WHL PROJECTS - CASE STUDY
Shell Construction – Two-Storey Extension & Structural Works, Wilmslow
Overview
WHL Projects were instructed to deliver the shell construction phase of a major residential extension and structural alteration project in Greater Manchester. The works included a new two-storey rear extension, significant internal knock-throughs, chimney alterations, and multiple complex roof zones. Working closely with WHL Surveying & Engineering, the team handled all structural calculations, steel coordination, and sequencing to get the project to a watertight shell ready for internal fit-out.
Key Shell Construction Elements
1. Two-Storey Extension Envelope
The extension was constructed using hand-selected Belgium brick, laid to match the architectural spec and tied into the existing structure. Key details included:
Bespoke window reveals with deep-set returns and minimal edge exposure
Feature brickwork coursing and clean external lines for future render/brick interface
Integration with existing building fabric while accommodating height and level changes
2. Roof Systems
Multiple roof types were delivered as part of the shell phase:
A traditional natural slate roof to the main extension, tied into the existing
A built-up warm flat roof system using tapered insulation and single-ply membrane detailing
Frameless skylight apertures formed in structural upstands, ready for specialist glazing
Full garage roof replacement, including strengthening works and new Velux rooflight openings
3. Structural Steel and Load Transfer
The scheme involved a high volume of structural steelwork—over 30 steel sections—including:
Cranked beams to form vaulted ceilings and maintain internal head height
Long-span steels to support open-plan areas and chimney knock-throughs
Close coordination between steel installation, padstones, and bearing point prep
All steel was set out and installed in line with engineered specs and site tolerances, with live tracking of each section through fabrication to install.
4. Chimney & Knock-Through Alterations
Structural knock-throughs were carried out internally, including:
A chimney breast opened out to form a feature cooker recess
Load-bearing wall removals to create future open-plan kitchen and living spaces
Installation of steels for load transfer, with temporary works designed and installed in-house
Summary
This shell phase demonstrates WHL Projects’ ability to manage complex extensions and structural works to a high standard—coordinating large-scale steelwork, bespoke masonry, intricate detailing, and varied roof types. Delivered watertight and structurally complete, the project is now primed for internal fit-out and finish, with a full renovation to follow.
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