Design & build: Shouting from the rooftop

Builders Dan and John mid construction of the roof substructure, an intricate framework creating the falls on the roof. Photo / Ben Crawford

The Block NZ 2012 winner Ben Crawford and his fiancé Kylie are building their dream home. Share their proud moments and pitfalls here every week.

Builders can be wily characters. They've been there, done that, they've got a clever solution to any problem and an inappropriate wisecrack for every situation.

So it wouldn't surprise me if the guys had a master plan in place from early on. To push ahead on our bedroom pod and leave the living pod until later, knowing full well we'd feel obliged to put on two roof shouts. Cheeky buggers!

Okay, it's a bit far-fetched to think they'd alter the schedule of our entire build for a few brewskis, although as our building head honcho, Ray Sale, rebuffed my theory, he did have a wry smile.

But we marked a huge milestone in the construction of our home with much excitement this week. When the final roll of bitumen membrane was welded into place, the roof on our bedroom pod was completed, so Kylie and I laid on the traditional celebratory drinks.

We really enjoyed getting together to stop and celebrate with the team that has worked so hard to make our home a reality and also to thank everyone for being so awesome.

It was also a chance to butter the group up a little - to encourage them to put on the superchargers and polish the rest of the house off so we can move in.

It has been fascinating watching our roof come together over the past couple of weeks, observing first-hand how robust and incredibly watertight it is.

First, our builders built the parapet around the top of the pod to provide the illusion of a perfectly flat roof. Then they spent hours crafting its substructure - creating the falls needed to direct water straight into the gutters - before laying plywood over the top of this intricate framework.

With the structure in place, it was time for Terracon Industries to come in and apply the Nuraply 3PM membrane system that makes the roof watertight and provides it with a striking finish.

Terracon's Luis Canio torches the cap sheet onto the base layer below. This is the final stage of the Nuraply 3PM membrane roof system. Photo / Ben Crawford

Terracon was one of three approved applicators we considered. Kylie and I decided they were the guys for the job after meeting owner Nigel Campbell in his Albany headquarters. They are flat-roof application experts, but we also clicked straight away, which I think is vitally important in the build process.

And that hasn't changed since. They are some of the best communicators and nicest bunch of guys we've had the pleasure of working with.

Terracon began by applying a bitumen primer over the plywood surface. When the primer was dry, a peel-and-stick base sheet went down in long lengths, following the pitch of the roof to eliminate the chance of leaks.

The final, most exciting stage to watch was the application of the bitumen cap sheet with its lovely mineral chip finish.

The bitumen primer being applied to the roof substructure. Photo / Ben Crawford

As each sheet was rolled out, it was heat-welded to the base layer with a gas flamethrower. Quite the spectacle, especially on top of a wooden house in a tinder-dry bush setting.

With some final detailing work and vents installed, the roof was completed and our bedroom pod was officially watertight. The double membrane layers form a bulletproof back-up system and provide us with peace of mind in the heaviest rain.

It has been a visual feast these past two weeks. As well as the roof being finished, the bedroom pod has been clad in cedar, too. And damn, it looks good. There was much time spent deliberating with our patient timber merchants at Rosenfeld Kidson, and we couldn't have been happier with our choices when we first saw the boards on the house.

We love our cedar cladding, especially how good it looks with the dark joinery and lush foliage. Photo / Ben Crawford

Yummy. How good does that cedar cladding look!? Photo / Ben Crawford

The contemporary, horizontal shiplap profile and smooth, dressed face was the exact look we hoped for. It is sleek and complements the natural setting perfectly; combining wonderfully with the dark joinery and lush foliage most of the structure is nestled under.

But she's a different story on the other side of the stream. Our living pod has barely progressed while we wait for the delivery of steel for the sub-floor. However, with the promise of its arrival next week, we're hopeful we'll be hosting our second roof shout in record-breaking time.

Wily builders.

• Find out more about Ben and Kylie's dream home at ourdreamhome.co.nz

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For more information on the Kiwibank First Home Buyer's Guide visit: kiwibank.co.nz and search for "first home".