Geoff Dolan contacted our workshop in mid-2010 after finding the Pinecone website. A short inquiry on what we were all about led to a builder-client relationship that was to last 4 years, and involved a challenging design supply and build program, lots of emails between our design team, local engineers and Marlborough Council, and concluded with a completed look that was simply stunning.

The project was in the remote and beautiful Northwest bay, Perlorus Sound, about 50 min (by boat) from Havelock. The proposed site was still to be subdivided, had boat access only, no power, and was accessed only by a quad bike track, and was also 50 vertical metres from sea level.

Delivery of materials would have to be coordinated with barges, helicopters & manpower. The advantage that Pinecone has, is we understand pre-fabrication & portal framing in housing. Special design jobs like this are our signature.

The complete 2 level structural portal-frame with precut floor & roof timber was constructed and freighted across the Cook Strait from the Pinecone workshops in Manor Park, Lower Hutt to a Havelock storage unit. From a barge moored on the coast, a helicopter was used to ferry poles, concrete (after a pump failed) all structural timber, roof, claddings & window joinery.

Smaller items & tools were taken by foot and quad bike. A generator supplied power, a digger & auger came by barge to drill the foundations, and all this was during the rainy period. The logistical side of the project was up to Geoff, who performed amazingly. Much can be said on the team’s effort, but we were all very proud of the result. The views are amazing from the ‘cigar & whiskey room’.

Clem’s team has designed/prototyped/tested over the last several years, portal frame design, which are adapted to a wide range of building shapes.

Timber portal frame design in housing is not common, but has many advantages with difficult & poor access sites, because of the component design & ease of assembly, leading to less site time spent, and a quicker floor-to-roof install of the structural components in a design.

Emma Gibbs hired Pinecone because she was looking for a unique home. Emma & Ken Simms had been looking for a site to build on, and finally settled on a steep access section in Korokoro, Lower Hutt with a stunning harbour and valley views.

Pinecone’s design team worked with the modest budget, to provide an answer to a challenging site. One of the advantages that Pinecone bring to the table with there clients is we have designer/ engineer and builder/project manager all with knowledge of pre-fabrication and portal framing.

There was also the need for Pinecone’s experience on project management from start-to-finish, as this was Emma’s and Ken’s first home they had owned and built. The pole foundations were installed by ramming steel pins into the rock layer. Timber bearers & floor were installed, along with a adjoining retaining wall.

The ‘gull-wing’ two-storey design was decided on as a variation to the ½ round shape. This was attractive as it faced the view and gave a vertical wall to attach decks too. Pinecone has always promoted the use of weatherboard claddings, and this home was finished in the ‘bevelback’ profile. Clem at Pinecone has designed/prototyped/tested over the last 6 yrs, portal-frame design, which can be adapted to a wide range of building shapes.

These are CNC cut and built from SLVL (Structural Laminated Veneer Lumber) supplied from the Juken Nissen manufacturing plant, in Gisborne. We have customised every job for each specific site.

Timber portal frame design in small commercial & housing is not common, but has many advantages with difficult & poor access sites, because of the component design & ease of assembly, leading to less site time spent, and a quicker floor-to-roof install.

Ian & Meryl Flux came to Pinecone’s pre-fab factory at Benmore Cres, Manor Park, Lower Hutt in Jan 2012, for info into a two-level ½ round barn design, to replace an existing old garage.

One of the reasons that they were interested in a Pinecone barn was they could project manage a lot of the the job themselves, with our team fabricating & installing the portal frame structure & roof claddings.

There was also the need for off site pre-fabrication, as storage/work area was limited, and the access road to the site was poor. The delivery of components pre-made, ready to install, was an attractive option. The ease of Pinecone’s installation, speeds up the construction process from floor-to-roof, as this job was being done in the winter period.

Ian is a capable farmer, DOC worker, and helped build a lot of his barn under our supervision. This was exactly what he required, as the design gave him a garage, studio, and firewood store.

Clem Thorn at Pinecone has designed/prototyped/tested over the last 6 yrs, portal-frame design, which can be adapted to a wide range of building shapes. Pinecone currently has generic plans in ½ round, 1 & 2 storey units, and 15-45 degree 1 & 2 storey units, and other variations too.

These are built from SLVL (Structural Laminated Veneer Lumber) supplied from the Juken Nissan Gisborne factory, to Pinecone, where we use CNC machinery to cut and form the shapes we need for each job. We have customized every job we have done to date, for each clients need.

Portal frame design in small commercial & housing is not common, but has many advantages, as with our designs the building loads are taken by the frame and no internal load-bearing walls are required, giving you the flexibility to design the interior as you wish.