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At Dye House Barn, Culmex took on the challenge of converting a dilapidated stone and cob barn into a luxurious, contemporary home. This comprehensive project in Willand, Devon, showcased our expertise in construction, restoration and design, providing a full turn-key solution from start to finish.
The original structure
The original structure consisted of an old stable area, a main stone barn, and a small brick side extension known as the piggery. Due to poor foundations, the piggery required complete demolition and reconstruction using a cavity blockwork and brick slip system. Within the main barn, we meticulously stripped out the old floors and stables, replacing them with structurally sound, thermally compliant floors equipped with a state-of-the-art underfloor heating system.
Structural upgrades
One of the most significant challenges came with the roof, which was not level. We dismantled the original roofing, levelled the wall plates using matching stonework on one side and timber cladding on the other, and installed a new, expertly crafted roof with decorative, hand-cut feature trusses. On the interior, these trusses created a vaulted ceiling detail, adding character and charm to the space.
To address dampness and ensure longevity, we installed a cavity wall drainage system, ensuring breathability for the cob and stone structure. The barn also underwent a full thermal upgrade with the addition of damp-proofing, timber studwork, and high-grade insulation.
Modern finishes
Every detail of the barn was designed with both functionality and style in mind. We collaborated with a local joinery team to provide custom Idigbo timber windows and doors, including barn and French doors, designed to fit seamlessly with the rustic charm of the property.
Inside, our team handled plasterboarding, skimming, and finishes, including the installation of Mayflower bathrooms with full tiling and a new kitchen designed by the client with Howdens. Flooring throughout the barn was a carefully selected mix of timber, carpets and tiles, expertly installed by our team to enhance each room’s design.
Sustainable systems
The barn is powered by renewable energy, featuring an air source heat pump that drives both heating and hot water. Mains electricity and sewer systems were integrated, and high-speed fibre internet was installed to ensure the home is fully equipped for modern living.
A collaborative effort
Operating under a JCT 2016 Intermediate Contract (designed for mid-sized building projects where detailed specifications are required, but not complex enough to warrant a “Major Project” contract), we delivered this bespoke renovation over 30 weeks. From the initial design phase through to decoration and fit-out, we worked closely with the client to tailor every aspect of the barn to their needs. This included supporting the design process, tweaking layouts, sourcing materials, and engaging suppliers to ensure the highest quality finishes.
A barn conversion to be proud of
What was once a crumbling barn with an unstable piggery is now a magnificent home that blends rustic charm with modern comfort. Dye House Barn serves as a testament to our dedication, craftsmanship, and ability to deliver exceptional results from initial concept to final handover.
Looking to breathe new life into a property of your own? Contact us today to discuss how we can turn your vision into reality.
