Note: Descriptions are shown in the official language in which they were submitted.
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Title: Improvements in and relating to construction of conservatory roofs
~E~~~IPTI~i~~
This invention concerns improvements in and relating to construction of
conservatory roofs.
Conservatory roofs are generally constructed by mounting glazing panels
between roof beams supported at one end from a ridge beam and at the other
end from an eaves beam. The roof beams are fixed at each end by means of
screws/bolts through the roof beams into the ridge or eaves beam. The
positioning of the roof beams has to be marked out to ensure that the roof
beams are positioned accurately. If the roof beam positioning is incorrect,
the
aesthetic appearance of the roof may be impaired and a proper seal with the
glazing panels may not be achieved. An object of this invention is to provide
an improved way of securing roof beams in constructing a conservatory roof.
According to the invention it is proposed that roof beams be provided at
least at one end a connector that can engage a cooperating formation of an
eaves and/or ridge beam or a component of a roof system associated with
either the ridge or eaves beam, preferably in a snap-fit manner. Preferably
also the connectors will lock in place.
The invention further provides a conservatory roof comprising a ridge
beam, an eaves beam and roof beams engaged with either or both of the
ridge and eaves beams by means of connectors engage cooperating
CONFIRMATION COPY
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formations of the ridge and/or eaves beams, preferably in a snap-fit manner.
Preferably also the connectors will lock in place.
~a roof beam connector of the invention is preferably arranged to engage
with a ridge ~r eaves beam or a component associated therewith in sliding
fashion. Preferably the connector will have an end face that can rest against
a
corresponding face of the ridge or eaves beam or component associated
therewith.
In a preferred embodimenfi of the invention a roof beam connector has a
first connector part for hooking over part of a ridge or eaves beam or an
associated component thereof. The connector preferably has a second
connector part for engaging in a groove or slot of a ridge or eaves beam or an
associated component thereof. The second connector part of the roof beam
connector preferably comprises a lug on a resilient finger of the connector.
The connector preferably has a third connector part comprising a foot for a
groove or slot of a ridge or eaves beam or a component associated therewith.
Preferably the connector of the invention has means for attachment
thereof to a roof beam end. The connector preferably has a stem that is
shaped to receive a roof beam end or a stem that is shaped to fit into a roof
beam end. Preferably the connector is adapted for use with roof beams of the
type described in our co-pending application (P5139) .
Such roof beams comprise a core profile of metal, a plastics member
fitted fio the core profile and providing at least one ledge for carrying an
edge of
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a sheet of glazing material and a cap mountable on the plastics member for
retainirig the glazing sheet thereon.
In a fiirst preferred embodiment the core profile is a llollow extrusion
and the plastics member is a sheath for the core profile. In another preferred
embodiment, the plastics member is mountable on top of the core profile. For
example, the plastics member may be a sliding fit or a snap fit on the top of
the
core profile. Reinforcement may be provided internally of the core profile,
such
as in the form of steel profiles inserted into the core profile. Such
reinforcement
is mainly intended for use with core profile lengths over a predetermined
threshold for additional strength. The core profile and or the sheath are
preferably shaped to reduce direct contact between them. For example, the
sheath may have on its inner spaced surface ribs or the like to provide the
only
lines of contact with the core profile in certain regions. Additionally or
alternatively, the core profile bar can have spaced feet or flanges that make
end
contact with the sheath.
A preferred sectional profile for the core profiles used in the invention is
that of a trapezium having a narrow base and wider top. The sheath preferably
has a corresponding profile.
The plastics member, such as the sheath, preferably has a pair of
ledges one each side of a connection formation for attachment of the cap. The
ledges preferably have gasket material, such as of rubber or other suitable
elastomeric material, thereon for sealing against the underside of glazing
material. The gasket material may be fitted in grooves or the like in the
ledges or
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may be bonded to or co-extruded onto the ledges. Between the ledges and the
connection formation, the sheath preferably has longitudinal channels to
provide
drainage passages in case of water penetration through the roof beam.
The connection formation of the plastics member, such as the sheath,
is preferably in the form of a slot whose sides extend upwardly from the top
of
the sheath. The sides end with internal lips, whose top surfaces are
preferably
chamfered for ease of entry of a connection formation of the cap. The cap
preferably has an, in use, depending connection formation having at least one
pair and preferably two pairs of ribs thereon that can be pushed into the slot
of
the plastics member and retained there with glazing material sandwiched
between the cap and the ledges of the plastics member. Two pairs of ribs are
preferably provided on the cap connection formation, so as to allow the cap to
be fitted at two different heights relative to the plastics member to
accommodate
glazing materials of different thickness. Alternatively, the cap may have a
single
pair of ribs and the slot of the plastics member may have two pairs of
internal
barbs or the like to allow the cap to be fitted over two different thicknesses
of
glazing material.
The cap is preferably generally of T-section, the stem of the T providing
the connection formation. The cross bar of the T-section prefierably has
gasket
material at ends thereof, such as ofi rubber or other suitable elastomeric
material, for sealing against the topside of glazing material. The gasket
material
may be flitted in grooves or the lil<e in the ends ofi the carp crossbar or
may be
bonded to or co-extruded onto the ends thereof. The cross bar of the cap is
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preferably arcuate and ends thereof preferably depend to meet the glazing
material.
~4 ridge beam for use with roof beam connectors of the invention is
preferably a hollow extrusion having on one or both sides a formation for
receiving a connector of the invention. The formation preferably provides a
sloping face against which an end face of the connector can abut. above the
end face the ridge formation preferably has a ledge over which a hook
formation
of the connector can sit. The end face of the ridge formation preferably also
includes a slot or groove to receive a lug or the like of a resilient finger
of the
connector. The lug preferably snaps into the slot or groove when the connector
is attached to the ridge beam, to prevent the connector being lifted out of
engagement with the ridge beam formation. Extending outwardly from the end
face of the ridge beam formation, there is preferably a channel shaped flange
to
receive a foot of the connector.
To facilitate erection of a conservatory roof using connectors of the
invention, it is further proposed that the ridge beam connection formation be
notched at the required intervals for positioning of the roof beams. Such
notches are preferably provided in the ledge for the hook formation of the
connector. Then the connector can have a nib on the underside of the hook
formation to locate in an appropriate notch of the ridge connector formation.
This will allow the positioning of the roof beams to determined in the factory
and the appropriate notches cut or formed, so that erection of the roof on
site
is facilitated.
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An eaves beam for use with roof beam connectors of the invention is
preferably a hollow extrusion having on one side a formation for receiving a
connector of the invention. The formation preferably provides a sloping face
against which an end face of the connector can abut. above the end face the
eaves formation preferably has a ledge over which a hook formation of the
connector can sit. The end face of the eaves formation preferably also
includes
a slot ~r groove to receive a lug or the like of a resilient finger of the
connector.
The lug preferably snaps into the slot or groove when the connector is
attached
to the eaves beam, to prevent the connector being lifted out of engagement
with
the eaves beam formation. Extending outwardly from the end face of the eaves
beam formation, there is preferably a channel shaped flange to receive a foot
of
the connector.
To facilitate erection of a conservatory roof using connectors of the
invention, it is further proposed that the eaves beam connection formation be
notched at the required intervals for positioning of the roof beams. Such
notches are preferably provided in the ledge for the hook formation of the
connector. Then the connector can have a nib on the underside of the hook
formation to locate in an appropriate notch of the eaves connector formation.
This will allow the positioning of the roof beams fio determined in the
factory
and the appropriate notches cut or formed, so that erection of the roof on
site
is facilitated.
~t corners of a conservatory roof, it may be convenient to provide eaves
beam connectors rather than join lengths of eaves beam together directly.
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Such eaves beam connectors will preferably have formations adapted to
receive the roof beam connectors of the invention in a similar manner.
For connection of roof beams at the end of the ridge beam it is proposed
to provide a ridge end component having locations adapted to receive roof
beam connectors of the invention in a similar manner to the ridge beam itself.
It is envisaged that the ridge end component will have specific locations for
roof beam connectors at fixed radial angles to each other. The ridge end
component will preferably have a stem adapted to fifi within the end of the
ridge beam.
Where a ridge beam is to be connected to an existing wall, a flashing
plate is preferably provided, over which flashing material can be provided
that
is fixed into the existing brickwork. The flashing plate is preferably
locatable
on the ridge cap. The flashing plate preferably has scribed lines or grooves
to
demark removable strips of the plate to take it to a height below a suitable
brick course level for the flashing material.
This invention will now be further described, by way of example only,
with reference to the accompanying drawings, in which:
Figure 1 is a plan view of a typical Victorian style conservatory roof;
Figure 2 is a plan view of a typical Georgian style conservatory roof;
Figure 3 is an end view of part of a conservatory roof showing a roof
beam for use with a connector of fibs invention;
Figure 4 is and end view of a ridge beam and roof beam connectors
according to the invention;
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Figure 5 is a perspective view of the ridge beam and connectors of
Figure 4;
Figure 6 shows the ridge of Figures 4 and 5 with decorative cappings
added;
Figure 7 is an end view of the ridge shown in Figure 6;
Figure 8 is a view from below of the ridge of Figure G:
Figure 9 shows the ridge of Figures 4 to 6 with a ridge end connector
component;
Figures 10, 11 and 12 are respectively plan, front and side elevational
views of an alternative ridge end connector component;
Figures 13 and 14 are perspective views from above and below the ridge
cap at a wall end of the ridge;
Figure 15 shows the ridge end from above;
Figure 16 is a section through an eaves beam for a conservatory roof of
the invention;
Figure 17 shows the eaves beam with a roof beam connector in section;
Figure 18 is an external view of the eaves beam of Figure 16 with a roof
beam connector attached;
Figure 19 is an internal view of the eaves beam of Figure 16 with a roof
beam connector attached;
Figure 20 shows a right angle eaves corner arrangement from the
interior with roof beam attached;
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Figure 21 is an external view of the corner arrangement of Figure 20
without the roof beam;
Figure 22 is an internal view of the corner arrangement of Figure 20
without the roof beam;
Figure 23 is an internal view of a 135° eaves corner arrangement;
Figure 24~ is an external view of the eaves arrangement of Figure 23; and
Figure 25 is an internal view of the eaves arrangement of Figure 23 with
internal trim in place.
Referring to Figure 1 of the drawings a typical Victorian conservatory roof
1 has a first part 2 having a central ridge 3 with rectangular roofing panels
4
sloping down to an eaves beam 5 and supported between roof beams 14. One
end of the ridge is abutted against a wall and at the opposite end of the
ridge is
a radius end 6 having its roof formed of triangular roofing panels 7.
Figure 2 of the drawings shows a typical Georgian style hipped roof 3
having a first part 9 having a ridge 10 and transom roof beams 14 extending at
right angles therefrom down to eaves 12. The hipped part 13 of the roof has a
pair of hipped roof beams 15 extending to corners of the roof and jack rafters
16
connecting those beams 15 to the eaves.
Turning to Figure 3 of the drawings a hipped roof beam 15 comprises a
core profile 17 of hollow section extruded from aluminium, an extruded
plastics
sheath 13 fitted over the core profile and a cap 20 mounted on the sheath and
trapping edges of the glaring panels between the sheath and the cap. The core
profile is a trape~i~am in section having a narrower base 22 than top 24~. The
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base has along opposite edges ribs 26 that act as feet for the base and
provide
minimal contact between the base and the sheath in that region. The top 24 of
the core profile beam has a pair of flanges 2~ ea~tending upwardly and
outwardly
therefrom that provide surfaces 28 that contact the inside surface of the
sheath.
The sheath has a corresponding sectional profile to that of the core
profile. Its sidewalls 30 each have a longitudinal rib 32 that serves to space
the
core profile from the sheath to minimise contact between them. Similarly, the
top
wall 34 of the sheath has depending ribs 35 again that space the top wall of
the
core profile~from the inside surface of the sheath top wall. Within its top
corners
the sheath has a pair of ledges 36 that form channels 38 to locate the flanges
26
of the core profile.
The top wall 34 of the sheath has near its side edges gasket material
35 of rubber or other suitable elastomeric material co-extruded or bonded
thereon for sealing against the underside of glazing panels 12 mounted on the
roof beam. Centrally of the top wall 34 of the sheath is an upstanding
connection
formation 40 for attachment of the cap to the sheath. Either side of the
formation
40 is a groove 42 providing a drainage passage for any water or condensation
that may collect on the sheath.
The connection formation 40 is in the form of a slot having a relatively
narrow opening between lips 46 at the top ends of the slot sides 48. The cap
20
is generally T-shaped in section and has an arcuate top 50 and a depending
limb 52 that has two pairs of barbs 54~ on opposite sides thereof. The barbs
are
shaped so as to pass relatively easily into the slot 40 but to be difficult to
remove
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or displace therefrom. Two pairs of barbs are provided to allov~i the cap to
accommodate two different thicknesses of glaring panel. The cap top has its
ends 58 turned downwards and gasket material 59 of rubber or other suitable
elastomeric material co-extruded or bonded onto the ends 58 for sealing
against
the top surfaces of the glaring panels. because fibs cap is extruded of
plastics
material it has some inherent resilience, so that when pushed down onto the
sheath and located thereon, the positioning of the barbs will enable the cap
ends to exert holding and sealing pressure on the glaring panels.
It is to be noted that the transom or radius end roof beams 14 are of
similar construction to the roof beams 15 but with caps that have shorter
sides
compared to sides 58 and a shorter stem 52.
The hollow nature of the roof beam bar allows for fitting of roof beam
plastics connectors 70 that can cooperate with formations of a ridge beam and
eaves beam (72, 74) for ease of fitting. The connectors 70 permit snap fitting
with cooperating formations of the ridge and eaves beams. The connectors 70
may alternatively be made of metal.
In Figures 4 to 8 of the accompanying drawings, a ridge beam 72 for a
conservatory roof is formed as a hollow aluminium extrusion having a base 76,
a
top 78 and sides 80 and 82. The base 76 has at each side a depending L-
shaped ledge 84, the ledges providing attachment locations for a decorative
cover 86 below the ridge as shown in Figures 6 and 7. The base also has a
further pair of L-shaped ribs 88 that face each other and provide a channel
for
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receiving a wedge or nut 90, which is part of an arrangement for holding down
top decorative cover 92 on the ridge, which will be described in detail below.
The sides 80 and 82 of the ridge beam are shaped to provide roof
beam connector receiving formations. These formations comprise flanges 9G
extending laterally from the bottom of each of the sides 80 and 82 and are in
the
form of upwardly open channels. R~ minor lower part 98 of each side 80 and 82
protrudes relative to the major upper part of each side. Spaced above the
protrusions 98 is a second larger box-secfiion protrusion 100 having a bottom
wall that with the protrusion 98 forms a slot 102, an outer abutment face 104
and a top 106 having an outer higher part 108 and an inner lower part 110 that
forms with side 80 or 82 a channel 112.
The roof beam connectors 70 have a stem 120 that fits into the end of a
core profile 16. The stem 120 has bolt holes 122 for receiving bolts (not
shown)
to fix the connector in the end of the roof beam. The ribs 26 of the core
profile of
the roof beam provide turning restraint for the bolt heads or nuts. The
connector
70 has connecting formations to allow it to be connected to the connector
formations of the ridge 72. The connector formations comprise a hook 124 that
fits over the top 106 to sit in channel 112, a foot 126 to sit in the channels
of
flanges 96 and a lug 128 on resilient finger 130 to snap fit into the slot 102
(see
also Figure 14). In forming a connection between a connector 70 and the ridge
beam 72, the opposite end of the connector 70 to the stem has a face 130 that
is slid down the abutment face 104 of the ridge beam until the hook and the
foot
of the connector sit in their appropriate channels and the lug snaps into its
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groove. The connector cannot then be released without retraction of the lug
from
its groove.
In order to ensure correct positioning of a a~nnector 70 and hence its
roof beam on the ridge, the top 106 of the box-section protrusion 100 is
notched
at appropriafie intervals and the underside of the hook 124 of the connector
70
has a nib 132 that locates in the appropriate notch. Thus, the ridge beam can
be
prepared in the factory with notches at the correct intervals, to facilitate
erection
of the roof on site.
The top 106 of the protrusion 100 has its outer higher part 108 formed
as a longitudinal channel 138 with its sides having inner lips 140. These
channels are to receive plastics sealing trims 142 between the roof beams (see
Figure 7).
The top 78 of the ridge beam 72 has a pair of generally upstanding
flanges 150, on which locate rain baffles 152. The rain baffles 152 are
generally
L-shaped, one leg 154 having a slot to locate the rain baffle on a flange 150
and
a second leg 156 having co-extruded gasket material strips 158 and 160
extending normally to the end of the leg 156. The cover 92 sits on the second
legs of the rain baffles 152 and is held down by captive bolts 162. The bolts
have a rectangular head 164 with lips 166 on its shorter sides. The bolts have
a
stem 168, which has a lower part serrated on opposite sides for receiving a
wedge shaped retaining element 90 with a generally U-shaped slot therein
having in the base of the U-shaped slot a web that is engageable in a
serration
172 of the stem 168 of the bolt 1 ~a2 (see Figure 8).
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On the underside of the cover 92 is a channel formation 174 having
returned edges 176. The channel 174 is wide enough to receive the head of a
bolt with its longer sides parallel thereto, when the bolt can be turned
through
90°, so that the lips 166 of the head of the bolt are retained by the
returned
edges of the channel 174. At its other end the bolt stem passes through an
aperkure in the base 76 of fibs ridge beam. The flanges 33 extending below the
base provide a slot for receiving the wedge shaped element 90. The element
has on its sides retaining ribs, one of which extends along the full length of
the
element and the other being shorter, whereby the element can be manoeuvred
into the slot. Once there, the element is slid along to engage and retain the
stem
of the bolt.
The decorative cover 92 has an aesthetic profile but it is also capable of
receiving in snap-fit fashion other decorative ridge elements, such as
cresting
pieces.
Also in Figures 6 and 3 of the drawings can be seen a generally U-
shaped trim 93 that snap fits under the roof beam 16 to conceal any gaps due
to
cutting tolerances.
Referring now to Figures 9 to 12 of the accompanying drawings, at a
ridge end remote from a wall against which a conservatory is erected, the
ridge
beam is provided with a ridge end member moulded of plastics material or
alternatively made of metal. Figure 9 shows a ridge end member 200A with
provision for attachment of three radially arranged roof beams and Figures 10
to
12 show a ridge member 200 for receiving four radially arranged roof beams.
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The ridge end members 200 each have a stem 202 shaped to be slidingly
received in the end of a ridge beam 72, where it may be secured by means of
screws through the ridge beam or by any other suitable securing means, such
as bolts or by crimping.
The ridge end members have locations generally designated 204 for
receiving roof beam connectors 70 of the type already described above. Such
locations 204 comprise a channel closed at its bottom end and having a base
206 with returned side edges 208. The side edges 208 provide lateral restraint
and guidance for the connectors. Each location provides a lower slot 210 for
the
foot of a connector 70, a ledge 212, past which the lug of the connector can
snap as the connector is lowered, and the hook of the connector can sit over
the
free edge of the base 206.
At the wall end of the ridge beam, as shown in Figures 13 and 14 of the
drawings, there is provided a flashing trim 310. The flashing trim 310 has a
wall
plate 312 and a connector part 314 projecting therefrom. The wall plate 312
has
a series of parallel scribed lines or grooves 316, whereby the height of the
plate
can be altered to match a suitable brick course height, at which flashing
material
to overlie the wall plate is to be fixed. The connector part 314 is shaped to
be a
snap-fit onto the top of the ridge cap 92.
As shown in Figure 15 of the drawings at the ridge end of the roof a
cover trim 320 is provided over the ends of the roof beams. The trim is shaped
to the contours at the ridge end and has a groove 322 in its underside fio
receive
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silicone sealant, which is spread by the action of pressing down the trim onto
the
tops of the roof beams.
Figures ~4 to 22 illustrate arrangements at the eaves of a conservatory
roof according to the invention. In constructing a conservatory roof an eaves
beam 74 is fixed on top of windows or walls forming sides of the conservatory.
The eaves beam 74 is formed as a hollow aluminium extrusion and has a base
242, an outer will 244, an inner wall 246 and a sloping top 24~.
The outer wall 244 has upper and lower longitudinal slots 250, 252 for
receiving snap-in external cladding 254 of plastics material. The inner wall
246 is
shaped in a similar fashion to the side of the ridge beam 72 to provide
locations
for attachment of roof beam connectors 70. Thus, the inner wall 246 has a
flange 256 extending therefrom in the form of a channel to receive the foot of
a
connector 70. Above the flange is a groove 25~ for receiving the snap-in lug
of a
connector 70 and the top of the eaves beam provides a location over which the
hook part of a connector 70 can sit. As with the ridge beam, locations for the
connectors are provided in the top of the eaves beam in the factory in the
form
of notches at predetermined intervals, in which the nibs of connectors can
locate.
Between the roof beams internal plastics cladding pieces 260 and 262
are added to the eaves beam. The cladding piece 260 fits over the top of the
eaves beam and locates in a channel 266 in the top of the eaves beam. On top
of the cladding piece 2G0 is a strip of double-sided tape 26~ , onto which
glaring
panels will sealingly sit. The cladding 260, being generally lJ-shaped in that
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region will be able to move as the glazing expands and contracts in different
temperature conditions. Externally of the roof, the cladding piece 260 has co-
extruded gasket material 270 along its depending edge to form a weather and
thermal seal with the external cladding 254.
The external cladding has upper and lower grooves 290 and 292 that
provide locations for attachment of gutter brackets. Conventionally, the
presence of gutters at the eaves of a conservatory roof will provide some
thermal insulation. However, with the arrangement illustrated gutters are not
essential and the presence of the external cladding 254 can provide thermal
insulation for the eaves of the roof.
The second internal cladding piece 262 locates in a groove 272 on the
underside of flange 256 and in one or other of three grooves 274 in an
extension
276 of the base of the eaves beam. Three grooves are provided, so that the
cladding piece position can be adjusted relative to the position of the window
frame, on which the eaves beam is mounted, in order to accommodate on site
building tolerances.
At corners of the conservatory roof plastics or metal connectors 230 are
used to join eaves beam lengths. These connectors 230 are shaped to slidingly
fit into ends of eaves beams and also to receive roof beam connectors 70 (see
Figures 18 to 22 of the drawings). Figures 13 to 20 show a right angle corner
230A, such as in a Georgian style conservatory roof and Figures 21 and 22
show a 135° corner 230, such as in a Victorian style conservatory roof.
The
corner connectors 230 have locations for roof beam connectors 70 of a similar
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type to those provided in the ridge beam end pieces. The provision of corner
connectors means that eaves beam sections can be square cut at their ends,
which makes preparation work easier and reduces wastage.
Internally of corners of the roof at the eaves are corner pieces X00 that
conceal junctions between the roof beams and the internal cladding pieces (see
Figure 23). That allows for tolerances in the cutfiing of roof beams and
cladding
pieces.
The ridge beam, roof beams and eaves beams can all be cut to length
in the factory and have roof beam positions cut in the ridge and eaves beams
as
appropriate. Also, the roof beams can be fully assembled in the factory, i.e.
with
connectors 70 added and claddings and weatherproofing trims for the eaves
and ridge beam can be fitted in the factory, because the positioning of the
roof
beams has already been determined and allowed for. Altogether this will help
to
simplify and speed up the assembly of a conservatory roof on site.
