GB2538540A

GB2538540A - Roof beam, kit for constructing a roof frame structure, roof frame profile product and use of a roof frame profile product

Info

Publication number: GB2538540A
Application number: GB1508672.1A
Authority: GB
Inventors: Hoddinott Rhys; Leka Pullumb
Original assignee: LEKA SYSTEMS Ltd
Current assignee: LEKA SYSTEMS Ltd
Priority date: 2015-05-20
Filing date: 2015-05-20
Publication date: 2016-11-23
Anticipated expiration: 2035-05-20
Also published as: GB2538540B; GB201508672D0

Abstract

A roof beam for a single storey building, such as a single storey extension, is provided. The roof beam comprises glass-reinforced plastic. The roof beam may be one of the following: a ring beam; a ridge beam; a wall plate beam; a rafter beam; a roof hip beam or a roof valley beam. The beam may have inner and outer portions where the inner portion has a higher glass content than the outer portion which has a lower glass content. The beam may be of a box form. If the beam is a ring beam, mounted on a supporting structure S, it may have a forwardly projecting finger 8 arranged to be received within a tile 504. If the beam is a rafter beam it may have one or more laterally extending arms. If the beam is one of the other kinds it may include two internal support members within the box structure. The glass reinforced plastics may include A-glass, E-glass, E-CR glass, C-glass, D-glass, R-glass or S-glass.

Description

Roof beam kit for constructing a roof frame structure roof frame profile product and use of a roof frame profile product

BACKGROUND OF THE INVENTION

[0001] The present invention concerns a roof beam. More particularly, but not exclusively, this invention concerns a roof beam suitable for a single storey building, such as an extension to an existing structure, such as a conservatory, sunroom or orangery. The invention also concerns a kit for the construction of a roof frame structure, a roof frame structure, a roof frame profile product and use of a roof beam and a roof beam profile product in the construction of a roof structure.

[0002] The construction of single storey extensions, such as conservatories and sunrooms, is well known to those skilled in the art. Such extensions typically have a roof frame structure comprising a ring beam, a plurality of rafters and optionally a ridge beam. The rafters are attached to the ring beam (typically using appropriate brackets) and usually extend upwardly therefrom to a ridge beam. The rafters, ridge beam and ring beam are typically made from aluminium or wood. Aluminium melts at a relatively high temperature (over 600°C) which means that significant energy is used in the moulding or extrusion of aluminium to form the profile products (elongate piece of aluminium having an approximately constant cross-sectional shape and area). Furthermore, aluminium oxide (which may form on the surface of aluminium) can damage components used to cut or otherwise machine the profile products. Aluminium "sweats" i.e. it can encourage the formation of undesirable condensation. Aluminium is also thermally conductive which, in certain, circumstances, can be unwanted. Wood is a natural substance which is prone to naturally-occurring defects, such as knots, bowing, splitting, twisting and surface checks. Wood is also prone to infestation from insects, such as those which result in woodworm. Wood also has a certain moisture content which the wood has a tendency to try to maintain over a period of time, thus sustaining a risk of decay over a period of time. -2 -

[0003] The present invention seeks to mitigate one or more of the above-mentioned problems. Alternatively or additionally, the present invention seeks to provide an improved roof beam.

SUMMARY OF THE INVENTION

[0004] In accordance with a first aspect of the present invention, there is provided a roof beam for a single storey building, such as a single storey building extension, the roof beam comprising glass-reinforced plastic.

[0005] The roof beam of the first aspect of the present invention facilitates the production of a lightweight, yet strong, roof structure. Glass-reinforced plastic is commonly known as "GRP". The roof structure may be used on buildings which are more than one storey tall (e.g. buildings that are two storeys tall), but they will generally be used on buildings which are single storey, such as single storey extensions, like conservatories and sun rooms.

100061 The roof beam may comprise a ring beam, a ridge beam, a wall plate beam, a rafter beam, a roof hip beam or a roof valley beam. Those skilled in the art will be aware of these types of beam but for the avoidance of doubt a brief description of those beams is now given. A ring beam typically provides support for a roof structure, and is typically arranged to sit atop a supporting structure, such as a wall. The shape of the ring beam is typically defined by the shape of the underlying structure. A ridge beam is typically located at the top ridge of a roof structure, as is known to those skilled in the art. A wall plate beam is typically used to attach a roof structure to an adjacent structure. A rafter beam is typically used to space and support boarding and the like. Rafter beams typically extend upwards from a ring beam. A roof hip beam is typically located between two portions of a roof which meet to form an outwardly-projecting junction. A roof valley beam is typically located between two portions of a roof which meet to form a valley (or an inwardly-projecting junction).

[0007] The roof beam is suitable for use in the roof structure of a single storey building which may be free-standing but which is more typically attached to another building, and -3 -may therefore be considered to be an extension, such single storey extensions comprising (but not being limited to) conservatories, sun rooms, orangeries. Such single storey buildings may have a roof which is substantially opaque, transparent, translucent, or opaque with skylights, windows or the like. If the single storey building is an extension, there may or may not be doors (such as external doors) between the extension and the building to which it is attached.

[0008] The roof beam may be formed from glass-reinforced plastic, for example, by moulding pre-cursor material or passing pre-cursor material through a die (for example, by pultrusion). This may produce a beam which has a main body which is made from glass-reinforced plastic i.e. there are substantially no other components or constituents to the main body. Alternatively, the roof beam may comprise an inner portion comprising glass-reinforced plastic and an outer portion which has a lower glass content than the inner portion. For example, the roof beam may be elongate, having an elongate inner portion and an elongate outer portion. The roof beam may comprise two (optionally elongate) outer portions which have a lower glass content than the (optionally elongate) inner portion, the inner portion being sandwiched between the two outer portions. The roof beam may be provided with one or more surface portions which have a lower glass content than a portion of the roof beam which is more remote from the surface. This may be provided by using a so-called veil which has a lower glass content (for example, substantially no glass content). Optionally, at least 50% (optionally at least 60%, optionally at least 70%, optionally at least 80%, optionally at least 90%, optionally at least 95%, optionally at least 98% and optionally at least 99%) of the volume of material making-up the roof beam comprises glass-reinforced plastic. The remainder of the volume may, for example, comprise plastic without glass-reinforcement.

[0009] The roof beam may typically comprise one or more length of profile product. The profile product optionally comprises glass-reinforced plastic and is optionally formed from glass-reinforced plastic, for example, by passing a precursor through a die and curing the precursor (for example, using a pultmsion process). This may generate a roof beam profile product which has a main body which is made from glass-reinforced plastic i.e. there are substantially no other components or constituents to the main body. -4 -

Alternatively, the roof beam profile product may comprise an inner portion comprising glass-reinforced plastic and an outer portion which has a lower glass content than the inner portion. For example, the roof beam profile product may have an elongate inner portion and an elongate outer portion. The roof beam profile product may comprise two (optionally elongate) outer portions which have a lower glass content than the (optionally elongate) inner portion, the inner portion being sandwiched between the two outer portions. The roof beam profile product may be provided with one or more surface portions which have a lower glass content than a portion of the roof beam profile product which is more remote from the surface. This may be provided by using a so-called veil which has a lower glass content (for example, substantially no glass content). Optionally, at least 50% (optionally at least 60%, optionally at least 70%, optionally at least 80%, optionally at least 90%, optionally at least 95%, optionally at least 98% and optionally at least 99%) of the volume of material making-up the roof beam profile product comprises glass-reinforced plastic. The remainder of the volume may, for example, comprise plastic without glass-reinforcement.

[0010] Profile product typically has a uniform cross-sectional area and shape along its length, and is typically made by an extrusion or pultrusion process. The length of the profile product may vary, but is optionally from lm to 6m, optionally from 2m to 5m. The roof beam (and profile product) optionally has, in cross-section, multiple (optionally four) walls which form a supporting box structure. The roof beam (and profile product) optionally comprises one or more support members internally of the box structure. The one more of support members may extend between two walls, between a wall and an angle between two walls, or between two angles formed between walls. The mean thickness of each wall is optionally at least 1.5mm, optionally at least 2.0mm, optionally at least 2.5mm, optionally at least 3.0mm, optionally no more than 6.0mm and optionally no more than 5.0mm. If the roof beam (and profile product) comprises one or more support members, the support members may have approximately the same thickness as one or more walls.

100111 The cross-sectional area of the walls and one or more support members may optionally be at least 0.0005m2, optionally at least 0.001m2, optionally at least 0.0015m2, -5 -optionally at least 0.002m2, optionally at least 0.003m2, optionally no more than 0.01m2, optionally no more than 0.008m2.

[0012] The roof beam (and optionally profile product) optionally has a mass per unit length of no more than 10.0kg/m, optionally no more than 7.0kg/m, optionally no more than 6.014m, optionally no more than 5.0ke/m, optionally at least 2.0kg/m, optionally at least 2.5kg/m, optionally at least 3.0kg/m, optionally at least 3.5kgan and optionally from 3.0 to 6.0kg/m.

100131 The length and shape of the roof beam will depend on the type of beam. For example, the ring beam typically comprises several lengths of ring beam profile product, typically arranged and attached to one another to form the ring beam. Each rafter beam and the ridge beam (if present) typically comprises one (and only one) length of roof beam profile product.

[0014] If the roof beam is a ring beam, then the ring beam ( and optionally the ring beam profile product, if present) optionally has a mass per unit length of no more than 8.0kg/m, optionally no more than 7.0kg/m, optionally no more than 6.0kg/m, optionally no more than 5.0kg/m, optionally at least 2.0kg/m, optionally at least 2.5kgan, optionally at least 3.0kg1m, optionally at least 3.5kg1m, optionally from 3.0 to 6.0kg1m and optionally from 3.5 to 5kg/m.

[0015] The ring beam (and ring beam profile product, if present) optionally has, in cross-section, multiple (optionally four) walls which form a supporting box structure. The ring beam (and optionally the ring beam profile product, if present) optionally comprises one or more support members internally of the box structure. The one or more support members may extend between two walls, between a wall and an angle between two walls, or between two angles formed between walls. If the box structure comprises four walls, the four walls may comprise front, rear, upper and lower walls, "front", "rear", "upper" and "lower" being indicative of the position of the respective walls in use. The mean thickness of each wall is optionally at least 1.5mm, optionally at least 2.0mm, optionally at least 2.5mm, optionally at least 3.0mm, optionally no more than 6.0mm and optionally no more than 5.0mm. If the ring beam comprises a support member, the support member may have approximately the same thickness as one or more walls. The cross-sectional -6 -area of the walls and the support member may optionally be at least 0.0005m2, optionally at least 0.001m2, optionally at least 0.0015m2, optionally at least 0.002m2, optionally at least 0.003m2, optionally no more than 0.01m2, optionally no more than 0.008m2 and optionally no more than 0.006m2. The lower and front walls may be substantially perpendicular to one another. The upper wall may extend rearwardly and upwardly from the front wall. The rear wall may extend rearwardly and downwardly from the upper wall to the lower wall.

100161 The cross-sectional area of the ring beam (and ring beam profile product, if present) may optionally be at least 0.00251112, optionally at least 0.005m2, optionally at least 0.008111', optionally at least 0.01m2 and optionally no more than 0.04m2.

100171 The height of the ring beam (and ring beam profile product, if present) may optionally be at least 50mm, optionally at least 70mm, optionally at least 90mm, optionally at least 100mm, optionally at least 120mm, optionally no more than 300mm, optionally no more than 250mm, optionally no more than 200mm and optionally no more than 150mm.

[0018] The depth of the ring beam (and ring beam profile product, if present) may optionally be at least 50mm, optionally at least 70mm, optionally at least 90mm, optionally at least 100mm, optionally at least 120mm, optionally no more than 300mm, optionally no more than 250mm, optionally no more than 200mm and optionally no more than 150mm.

[0019] The ring beam, (and ring beam profile product, if present), optionally comprises an abutment for boarding placed on the ring beam. The abutment is optionally located forward of the front wall. The ring beam (and ring beam profile product, if present) optionally comprises a forwardly-projecting finger arranged to be received within a slot provided by a tile.

100201 If the roof beam is a rafter beam, the rafter beam (and the rafter beam profile product (if present)) optionally has a mass per unit length of no more than 7.0kg/m, optionally no more than 6.0kghn, optionally no more than 5.0kg/m, optionally no more than 4.0kg/m, optionally at least 2.0kg/m, optionally at least 2.5kg/m, optionally at least 3.0kg/m, optionally from 2.5 to 6.0kg/m and optionally from 3.0 to 5.0kg/m.

[0021] The rafter beam (and rafter beam profile product, if present) optionally has, in cross-section, multiple (optionally four) walls which form a supporting box structure. The rafter beam optionally comprises one or more support members internally of the box structure. The one or more support members may extend between two walls, between a wall and an angle between two walls, or between two angles formed between walls. The box structure may be substantially rectangular in cross-section. The mean thickness of each wall is optionally at least I.5mm, optionally at least 2.0mm, optionally at least 2.5mm, optionally at least 3.0mm, optionally no more than 6.0mm and optionally no more than 5.0mm. If the rafter beam comprises a support member, the support member may have approximately the same thickness as one or more walls. The cross-sectional area of the walls and the support member may optionally be at least 0.0005m2, optionally at least 0.001m2, optionally at least 0.0015m2, optionally at least 0.002m2, optionally at least 0.0031112, optionally no more than 0.0 I m2, optionally no more than 0.008m2 and optionally no more than 0.0061112.

[0022] the cross-sectional area of the box structure may optionally be at least 0.0025m2, optionally at least 0.005m2, optionally at least 0.006m2, optionally no more than 0.01m2 and optionally no more than 0.04m2.

[0023] The height of the rafter beam (and rafter beam profile product, if present) may optionally be at least 50mm, optionally at least 70mm, optionally at least 90mm, optionally at least 100mm, optionally at least 120mm, optionally no more than 300mm, optionally no more than 250mm, optionally no more than 200mm and optionally no more than I 80mm.

[0024] The width of the box structure of the rafter beam (and rafter beam profile product, if present) may optionally be at least 20mm, optionally at least 30mm, optionally at least 40mm, optionally at least 50mm, optionally no more than 200mm, optionally no more than 150mm and optionally no more than 200mm.

100251 The rafter beam, (and rafter beam profile product, if present), optionally comprises one or more laterally-extending arms, and typically two laterally-extending arms, one either side of the box structure. Such laterally-extending arms typically provide support surfaces for insulating panels. The rafter beam may comprise one or more legs -8 -depending from a respective arm. For example, each arm may be provided with two spaced legs, a first leg projecting downwards from the end of the arm and a second leg located between the first leg and the box structure.

[0026] The width of the rafter beam (and rafter beam profile product, if present), including any projecting arms, may optionally be at least 50mm, optionally at least 60mm, optionally at least 70mm, optionally at least 80mm, optionally no more than 200mm, optionally no more than 150mm and optionally no more than I 00mm.

100271 The rafter beam may be at least lm long, optionally no more than 3m long, and optionally from 1.5 to 2.5m long.

[0028] If the roof beam is a ridge beam, roof hip beam, roof valley beam or roof wall plate beam, then said beam (and said beam profile product, if present) optionally has a mass per unit length of no more than 8.0kg/m, optionally no more than 7.0kg/m, optionally no more than 6.0kg/m, optionally no more than 5.0kg/m, optionally at least 2.0kg/m, optionally at least 2.5kg/m, optionally at least 3.0kg/m, optionally at least 3.5kg/m, optionally at least 4.0kg/m, optionally at least 4.5kg/m, optionally from 4.0 to 6.0kg/m and optionally from 4.0 to 5.5kg/m.

100291 Said beam (and said beam profile product, if present) optionally has, in cross-section, multiple (optionally four) walls which form a supporting box structure. Said beam optionally comprises one or more (for example, two) support members internally of the box structure. The one or more support members may extend between two walls, between a wall and an angle between two walls, or between two angles formed between walls. The one or more support members may extend between two walls, for example, laterally across the box structure. The mean thickness of each wall is optionally at least I.5mm, optionally at least 2.0mm, optionally at least 2.5mm, optionally at least 3.0mm, optionally no more than 6.0mm and optionally no more than 5.0mm. If said beam comprises a support member, the support member may have approximately the same thickness as one or more walls. The cross-sectional area of the walls and the support member(s) may optionally be at least 0.0005m2, optionally at least 0.001m2, optionally at least 0.0015m2, optionally at least 0.002m2, optionally at least 0.003m2, optionally no more than 0.01m2, optionally no more than 0.008m2 and optionally no more than -9 - 0.006m2. The box structure may optionally be substantially rectangular in cross-section. The upper and/or lower wall may optionally be curved or be provided with sloping portions.

[0030] The cross-sectional area of said beam (and said beam profile product, if present) may optionally be at least 0.0025m2, optionally at least 0.005m2, optionally at least 0.008m2, optionally at least 0.01 m2 and optionally no more than 0.04m2.

[0031] The height of said beam (and said beam profile product, if present) may optionally be at least 80mm, optionally at least 100mm, optionally at least 120mm, optionally at least 130mm, optionally at least 150mm, optionally no more than 300mm, optionally no more than 280mm, optionally no more than 250mm and optionally no more than 200mm.

100321 The width of said beam (and said ridge beam profile product, if present) may optionally be at least 20mm, optionally at least 30mm, optionally at least 40mm, optionally at least 50mm, optionally at least 60mm, optionally no more than 300mm, optionally no more than 200mm, optionally no more than 150mm and optionally no more than 100mm.

100331 Said beam may be at least lm long, optionally no more than 3m long, and optionally from 1.5 to 2.5m long, depending on the use of the beam.

[0034] The fibre may comprise fibres well known to those skilled in the art of glass reinforced plastic. For example, the fibre may comprise one or more of E-glass, A-glass, E-CR-glass, C-glass, D-glass, R-glass and S-glass.

[0035] The fibre may be provided in one or more form, for example, one or more form known to those skilled in the art, such as microspheres, woven or chopped. Often, the fibre will be provided in more than one form. For example, some fibre may be provided in chopped form and some fibre may be provided in un-chopped form.

100361 The plastic used to make the matrix in which the glass is dispersed may be any such plastic well-known to those skilled in the art. For example, the plastic may be a thermosetting plastic or a thermoplastic. The plastic may comprise one or more of a polyester, polyepoxy or polyvinyl ester, for example. For example, the plastic may comprise an isophthalic polyester.

-10 - [0037] In accordance with a second aspect of the present invention, there is provided a roof frame structure comprising one or more roof beams in accordance with the first aspect of the present invention.

[0038] The roof frame structure may comprise one or more roof beams in accordance with the first aspect of the present invention and one or more conventional roof beams, such as those made from wood or aluminium. More preferably, the roof frame structure comprises a plurality of roof beams in accordance with the present invention, more preferably substantially all of the roof beams being in accordance with the first aspect of the present invention, [0039] The roof frame structure may comprise one of more of a ring beam, a ridge beam, a wall plate beam, a rafter beam, a roof hip beam and a roof valley beam in accordance with the first aspect of the present invention. The roof frame structure optionally comprises a ring beam, one or more rafter beams and one or more of a ridge beam, a wall plate beam, a roof hip beam and a roof valley beam in accordance with the first aspect of the present invention. If the roof frame structure comprises at least two of a ridge beam, a wall plate beam, a roof hip beam and a roof valley beam in accordance with the first aspect of the present invention, then the cross-sectional profile of said at least two beams may optionally be the same. Said at least two beams may be made from substantially identical beam profile product.

[0040] The roof frame structure may comprise from 6 to 30 rafter beams, and optionally from 10 to 20 rafter beams, at least one (optionally more than one and optionally each) of which is a rafter beam in accordance with the present invention.

[0041] At least two (and optionally at least 4) of the rafter beams are typically mutually parallel.

100421 At least two (and optionally at least 4) of the rafter beams are typically substantially the same length.

100431 The roof frame structure optionally comprises means of securing lengths of ring beam together, optionally at an angle to one another.

100441 The roof frame structure optionally comprises means for securing a rafter beam to a ring beam (if present).

[0045] The roof frame structure optionally comprises means for securing a rafter beam to a ridge beam (if present).

[0046] The roof frame structure optionally comprises means for securing a ring beam to an adjacent structure, such as a house.

[0047] The roof frame structure optionally comprises means for securing a ring beam to an underlying supporting structure.

[0048] According to a third aspect of the present invention there is also provided a kit for the construction of a roof frame structure in accordance with the second aspect of the present invention, the roof frame structure comprising a ring beam and one or more rafter beams, the kit comprising one or more lengths of ring beam profile product suitable for the production of a ring beam, one or more lengths of rafter profile product suitable for the production of the one or more rafter beams and optionally one or more lengths of beam profile product suitable for the production of a ridge beam, roof hip beam, roof valley beam or a roof wall plate beam, wherein at least one of the ring beam profile product, rafter beam profile product and, if present, the beam profile product suitable for the production of a ridge beam, roof hip beam, roof valley beam or a roof wall plate beam comprises glass reinforced plastic.

[0049] The ring beam profile product, rafter beam profile product and, if present, the beam profile product suitable for the production of a ridge beam, roof hip beam, roof valley beam or a roof wall plate beam may have those features described above in relation to the roof beam of the first aspect of the present invention.

[0050] According to a fourth aspect of the present invention there is also provided a roof structure comprising the roof frame structure in accordance with the second aspect of the present invention and a covering supported by the roof frame structure. The covering may be any covering known to those skilled in the art. The covering may be opaque, translucent or transparent. The covering may be predominantly opaque, but with one or more translucent or transparent portions. The roof structure may comprise insulation. [0051] The roof structure may comprise waterproofing immediately below the covering. For example, the waterproofing may be provided by boarding provided with waterproof layering. The boarding may overlay the ridge beam and the rafter beams.

-12 - [0052] The roof structure may comprise sheeting supported by the rafter beams, defining a space between the boarding and the sheeting. The sheeting may, for example, be in the form of a weather proof board material which is optionally lightweight.

[0053] According to a fifth aspect of the present invention, there is provided a use of a profile product comprising glass reinforced plastic in a ring beam, rafter beam, ridge beam, roof hip beam, roof valley beam or a roof wall plate beam of a single storey building, typically in the form of a single storey extension. The profile product may comprise those features described in relation to the roof beam of the first aspect of the present invention.

[0054] According to a sixth aspect of the present invention, there is provided a profile product comprising glass-reinforced plastic for use in a ring beam, rafter beam, ridge beam, roof hip beam, roof valley beam or a roof wall plate beam in accordance with the first aspect of the present invention. The profile product may comprise those features described above in relation to the roof beam of the first aspect of the present invention. [0055] It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the profile product of the sixth aspect of the invention may incorporate any of the features described with reference to the roof beam of the first aspect of the invention and vice versa.

DESCRIPTION OF THE DRAWINGS

[0056] Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which: [0057] Figure 1 shows an end view of a profile product used in a ring beam according to a first embodiment of the invention; 100581 Figure 2 shows an end view of a profile product used in a rafter beam according to a further embodiment of the invention; [0059] Figure 3 shows an end view of a profile product used in a ridge beam according to a further embodiment of the invention; -13 - [0060] Figure 4 shows a simplified perspective view of a roof frame structure according to a further embodiment of the invention incorporating the profile products of Figures 1, 2 and 3; [0061] Figure 5 shows a schematic perspective view of a roof frame structure showing various roof beams in accordance with an embodiment of the present invention; and [0062] Figure 6 shows a simplified schematic view of a roof frame structure showing a roof wall plate in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

[0063] Figures 1, 2 and 3 show an end view of examples of three profile products 1, 101, 201 in accordance with embodiments of the present invention, those profile products being used in a ring beam, rafter beam and ridge beam, respectively, of a conservatory. Each of the three profile products 1, 101, 201 is elongate (typically having a length of 6m, or whatever length is deemed to be appropriate for handling), and has the same cross-sectional area and shape along its length. Each profile product 1, 101, 201 is formed by pultrusion of glass reinforced plastic. Pultrusion is well-known to those skilled in the art of glass reinforced plastic (it being the standard technique used to make glass reinforced plastic), but essentially comprises pulling the glass fibre and resin precursor through a die which forms the shape of the profile product and curing the resin precursor by heating, thereby forming glass-reinforced plastic. The fibre used is E-glass fibre, in three possible forms (continuous roving, continuous mat strand and stitch-bonded mat) in combination with chopped matting. The plastic is isophthalic polyester resin, a resin well-known to those skilled in the art of GRP manufacture. In the present case, a polyester surface veil is applied to the surface of the profile, such veils being well-known to those skilled in the art of GRP manufacture. The thickness of the glass reinforced plastic is 4mm, except at and near corners, where the glass reinforced plastic is thicker, to avoid problems associated with corners of small radius of curvature. Each of the profile products 1, 101, 201 will now be described.

-14 - [0064] Referring now to Fig. 1, the profile product 1 for a ring beam comprises a front wall 2, upper wall 3, rear wall 4 and lower wall 5, those walls forming a supportive box structure 10, the use of which will be described below. The profile product 1 further comprises a brace member 6, which extends from the intersection of front 2 and lower 5 walls to midway up rear wall 4. Front wall 2 has a height of about 120mm and is substantially normal to lower wall 5 which has a length in cross-section of about 120mm. Upper wall 3 has a length in cross-section of about 55mm and is substantially normal to rear wall 4 which has a length in cross-section of about 155mm. Upper wall 3 is angled at about 24 degrees relative to lower wall 5. Profile product 1 comprises a frontward-projecting arm 6 which comprises a stop portion 7 and a lip 8. The profile product 1 has a mass per unit length of 4.8 kg/m. The cross-sectional area of the glass reinforced plastic is 2.068 x 10-3m2.

[0065] Referring now to Fig. 2, profile product 101 for a rafter beam comprises two side walls 102, 104, an upper wall 103 and a lower wall 105 which together form a box structure 110. The box structure 110 is substantially rectangular. The total height of the profile product is 150mm. The width of the upper wall is 50mm. Profile product 101 comprises two elongate arms 105, 106 which extend about 20mm to either side of box structure 110. Each elongate arm 105, 106 provides a surface 105a, 106a respectively for supporting an overlying board or panel, as will be described below. Legs 107a, 107b depend from arm 105 and legs 108a, 108b depend from arm 106. The legs 107a, b, 108a, b provide support to the arms 105, 106 and the overlying panels or boards. Spaces (only one of which is labelled 109) are provided between adjacent legs 107a, b, 108a, b. The profile product 101 has a mass per unit length of 3.5kg/m. The cross-sectional area of the glass reinforced plastic is 1.85 x 10-3m2. The maximum deflection of a portion of the rafter profile product 101 was calculated as being from 2.46 to 5.45mm when a 900N load is applied to the centre a 3.5m long portion of rafter profile product 101, depending on the precise nature of how the ends of the profile product 101 are supported or attached. [0066] Referring now to Fig. 3, profile product 201 for a ridge beam comprises two side walls 202, 204 and an upper 203 and lower 205 wall, those walls forming a box structure 210. The box structure 201 is substantially rectangular in cross-section, save that upper -15 -and lower walls 203, 205 each comprise sloping portions 206, 207, 208, 209. Brace portions 211, 212 extend between the two side walls 202, 204. The profile product 201 is about 180mm high and 70mm wide, and has a mass per unit length of 4.775kg/m. The cross-sectional area of the glass reinforced plastic is 2.51 x 10-3m2.

[0067] The profile products 1, 101 and 2W may be used to make an embodiment of a conservatory roof frame structure in accordance with the present invention, as will now be described. A simplified, perspective exploded view of an embodiment of the conservatory roof frame structure is shown in Fig. 4. Roof frame structure 301 comprises a ring beam 302, a plurality of rafters (only some of which are labelled; 303a, 303b, 303c, 303d, 303e, 303f, 303g, 303h) and a ridge beam 304. The ring beam 302 comprises several lengths of ring beam profile product (only some of which are labelled; la, lb, lc, 1d) which are attached together to form a ring beam 302. The cross-sectional shape of the ring beam profile product is shown in Fig. 1. Each rafter 303a, 303b, 303c, 303d, 303e, 303f, 303g, 303h comprises a length of rafter beam profile product 101, the cross-sectional shape of which is shown in Fig. 2. The length of each rafter depends on its position in the roof structure 301. Referring to Fig. 4, rafters 303a, b, c, d are substantially parallel to one another and evenly spaced. There are a corresponding set of rafters (not shown) to the rear of the roof structure. Six rafters (four of which are shown; 303e, f, g, h) are arranged to form a shaped end to the roof structure. Those six rafters are attached to a domed plate 320 which is attached to the ridge beam 304. The ridge beam 304 comprises a length of ridge beam profile product 201, the cross-sectional shape of which is shown in Fig. 3. One end of each of the rafters 303a, b, c, d is attached to the ridge beam 304 as shown by the dotted lines labelled 303 in Fig. 3. The end of each rafter 303a, b, c, d, e, f, g, h remote from the ridge beam 304 is attached to the ring beam (denoted by ring beam profile product 1) as shown in Fig. 1 by the dotted line labelled 303. The roof structure 301 will rest on a supporting structure shown as dotted line feature S in Fig. 1, as is well known to those skilled in the art. Furthermore, the roof structure 301 will be attached to the side of a building (not shown), as is well known to those skilled in the art.

-16 - [0068] An embodiment of a roof structure in accordance with the present invention will now be described with reference to Figures 1, 2 and 4. Further components are added to the roof frame structure 301 to produce a roof structure in accordance with the present invention. Referring now to Fig. 2, insulating panels are provided between adjacent rafter beams; the insulating panels, shown as 401, 402 are supported by arms 105, 106. Referring now to Fig. 1, waterproof laminated sheet 501 is placed on top of ring beam upper wall 3 and rafter 303. Abutment portion 7 helps locate the end of the sheet 501, and prevent it from moving. The upper and lower surfaces of the laminated sheet 501 are provided with sheets of PVC (not shown). A covering 502 in the form of tiles 503 is provided. The end tile 504 is provided with a hook which provides a slot for the receipt of lip 8. Referring to Fig. 2, a lightweight insulated weather-proof board shown as 403 is attached to the underside of rafter 303. The gap between insulating panels 401, 402 and board 403 is suitable for locating electrical wires and the like.

[0069] The examples above demonstrate how glass-reinforced plastic may be used to produce roof ring beams, rafter beams and ridge beams for single storey extensions, such as conservatories, orangeries, sunrooms and the like. Figure 5 shows roof hip beams 200 and roof valley beams 300 in accordance with an embodiment of the present invention. Note the L shaped roof ridge beam 250. Figure 6 shows a roof wall plate beam 400 which is used to attach a roof structure 500 to an adjacent building 600.

[0070] Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein. By way of example only, certain possible variations will now be described.

[0071] Those skilled in the art will realise that other cross-sectional shapes may be used for the various profiles of the ridge beam, rafters and ring beam.

100721 The example above is described in relation to a conservatory having one particular shape and roof structure. Those skilled in the art will realise that extensions and roof structures having different footprints may be formed (such as lean-to, L-shaped, P-shaped, T-shaped, Edwardian, Victorian and lantern). Furthermore, the extensions need not always have a ridge beam.

-17 - [0073] The examples above are described in relation to a conservatory. Those skilled in the art will realise that other single storey extensions and buildings may be formed, such as a summer house or an orangery, for example.

[0074] Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.

Claims

-18 -CLAIMSI A roof beam profile product for a single storey building, such as a single storey extension, the roof beam profile product being elongate and having a uniform cross-sectional area and shape along its length, the roof beam profile product comprising glass-reinforced plastic.
2. A roof beam profile product according to claim 1, wherein the roof beam profile product comprises a ring beam profile product, a ridge beam profile product, a wall plate beam profile product, a rafter beam profile product, a roof hip beam profile product or a roof valley beam profile product.
3 A roof beam profile product according to claim 1 or claim 2, wherein the roof beam profile product comprises a main body made from glass-reinforced plastic.
4. A roof beam profile product according to claim 1 or claim 2 comprising an inner portion comprising glass-reinforced plastic and an outer portion which has a lower glass content than the inner portion..
5. A roof beam profile product according to any preceding claim wherein the profile product has, in cross-section, multiple walls which form a supporting box structure.
6. A roof beam profile product according to claim 5 wherein the profile product comprises one or more support members internally of the box structure, the one more of support members extending between two walls, between a wall and an angle between two walls, or between two angles formed between walls.
7. A roof beam profile product according to claim 5 or claim 6, wherein the mean thickness of each wall is at least 1.5mm and no more than 6.0mm.
8. A roof beam profile product according to any of claims 5 to 7 wherein the cross-sectional area of the walls and one or more support members may be at least 0.0005m2 and no more than 0.01m2.
9. A roof beam profile product according to any of claims 5 to 8 wherein the profile product has a mass per unit length of at least 2.0kg/m and no more than
10.0kg/m.

-19 - 10. A roof beam profile product according to any of claims 5 to 9 when dependent on claim 2, wherein the roof beam profile product is a roof ring beam profile product, the box structure of the ring beam profile product comprising front, rear, upper and lower walls.
11 A roof beam profile product according to claim 10, the lower and front walls being substantially perpendicular to one another, the upper wall extending rearwardly and upwardly from the front wall and the rear wall extending rearwardly and downwardly from the upper wall to the lower wall.
12. A roof beam profile product according to claim 10 or 11, the ring beam profile product comprising an abutment for boarding placed on the ring beam, the abutment being located forward of the front wall, the ring beam profile product comprising a forwardly-projecting finger arranged to be received within a slot provided by a tile.
13 A roof beam profile product according to any of claims 5 to 9 when dependent on claim 2, the roof beam profile product being a rafter beam profile product, the rafter beam profile product comprising one or more laterally-extending arms, and typically two laterally-extending arms, one either side of the box structure.
14. A roof beam profile product according to claim 13, the rafter beam profile product comprising one or more legs depending from a respective arm.
A roof beam profile product according to any of claims 5 to 9 when dependent on claim 2, the roof beam profile product being a ridge beam profile product, roof hip beam profile product, roof valley beam profile product or roof wall plate beam profile product, said beam product profile comprising two support members internally of the box structure.
16. A roof beam profile product according to any preceding claim wherein the fibre in the glass reinforced plastic comprises one or more of E-glass, A-glass, E-CRglass, C-glass, D-glass, R-glass and S-glass.
17. A roof beam profile product according to any preceding claim wherein the plastic is be a thermosetting plastic or a thermoplastic.

-20 -
18. A roof beam profile product according to claim 17 wherein the plastic comprises one or more of a polyester, polyepoxy and polyvinyl ester.
19. A roof beam comprising one or more lengths of roof beam profile product according to any of claims 1 to 18.
20. A roof frame structure comprising one or more roof beams in accordance with claim 19.
21 A roof frame structure according to claim 20 comprising one of more of a ring beam, a ridge beam, a wall plate beam, a rafter beam, a roof hip beam and a roof valley beam in accordance with claim 19.
22. A roof frame structure according to claim 20 or claim 21 comprising a ring beam, one or more rafter beams and one or more of a ridge beam, a wall plate beam, a roof hip beam and a roof valley beam in accordance with claim 19.
23 A roof frame structure according to any of claims 20 to 22 comprising at least two of a ridge beam, a wall plate beam, a roof hip beam and a roof valley beam in accordance with claim 19, the cross-sectional profile of said at least two beams being the same.
24. A roof structure comprising the roof frame structure in accordance with any of claims 20 to 23 and a covering supported by the roof frame structure.
25. Use of a profile product comprising glass reinforced plastic in a ring beam, rafter beam, ridge beam, roof hip beam, roof valley beam or a roof wall plate beam of a single storey building, typically a single storey extension.