1 12 Acoustic Foam Panel Max

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Assembly
instructions
Conservatory Roof
Range
Technological leader
of insulating
conservatory roofing
AV Composites
ZA de la Massane
11 Av. des Joncades Basses
13210 Saint Rmy de Provence
Tl. :+(33) 4 32 61 92 95
Fax: +(33) 4 90 15 43 39
Web : www.avcomposites.com
Mail : contact@avcomposites.com

Document Identification

GDP AVC 2006-01

Indice:

A
ITEM Product
ASSEMBLY INSTRUCTIONS FOR CONSERVATORY
ROOF PANELS
DESIGNATION Conservatory Roof Panels
CRF / DEF : BE GDP 2006-01

Rfrence : Assembly instructions 2005-01
Ce document est la proprit dAV Composites. Il ne peut tre utilis, communiqu ou reproduit sans son accord pralable.
This document is the property of AV Composites. It can't be used, communicated or reproduced without its writen permission.
Page 1

Assembly Instructions for
Conservatory Roof Panels

1. Layout of the Conservatory roofing:

1.1. Size of the conservatory :

For the construction of a conservatory, please specify the width (l) and the length (L) of the
conservatory you want.

This will allow to determinate the previsted area of the conservatory.
S= l x L

1.2. Panels length :

1.2.1. Determination of the roof slope :

For that, it is necessary to determinate the overall sizes:
- Height H of the previsted roof on the lower part ( at the sandpit level)
- Height H possible on the higher part of the previsted conservatory, taking the existing
parts of the house into account (windows, tiles, etc)

l
L


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The total height of the roofing at the highest point will be H + h.
Thus, the slope will be: h/l (in %).

Nota: Mind you, it will be necessary to have at least a slope of 10% (that is to say h=1m (mini) for
1=10m).

1.2.2. of the Panels :

The calculation of the panelslength can be done in different ways :

*** Pythagore :
LP = (l x l + h x h)
*** Tangente :
Calculation of the angle in degrees: a = arctang (h / l)
LP = l / (cosine a)

*** Or to measure on the premises !

1.3. Number of free-standing panels :

The number of N panels will be:

N = L (in m) / 1,2 (round up to the upper figure)

Nota : In order to have a better aesthetic value, it is possible to cut the last panel(not entire)into 2
parts, in order to put these two pieces at both ends. Thus you have a better symmetry.

H
h
H
l
LP


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1.4. Number of panels :

The number of N panels will be :

Old version :
N = L (in m) / 0.82 (round up to the upper figure)

New version :
N = L (in m) / 1,2 (round up to the upper figure)

2. Cutting of the insulating panels, of the aluminium profile, and
accessories:

2.1. Lower wall hook :

The aluminium lower wall hook will be cut at the width of the conservatory L:

2.2. Junction key :

Make the cut of the junction keys at the length of the panels LP, plus around 10mm for free-
standing aluminium panels.

2.3. Roof side closure60 :

The length of the roof side closure will correspond to the conservatory rim. For a rectangular
conservatory, we will have a length of: L (+s) +2 x (l + s)


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It will be necessary to take into account the off cut that is due to the curved cut, and then you will
have a sub-length S:

2.4. Insulating conservatory roof panels :

Conservatory insulating panels (free-standing) will bec ut at the length LP+10cm mini, integrating
a sub-length of about 10cm minimum, to warranty a spillover of the panels regarding the sandpit.

Nota :
In order to have a good aesthetic value, we recommend you (for conservatory width that are not
multiples of 1200mm) to have the two ending free-standing panels cut at the same width. In that
case, the assembly will begin on the middle part of the conservatory, and will end on the two side
panels that will be put at last ( the cutting can be done at that moment in order to be sure of the
width of the cutting).


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3. Assembly of the aluminium profile for the lower wall hook:

The following operations have to be done :
To mark the conservatory roof height (H+h) on the two extremities
To mark with a chalk line the position of the lower wall hook, taking into account the
height of the panels.
Be sure the supporting wall does not have too much irregularities. If so, it will be
necessary to modify it with mortar in order to have a flat part for the fastening of the lower
wall hook.
Make drillings lower wall hook with a spacing of 150mm between each hole.
Mark the fixation hole on the wall, and drill with the lower wall hook.
Position a self-adhesive joint compriband of 15x20 on the previsted part behind the
lower wall hook, in order to warranty a good watertightness.
Fix the lower wall hook on the supporting wall thanks to aluminium screws and plugs, or
make epoxy chemical sealing.

Self-adhesive compriband of 15x20mm
Fastening hole


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Make an acrylic mastic joint (or polyurethane or silicon) between the lower wall hook and
the wall, on the upper part.

4. Start-up of the roof with free-standing panels:

During the start-up of the roof, it will be necessary to remove the safety film on about 5 cm all around
the panels, on the 4 sides, in order to remove the whole safety film when the whole conservatory will be
finished.

4.1. Fitting of the first free-standing panel:

Width of the conservatory multiple of 1200mm :
The fitting of the first panel can become on any gable. The choice will be taken according to
the fitting easiness, and possibly according to the external surrounding (wall, tree,)

Width of the conservatory not multiple of 1200mm :
The fitting of the first panel will become on the central part of the conservatory.

The first panel is posed on the lower wall hook and on the sandpit of the conservatory, while
respecting a good perpendicular of the panel in comparison with the lower wall profile and/or the
sandpit.

4.2. Fastening of the first free-standing panel :

When the first panel is well placed on the lower wall hook, you have to fasten it in order to have the
possibility to place the other collaterals panels in good conditions.
Thus, the panel will be fastened on the lower wall hook with a self drilling SFS screws (Ref:
SXC5-S19-5.5x87)


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On the Top of the Panel:

On the Down of the Panel :


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4.3. Fitting of the junction key :

The junction key chopped at the good length will be fitted into the edge profile of the panel, letting
the over-length of 10mm sticking up from the low part of the roof conservatory, to allow the water
flow.

After having cut the good length of the junction key (7.5linear metre rod), integrating an over-
length of minimum 10mm, the different operations you have to do are the following:
Cut of the junction key : LP+10mm (maximum 15mm)
Fitting of the key into the panel edge, beginning from one side of the panel (generally the
upper)
Let the junction key stick up about 10 or 15mm on the lower part of the conservatory in
order to allow rainwater flow.
Continue the fitting of the junction key along the whole length of the panel with your hand
or with a rubber mallet.


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4.4. Fastening of the next free-standing panels :

The other panels will be placed according to the following descriptive:

Positioning of the panel on the sandpit and on
the lower wall profile.
Lubrication in the inside groove of the edge
with a silicone spray (if possible, in order to
make easier the fitting)
Positioning of the panel in contact with the
previous panel.
Fitting of the panel in the upper part thanks to
little motions.
Carry on of the fitting of the panel with the
junction key, while making little alternative
motions, up to obtaining a regular space
between the panels, from 1mm to 3mm on the
whole length.
After the fitting, push the panel in order to
flatten it against the upper part of the upper
aluminium profile.
Fasten the panel (see 4.2) with a SFS self
drilling screw (Ref SXC5-S19-5.5x87) on a
lower wall hook.
And so on and so forth

Thermal free-standing panels

Junction system for the free-standing
panels of 52mm

Nota :
In order to make easier the fitting, we recommend you to use a silicone spray you will spray in the
groove of the edge, or other lubricant products (dry soap, )


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4.5. Coating on the sandpit :

The coating on the sandpit consists in making the following operations:
Positioning of an hydrophobic self-adhesive foam joint compriband of 5x50 on the
sandpit profile or a plastic piece, in order to remove the risk of dew point phenomenon.
Positioning of a side closure on the panel extremities with self-drilling stainless steel
screws (ex: Self screw SFSSN2/13-7981-3.9x19)

NOTA :
Maybe it will be necessary to make a curved cut of the aluminium roof side closure,
between the sandpit and the gable.


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4.6. Coating on the gable:

The Coating on the Gable consists in making the following operations:

Positioning of a hydrophobic self-adhesive foam joint compriband of 40x50 on the
upper profile of the glass frame.
Positioning of a gable joint covering (of aluminium square type), in order to warranty
coating and aesthetic on the inside of the conservatory.
Positioning of a roof side closure on the gables, on the outside of the conservatory. Fasten
it with a self drilling stainless steel screw (ex: Self screw SFSSN2/13-7981-3.9x19)

Nota : Gable panels can slightly move, due to a temperature difference between the inside and the
outside siding materials (example: sunshine in mid-summer or heating on the inside of the
conservatory in winter,)


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4.7. Coating between the wall and the panels:

In order to warranty the coating of the roof conservatory in terms of thermal and watertightness bridge,
you have to make:
Positioning of a hydrophobic self-adhesive foam joint compriband of 40x50 on the
upper wall profile.
Positioning of the watertightness joint JJ 407 on the upper wall profile.
Fastening of the upper wall profile on the wall. Fasten it with a self drilling stainless steel
SFS screw (Ref: SXC5-S19-5.5x87)

Silicone cartridge

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Prize-winner of the national competition of innovative technologies organized by the Ministry of Research and

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