Somerset Orangery Project
Case Study:
Lightweight steel structures for a bespoke Orangery
Creating subtle stability for a standout family space.
This project involved the replacement of a tired, dilapidated conservatory with a bespoke new orangery at a private home in the South West.
MESH Engineering was appointed to deliver the structural design for the orangery, working closely with the architect and contractor to bring this high-spec project to life.
The Brief:
“The client’s vision was to create a bright, elegant orangery that connected the garden and kitchen, while enhancing the property’s architectural character and energy performance.”
Mark Jerzak, MESH Engineering
Challenges Encountered
Careful planning for a structurally sensitive, more sustainable build.
As with many of these types of projects, working with the existing structure came with its own complexities.
We carried out a detailed ground investigation of the original conservatory foundations to determine whether they could be reused. This is something that is rarely possible with older conservatories.
To our (and the client’s) benefit, we found the foundations were in good enough condition to retain, with an extension added where required for the orangery and some localised strengthening. Reusing existing materials helped reduce costs and embodied carbon making this a more environmentally responsible project from the outset.
Other considerations included the proximity of the family home’s basement, which influenced how we approached the design and foundation extension. The garden’s mature trees added another layer of complexity, with root barriers and heave protection measures required to protect both the foundations and tree roots.
Our Approach
Delivering structural strength and flexibility, while seamlessly supporting traditional stone cladding.
The new orangery’s traditional stone appearance hides a more modern solution underneath: a lightweight steel frame designed by MESH Engineering. This frame provides all the structural strength needed to support large glass spans, a high-performance glazed roof, and generous bi-fold doors, all while allowing the external stonework to remain purely decorative.
One major benefit of this approach is that all the walls can be fully insulated, improving thermal performance and long-term energy efficiency. The combination of steel frame with stone cladding creates the best of both worlds: traditional aesthetics with modern engineering performance.
Structural openings were a key part of our brief. The orangery includes a large set of bi-fold doors facing the garden, which required a wide-span opening carefully engineered to limit deflection. Even a 5mm drop in the beam can stop the doors from operating correctly, so precision here was essential.
The second major structural opening connected the orangery to the existing kitchen in the main house. Forming such a large opening in an existing external wall required careful detailing and a robust steel beam to maintain the structural integrity of the original building.
The Outcome
Our engineering precision enabled architectural beauty, blending form and function.
The result is a beautifully light-filled orangery that combines timeless elegance with contemporary structural performance. By reusing and extending the original foundations and employing a lightweight steel system, we helped reduce the overall environmental footprint without compromising on the project’s ambition.
The client now enjoys a seamless connection between their kitchen and garden, with generous glazing, flexible living space, and long-term comfort. And behind the refined finishes and classic detailing, our steelwork quietly does the heavy lifting.
Collaborators:
Architect: Mitchell Eley Gould
Windows, bi-fold doors, and interior: Bath Bespoke
Photo credit: Brett Salako