A fragile beginning
When work began, the cottage was in a precarious state. Large sections of wall had collapsed, floors were unsafe, and the old cob – a mix of clay, straw, and subsoil – had deteriorated beyond repair in places.
The upper section of cob had come down completely and we had to rebuild it from the ground up, while carefully retaining as much of the original structure as possible.
Working alongside engineers, the team devised ways to stabilise the walls with temporary props and heli bars, allowing them to rebuild without risking further collapse.
“It’s painstaking work,” says Andrew. “You can’t rush it. Every layer has to go on slowly, compacted and cured before the next one begins.”
The craft of cob
Cob is one of the world’s oldest building materials – sustainable, breathable, and beautifully tactile. It’s made using just clay-rich subsoil, straw, and water, mixed and compressed to form solid, load-bearing walls.
Richard demonstrated the process on site:
“We use roughly one compressed bucket of straw to twenty shovels of cob. It has to be mixed to just the right consistency – firm enough to hold a ball in your hands, but soft enough to tread down and bind together in layers.”
Unlike modern masonry, cob doesn’t rely on rigid joints or cement. Each “lift” (a layer of cob around 400-450mm high) must dry naturally before the next is added. The team use netted shuttering to hold the shape and allow air flow, compacting each layer by foot – an ancient method that’s oddly rhythmic to watch.
Over the summer, the warm weather helped the work progress at a steady pace, and wherever possible, material salvaged from the cottage itself has been reused.
“Everything that came off the building, we’ve saved,” says Richard. “We only add new straw and water. It keeps it authentic.”
Building for the future – the traditional way
The restoration doesn’t stop with the cob. Every detail has been considered to ensure the building remains healthy for generations to come – from limecrete floors and wood-fibre insulation to lime render and breathable finishes that allow the walls to ‘breathe’.
“Everything works as a system,” explains Andrew. “You can’t seal one part and expect the rest to cope. Breathable floors, breathable walls, breathable roof – it’s all connected.”
Heating will be provided through a low-temperature underfloor system, complemented by a small wood burner – keeping the charm of a traditional cottage while making it comfortable for modern living.
Collaboration and conservation
This project has been a true team effort. The owner, architect, engineers, craftspeople and the National Park Authority have all played a role – united by a shared goal of preserving traditional craft while meeting modern standards of safety and sustainability.
For Moulding, it’s another example of why their work goes beyond construction.
“It’s about stewardship,” says Rob. “These buildings have stood for hundreds of years. It’s our job to make sure they can stand for hundreds more.”
Keeping the knowledge alive
Perhaps the most rewarding part of the day was seeing the level of interest and enthusiasm from the visiting conservation officers. For Lori, the owner, this project has always been about more than a building – it’s about keeping a piece of history alive.
As Richard demonstrated how each lift is layered, compacted, and keyed to the next, you could sense the respect everyone had for the process. What might look like mud and straw to some is, in fact, an extraordinary blend of engineering, intuition, and craft – a reminder that the old ways still have a lot to teach us.
Photos and updates from the project will be shared on @thecountryhousebuilder.
Follow along for more behind-the-scenes stories from Moulding’s conservation and restoration projects across the South.
