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As a major part of the refurbishment and preservation work , contractors MFG Construction appointed Stella Rooflight to design and manufacture the Conservation rooflights to replace the original installations .
The roof structure is of hipped construction covered with Welsh slate and clay ridge tiles , supplemented by ornamental finials at each apex . The internal roof structure is of timber queen post construction ( a truss in which two posts are placed on a tie beam to support the principle rafters above , with the vertical posts held in place laterally by a collar beam ). These roof trusses are in turn engaged into the external masonry walls .
MFG commissioned Stella to produce four bespoke rooflights , of two sizes , the first two with a size of 15,260mm ( w ) x 1310mm ( h ) and the second pair at 2842mm ( w ) x 1304mm ( h ). Stella divided the large rooflight into five frames to ensure that framework was kept to a minimum and the amount of glazing maximised
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, while still providing manageable sizes . Each section consisted of five glazing bars and six glass units giving a total of 30 panes for each rooflight . The smaller rooflights were produced as single frames with a total of six glass units . Each pair of rooflights were linked together with a 316 stainless capping , giving the impression of two large individual rooflights , sitting adjacent to each other in the roof structure .
Due to the height of the building and the inaccessibility of the rooflights , regular cleaning was not going to be straightforward ,
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therefore carbon or mild steel frames were not an option due to the problems that can occur with rusting if they are not regularly maintained . As all Stella rooflights are manufactured using a Marine Grade 316 stainless steel frame and finished with a C5 marine powder coating , they were the ideal choice for the project .
Furthermore , the flush fit offered by the thin lines of steel and genuine glazing bars on each unit , would perfectly replicate the original Victorian design and satisfy the Planning and Conservation officers involved .
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As the rooflights needed to be individually designed to exactly match the size of the originals , a set of complex , detailed drawings were created by Stella , each showing the full assembly of the linked frames as well as files for each individual component , based on the precise measurements provided . |
Rooflight specification :
2 x Bespoke Stella Conservation Rooflights
Manufactured From 316 Stainless Steel
Size 2842mm ( w ) x 1304mm ( h )
Outer Frame in Single Section
5 Glazing Bars / 6 Double Glazed Units
Fixed ( Non-Opening ) Design
Black Powder Coat Finish In C5 Application
American Ash Interior Liners
2 x Bespoke Stella Conservation Rooflight
Manufactured From 316 Stainless Steel
Overall Rooflight Size 15,260mm ( w ) x 1304mm ( h )
Outer Frame In 5 Sections / Linked With 316 Stainless Capping
5 Glazing Bars / 6 Double Glazed Units Per Section ( 30 Panes Per Rooflight )
Fixed ( Non-Opening ) Design
Black Powder Coat Finish In C5 Application
American Ash Interior Liners
Due to the sheer size and weight of each rooflight , one of the major challenges for the MFG team was the positioning and installation of the rooflights , three storeys up in a building situated on a busy main road . To help overcome this challenge Stella allowed for four lifting eyes , which were welded to each individual frame during the manufacturing
process , allowing the contractor to lift the frames into position with a crane .
Having the entire supplier , manufacturing and assembly process based in the UK , the entire design and manufacture process took a total of eight weeks , including challenges posed by Covid-19 .
www . stellarooflight . co . uk
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