homebuyers with weak mortar tell me:

“The NHBC Resolution Service and recommendations are unregulated and totally outside the Financial Ombudsman’s jurisdiction making it open for abuse and for the NHBC to look after their direct customer, their housebuilder registered members.  It seems all the NHBC need to do is actually offer their Resolution Service in the first two years but they then have an open book to recommend whatever they want as we all know.” (e mail)

“The NHBC Consumer Affairs Manager made claims which contradicted their own findings report and they also went on to say that my mortar tests were meaningless and that the Mortar M classification rating system is only a guidance, and that BS EN 1996-1-1 Eurocode 6 can be ignored.” (Social media)

Yet the NHBC standards clearly state that the builder must comply with “relevant standards” this includes BS EN 1996-1-1 Eurocode 6 states: 3.2.2 Specification of masonry mortar (1) Mortars should be classified by their compressive strength, expressed as the 1etter M followed by the compressive strength in N/n1m2, for example, M5. Prescribed masonry m0rtars, in addition to the M number, will be described by their prescribed constituents, e. g. 1: 1: 5 cement: lime: sand by volume. 

NHBC have known about weak mortar issues for many years

NHBC Technical Newsletter July 2000 Issue 20
The consequences of getting it wrong are well known to NHBC. At the least it may mean raking out all joints and repointing and at worst it can be removing the outer leaf and rebuilding. The problem is that too little cement is added to the mix to ensure that the strength is achieved and, perhaps more importantly, the hardened mortar is durable.”

“Take appropriate action to ensure that the right mortar mix is used. The consequences of not doing so are costly and can easily be avoided. NHBC inspection staff will be looking at mortar more closely and may take samples for analysis where they believe the mortar is not up to strength.”

NHBC- "Low strength factory mortar"

NHBC Technical Extra September 2013 Issue 11

So why have warranty standards not been revised to reduce the likelihood of failing mortar in new homes?

Why have cement replacement materials such as GGBS not been banned in masonry mortar? Especially as the reduced cement (OPC) is more vulnerable to attack from sulphates in bricks.

Why have the NHBC Standards not been revised to include BS EN 998-2 2010 for factory supplied “design mixes” and requiring testing of site mortar samples by housebuilders to ensure compliance? 

Opinion

This industry must recognise the threat to UK homes posed by failing mortar. It must not be deliberately hidden, with homeowners that do reach agreement being legally silenced by NDAs. If Toyota can issue multiple recalls to around 7.43million car owners worldwide, surely the housebuilding industry has a duty to be open about weak mortar in new homes. This issue isn’t going away. Tens of thousands of new homes could, and in all probability do, have weak mortar. Many more are currently being built. As Jo Churchill MP for Bury St Edmonds said in the House of Commons debate on poor quality new homes:“…the repointing of joints on walls where purposeful demolition and reconstruction should have happened”

Nevertheless, “repointing to a depth of 25mm” is deemed by the NHBC as the industry’s normal practise where repointing works are required”  This, even when independent laboratory tests prove the cement content of factory-made design mix mortar is well below that required to achieve the durability, weatherproofing and structural performance required and when it is highly likely not to have “a life of 60 years” a definition of compliance with NHBC mandatory Technical Requirement R3

It is in my opinion inconceivable, that the NHBC’s “leading mortar expert” is not acting for and in the NHBC’s best interests, to limit the potential cost of weak mortar claims by understating and dismissing clear factual evidence of inadequate cement content in failing, independently tested, mortar samples. His repeated opinion and reliance is on the single fact that a ‘design mix’ need not meet the listed mix proportions solely on the basis that it is not a ‘prescribed mix’ and mix proportions cannot therefore be used to judge compliance with masonry codes and has no scientific basis of suitability or performance justification whatsoever.

The NHBC themselves do not cover themselves in glory either by making assumptions and dismissive statements in their letters to homeowners whose homes in some cases, are clearly and quite literally, disintegrating. Opinions are not fact. New homeowners that have homes built with mortar with insufficient cement content that is crumbling is an undisputable fact. The best they can hope repointing, without any investigations into the mortar bond strength with wall ties, the use of cement replacement such as GGBS or possible sulphate attack.

Unfortunately, this is an industry that runs roughshod over the interests of new homebuyers, fobbing them off with questionable expert opinions and interpretations, whilst hiding behind NDAs. Perhaps James Brokenshire’s  recent announcement of statutory New Homes Ombudsman will force  change.

Conclusion

Given the cost, disruption to homeowners and potential further reputational damage in this already tainted industry, you would expect that warranty providers would be updating their standards to reflect the now widespread use of factory produced mortar and covered by BS EN 998-2. If housebuilders persist in their apparent preference for design mix factory mortar, they must be required to take mortar samples during construction for their own independent testing, rather than relying on the manufacturer’s in-house test results.

Graham True told me: “I just do not know why the house builders can’t use the correct mortar. The cost difference is minimal. They should be made to use a Prescribed Mix since the Design Mixes fail.”
I totally agree.

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No Problem With New Home Quality Says HBF Stewart Baseley

Stewart Baseley, Executive Chairman of HBF interview on BBC Radio 4 Today – Saturday 11 February

Stewart Baseley HBFTrue to form the Home Builder’s Federation [HBF] the industry’s PR and lobby group, conducts a perfect whitewash on the facts as their executive chairman Stewart Baseley trots out a well-used, well-rehearsed HBF rhetoric. The two main points the industry is keen to focus on at the moment:
“promoting awareness of increases in output and rebut negative claims on build quality” are well covered. Mission accomplished! Move along there is nothing to see. Money well-spent? The HBF was funded mostly by its house builder members to the tune of £3,037,449 in the year to 31 December 2015.

Questions to Stewart Baseley, Executive Chairman of HBF
Do you accept there is a problem?
“No I don’t accept there is a problem although clearly there are in some cases that you have highlighted some of those on your report and I totally accept that anybody that’s in a situation where they have got a problem, it’s very serious for them.”

“No problem – some cases”
Fact: As Stewart Baseley knows, the NHBC paid out £90million in warranty claims for remedial works to fix serious defects in 11,000 new homes (an average of £8,181 each) in the 12 months to 31 March 2016. That equates nearly 9% of the 124,720 new homes built in the same period. In the previous year, the NHBC spent £86million on remedial works including £23million on foundations and £32million on superstructures to 11,000 new homes.

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NHBC hand millions in cash-backs to housebuilders

The NHBC has come into justifiable criticism in the national press recently. The NHBC provides warranties for around 80% of new homes built in any given year. Last year its accounts show it spent £90 million fixing 11,000 defective new homes. What is not listed is the total number of claims the NHBC rejected because the estimated cost of remedial work was judged (by the NHBC) to be less than their ‘minimum claim value’, currently £1,550. So unless buyer’s homes need costly repairs, their warranty claims are often rejected.

The NHBC state on their website:

“Our purpose is to work with the house-building industry to raise the standards of new homes and to provide protection for homebuyers in the form of Buildmark warranty and insurance. We are an independent, non-profit distributing company limited by guarantee – neither part of government, nor a charity. Our business is run by the Board of Directors with surpluses being re-invested in the improvement and development of our products and services.”

The standard of UK new homes is at its lowest since 2009 according to the results of the NHBC’s own Customer Satisfaction Survey!  So it might come as surprise to learn that in yesterday’s Guardian, Graham Ruddick reported that the NHBC has been paying around £10m-£15m every year to housebuilders in what he describes “is effectively a profit-share agreement.”

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NHBC CEO Mike Quinton Quits NHBC

Mike QuintonQuinton Quits! 

Mike Quinton resigned yesterday, following four years as Chief Executive of the NHBC. He was appointed to the role in October 2012, taking over from his predecessor Imtiaz Farookhi, who stepped down on 28 February 2012 after 14 years in the role.

Isabel Hudson, Interim Executive ChairmanThe NHBC statement said: “From 1st February the current Chairman, Isabel Hudson, (e mail: ifhudson@nhbc.co.uk)will become Executive Chairman and Neil Jefferson, Business Development Director, will step up as Managing Director until a permanent successor has been appointed.”

“Since his arrival in 2012, Mike has taken NHBC forward and led the organisation successfully through a period of significant growth in the new build sector, supporting builders to deliver high quality new homes.”

Mr Quinton said in a statement:

“After four years, I’m pleased to leave NHBC in a strong position and well equipped to face the challenges ahead. I leave behind an organisation making a vital contribution to the UK housing sector. NHBC is valued, trusted and relied upon by housebuilders and homeowners and I am sure the organisation will continue to flourish in the years ahead. I wish the management team and all staff the very best for the future.”

With an accountancy background, Mike Quinton joined NHBC in October 2012, “bringing a wealth of experience gained in the insurance sector.” He had previously held several senior executive management positions with major UK insurance companies, including Zurich Financial Services Group, Prudential and RBS Insurance (as MD of insurer Churchill).

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NHBC and David Wilson Homes on BBC Radio 4 You and Yours

The BBC Radio 4 ‘You and Yours’ programme on 26 October 2016, was  a great opportunity to further promote the setting up of a government-appointed New Homes Ombudsman and the implementation of the other nine APPG report recommendations. This is necessary because as the APPG Inquiry discovered, both housebuilders and warranty providers are failing new homebuyers despite a record £81million being spent on claims under the NHBC warranty to April 2015. It was disappointing that this Petition to Government was not mentioned.

The recent repeat of a BBC TV documentary, “Inside the Commons” – showed how government works and without a parliamentary debate, the APPG recommendations are very unlikely to be implemented anytime soon. Individual MPs, even if they are successful in the Private Member’s Bill ballot, rarely see their bill become law.

This You and Yours broadcast on BBC Radio 4 featured the ubiquitous new home buying “victim” selected to tell their ‘tale of woe’ with possible practical solutions to the widespread problems the industry is causing, overlooked or touched on very briefly. The programme gave housebuilder David Wilson Homes the opportunity to issue the usual insincere housebuilder  statement:- “rare isolated incidence – we are truly sorry – working with the homeowner to remedy as soon as possible”

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The new NHBC ‘Register of Site Managers’.

The NHBC launched its Register of Site Managers earlier this year. Their press release on 9 March 2016 said:

“Recognising the key role that site managers play in delivering high quality new homes, NHBC has developed a dedicated online resource to support them and assist in their development. With over 1,200 users in the first weeks, NHBC OnSite is an online resource providing site managers with access to a host of technical resources and career support and in addition, allows them to build their personal profile.”

It should be noted that the early take up could have been due to the free prize draw (an iPad Air 2, 16GB) for site managers signing up to NHBC OnSite before 30 April 2015.  www.nhbcsitemanager.co.uk

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House builders are cheating new home air leakage testing

Since 2006, Part L of the Building Regulations – The Conservation of Fuel and Power in England and Wales – has required mandatory air leakage testing of new buildings including homes. These regulations were further revised in 2010. But this does not mean every new home will be subject to an air leakage test to comply even under the latest 2010 Part L.

What is air leakage testing?

Air Leakage TestingAir leakage testing basically checks that a new home is air tight and will not let in draughts or provide a route for heat to escape through gaps in the structure. After sealing up all required vents to windows and extractors, air is then drawn out of the home via a large fan in an external doorway, with the pressure monitored for a set period of time to produce a measurement of the amount of air that leaks back into the home being tested.

So you would think that since 2010, all new homes would be relatively air tight, free of draughts and cheap to heat as a result?

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New Homes Ombudsman should be set up – An APPG Inquiry Recommendation

In his speech at the JCT Parliamentary Reception on 17 May 2016, APPG EBE chair Oliver Colvile MP highlighted the main findings of the Inquiry and some of the main recommendations, in particular that a New Homes Ombudsman “should be set up.” stating “this would mediate disputes between consumers and their builders or warranty providers to offer a quick resolution.”

It is to be hoped that this and all the recommendations in the Inquiry Report, due for publication at the beginning of June 2016, will be taken forward and fully implemented by Government at the earliest possible opportunity.

Official Ombudsman

Houses of ParliamentAn Ombudsman is usually appointed by the government or by parliament, but with a significant degree of independence. They are charged with representing the interests of the public investigating and addressing complaints against public bodies, private companies, organisations and sometimes entire industries. An ombudsman should be a totally independent body capable of investigating complaints of malpractice, maladministration or a violation of rights, both fairly and impartially.

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HBF Survey Shows New Home Satisfaction Levels Are Falling

HBF  Customer Satisfaction Survey Results 2016

The waiting is over. The results are in,  and the winner is……. well pretty much the whole house building industry if you believe the accompanying Home Builders Federation (HBF) editorial headlined “Homeowner satisfaction with new homes remains high.”

The HBF use the same phrases every year, irrespective of the survey results to market new homes. Why else would the HBF list on the front page their “key benefits of new homes” for the last four years, including the claim that “new homes are built to a higher standard than ever before and the customer satisfaction survey results reflect this” – well not over the last three years they don’t! Since 2013, the key satisfaction questions have provided results that show a marked decline from 91% in 2013 to 85% in 2016!HFB Survey Results

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