Soft Mortar Joints In Places

[PSE]

Earlier this week I asked Marshalls Premier Mortar for the "batch book records" for the mortar that was supplied for our property.  Marshalls refused and said that as Bellway are their direct customer they could only give such things to them. However they did say that Bellway already had this information.  When I asked Bellway for them they claimed that they didn't have them but as they were having a meeting yesterday, they should have them then.  I received an email from Bellway today stating:

"The Batch book records you have asked me for have not yet been despatched to myself as yet and I am informed after my meeting with 'Marshalls Mortar' representative yesterday that they will be forwarded to me as soon as they are located within their systems/Archives, which may take a little time.
Unfortunately I have to forward them onto the NHBC and not to you direct."

[New Home Expert]

Don't worry, you can get hold of them by making a Subject Access Request to Bellway after the meeting as I suggested.

Quite frankly, the way these three separate entities appear to be colluding behind your back, with the sole common aim of protect their common interests at your expense is as disgusting as it is disgraceful - and you can quote me on that!

Anyone who now still buys a Bellway new home after reading this thread, must need their head examined and sanity questioned by a medical professional.

[PSE]

I think you are 100% correct.   

I spoke to the NHBC Claims Handler today and I could feel the fear in his voice that he had been told to tell me absolutely nothing and was an absolute nervous wreck.  I asked him about Bellway rejecting the Updated Resolution Report and at first they said there was nothing on the file. When I said that the Bellway had told me they were dealing with him, he quickly changed the story to say they had received a email from them on Monday.  I also asked them about the "batch book records" and if when they receive them would, I be entitled to a copy, to which they replied that they did not know but would find out as they had never been asked for this before.

 

[PSE]

Just an update for you.

I sent the CEO's of both the NHBC and Bellway Homes emails regarding the updated Resolution Report stating that by just repointing 25mm to the facing bricks will this actually meet the NHBC Technical Requirements R3 as this was missing from the updated Resolution Report and only mentioned the NHBC Technical Requirement R4?

Also that it seems the 25mm repoint repair will probably suit everyone except myself as it will probably last long enough so they will all have no interest in my property when it finally fails (longer than 10 years but not the 60 years minimum as it should be).  Even though the NHBC Technical Requirements state:

"R3 Materials requirement
All materials, products and building systems shall be suitable for their intended purpose.
The structure of the home shall, unless specifically agreed otherwise in writing with NHBC, have a life of at least 60 years. Individual components and assemblies, not integral to the structure, may have a lesser durability and need planned maintenance, repair or replacement during that period." 

And surely mortar is integral to the structure?

I also stated that if the mortar to the facing bricks was not to standard it surely would also not be to the Load bearing Walls??

I did get a personal reply email from the CEO of the NHBC and it was also on a Sunday afternoon .

I then received a letter from the Bellway Homes MD firstly saying they were contesting the NHBC's decision and they were giving me their assurance that there was no underlying defect in the mortar that affects my property.  There was also a (fabricated for me) report from Marshalls Premier Mortar stating that they had visited the site on several occasions (even though I had previously stated to Bellway homes that if anyone visits regarding this issue I will always now want to be present) and the mortar was only suffering from frost damage by approximately 15% in total. 

I called the person who wrote the report and they then admitted that they had never actually visited the site and the report was based on when their Sales Manager visited in March 2016 (his visit was also not regarding the soft mortar even though it was mentioned but regarding the black particles (lignite) in the mortar).  The report also stated that at the time of production they were using a cement replacement that they are allowed to use and that the mortar tests would not of allowed for this.

I then got an email from the NHBC stating that if Bellway Homes contest the updated Resolution Report then it will have to go to arbitration and in which case the NHBC will be taking over the remedial works.

I then get another letter from the Bellway Homes MD stating that, even though there was nothing wrong with the mortar, they are now willing to repoint the whole of the property as the NHBC Updated Resolution Report states to bring a close to the matter.  The letter also included more correspondence from Marshalls Premier Mortar stating some of the mix proportion used, again the cement replacement used, and the maximum replacement percentage that can be used.  It also stated that the information was confidential and that they didn't want it put on the internet from my end (hence why I've not given the actual details).

The NHBC have now said they will be giving all the information to a Structural Engineer to visit and do a report.

And lastly another very interesting development has also come to light regarding this. 
Since the NHBC requested that the mortar was tested and the results came back with the ratios (cement:sand) 1:7-1:9 I have been using the services of a suitably qualified person.  I was also advised by the builder at the time the mortar testing was taking place the reason it was taking longer than anticipated was that the testing lab wanted to know exactly what cement was used in the mix.
I sent a copy of all the correspondence to the suitably qualified person for them to divulge.  They have stated that in the actual mortar test results it states a totally different cement replacement and quantity percentage used to what Marshalls are saying in the reports from them that were included in the Bellway Homes MD letters. 

I think someone has something to hide!

[New Home Expert]

Where to begin!
This clearly has the potential to be a huge scandal. 
Bellway getting the mortar manufacturer to fabricate reports and claiming to have visited your property. 
Bellway contesting the NHBC report/decision claiming that there is "no underlying defect in the mortar."

Until now I had never come across "cement replacement" in brick mortar. 
So quite what are they replacing the cement with?
It would appear that ground granulated blast furnace slag (GGBS) and Pulverised Fuel Ash (PFA) are being used by Marshalls instead of cement. No wonder Marshalls don't want this mix on the Internet!
More information on GGBS and PFA here

Bellway Homes have not been honest and appear to be trying to mislead to get away with the least expensive and least amount of work they can.  The NHBC likewise whilst being your best chance of resolution, are also not fully addressing the issue.
As I said previously, tell your neighbours, their homes will have almost certainly been built with the same mortar!

The mortar is an integral part of the structure. Loadbearing internal blockwork, presumably not tested as yet, will be, in all probability, constructed using the same weak mortar.  Unless, the external mortar is coloured.

Even with cement replacement the test results are not as per the mix Marshalls have given you.
I have e mailed Dr Peter Bonfield at the BRE with a link to this post to ask for his expert, non binding, observations as this is clearly an issue that needs independent expert clarification.