At Tŷ Green, we thrive on the challenge of transforming structures that others might overlook. Our latest project was no exception - a neglected railway carriage in need of complete restoration. What began as a weathered shell has now become a beautifully crafted guest space, blending historic character with modern comfort.
A Railway Carriage conversion with a Story
When we first arrived at the site , the railway carriage was little more than an empty, deteriorating shell. Previously converted into an open-plan room, it had no insulation, no damp protection, and years of exposure had left much of the timber rotten and warped. The metal framework, though still structurally sound, was heavily rusted and in need of careful treatment.
The owners, envisioned a space that would serve as a cosy guest retreat, complete with a living area and shower room. Our challenge was to rebuild the structure from the inside out while respecting its original character and ensuring it would stand the test of time.
Stripping Back & Restoring the Frame
The first step was to strip the carriage back to its bare bones. Every internal layer was carefully removed, revealing the full extent of the damage. One detail that stood out, however, was the original door hinges - still in good condition despite years of neglect. We kept them aside, later repurposing them as a feature in the final design.
With the structure exposed, we tackled the metal framework. The entire surface was ground back to remove corrosion before being treated with a rust-proofing solution. This ensured the original framework could be retained and protected for the future, reducing the need for new materials and keeping the restoration as sustainable as possible.
Rebuilding from the Ground Up
With a solid base to work from, we began the careful process of rebuilding the carriage. Due to the constraints of working within an existing metal shell, some elements of the construction required a different approach.
Floor:
Ensuring a continuous weatherproof membrane was a challenge, as the external metal framework prevented a standard installation. The solution was to build the floor in sections. First, a membrane was laid and carefully taped to maintain airtightness. The initial OSB layer was then fixed to the joists while upside down, allowing for secure fixing before flipping it over. The sections were then positioned, mechanically fixed at double joists, and insulated with sheep’s wool before a final OSB layer was installed.
Walls:
Unlike conventional construction, where walls are built first, the external cladding needed to be fixed in place before the internal wall structure could be installed. The walls were assembled flat, with battens, a weatherproof membrane, wood fibre insulation, and a timber stud frame, before being lifted into position and secured by fixing through the existing metal struts. This approach ensured a well-insulated and structurally sound result while working within the limitations of the carriage’s original framework.
Roof:
A new curved roof structure was built to match the original shape, providing the necessary strength while allowing for modern insulation. The roof build-up included OSB on the underside, sheep’s wool insulation between the curved beams, a layer of wood fibreboard, and an external weatherproof membrane. This combination provided excellent thermal performance while keeping the historic profile of the carriage intact.
Blending Tradition with Modern Comfort
Once the structure was complete, we moved on to the interior finishes, balancing traditional craftsmanship with modern comfort.
Windows & Doors: A large aluminium sliding door and window were installed, bringing in natural light and connecting the space to its stunning surroundings. External shutters provided a secondary layer of climate control, allowing the space to be shaded in summer or protected from harsh weather.
Insulation & Airtightness: A combination of 100% Welsh sheep’s wool and wood fibreboard insulation ensured the space was warm, breathable, and energy-efficient. Airtight membranes were carefully taped and joined at every seam, minimising heat loss.
Interior Finishes: UK-grown ash tongue-and-groove cladding lined the walls and ceiling, giving the interior a natural warmth. The ceiling was painted with breathable clay paint, complementing the sustainable materials used throughout. Rustic oak-engineered flooring added a durable and timeless finish underfoot.
Heating & Ventilation: A single-room MVHR (Mechanical Ventilation with Heat Recovery) unit was installed to maintain fresh air circulation without excessive heat loss. Heating was kept simple and flexible with a plug-in radiator, supported by the highly efficient insulation.
Sustainability at the Core
Sustainability played a key role in every decision made during this project. By restoring the existing structure rather than replacing it, we minimised material waste and preserved an important piece of history. Locally sourced timber, natural insulation, and high-efficiency glazing all contributed to reducing the environmental impact of the build. Even the rainwater management system was designed with longevity in mind, using aluminium guttering and fascia's, which are both fully recyclable and corrosion-resistant.
A New Lease of Life
The completed railway carriage is now a welcoming, functional guest space, offering comfort without compromising its character. From the carefully restored framework to the handcrafted interior finishes, every detail reflects the balance between history, sustainability, and modern living.
For us at Tŷ Green, projects like this aren’t just about building - they’re about breathing new life into forgotten structures. Whether it's a railway carriage conversion, a shepherd’s hut, or a bespoke timber cabin, the goal remains the same: crafting spaces that are thoughtful, efficient, and built to last.
If you're considering a unique restoration project or a sustainable build, get in touch to discuss how we can bring your vision to life.
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