There are many different processes involved in making Thermotec insulated roof panels. Each one of these processes is vital in creating a high quality conservatory roof panel so that you can enjoy the benefits of a new roof for your conservatory.
Step-by-step guide to making conservatory roof panels.
First of all, we measure your existing conservatory – all part of the home survey we provide.
Our trained surveyor unscrews the existing end caps on your conservatory roof bars, then removing the bar itself. The survey involves sketching out the shape of your existing glass or polycarbonate conservatory roof panels. As well as this the surveyor measures the exact sizes and angles too. This process repeats across the rest of the panels in your existing conservatory roof. At the end of this process, we replace the original panels.
Designing new panels for your conservatory.
At the factory, we use the home survey to input the panel sizes and details into bespoke CAD software. We accurately enter the dimensions, shapes and sizes. The software we use also creates all the folds and angles required to bend the panel to the required roof panel forming a fully sealed tray further down the production process.
As a result, when the panel comes together, every edge comes neatly together thanks to the software-designed process. Not only does this create a seamless and high quality panel but this software programs the design into the factory machinery.
Making our panels in the factory.
The first process is to take the aluminium sheet from stock using specific handling equipment. The full-size large aluminium sheet gets moved onto the saw and machining centre.
The second process is for the machining centre to cut the sheet to the required size. Additionally, individual blades create long grooves and notes in the panel sheet to fold the panel into a sealed panel further down the process. The panels remain fully protected with low tack tape ensuring the protection of the visible surfaces of your new roof panels.
Consistent quality is at the heart of every production process. When the blades cut the panel a vacuum sucks up the swarf and offcuts ensuring they do not land on the finished surface, keeping it clean and pristine. This is the surface you see from the inside as well as the outside of your conservatory.
After the panels get cut, they are hand pressed into a shaped tray. The next process welds and polishes the edges of the panels. As a result, the finished surface is smooth, clean and neat. Again protective tape remains in place throughout this process.
Powder coating the aluminium.
Painting your new conservatory roof panels is precise as well as a full quality assured process. First of all the panels undergo a thorough cleaning and pretreatment process, carried out by a professional applicator of polyester powder.
A series of pretreatment tanks with cleaning solution prepares the surface for the best adhesion of the polyester powder in your chosen colour. Finally, a final hand cleaning process prepares your panels before painting.
Final assembly of aluminium roof panels.
After powder coating of your panels, we glue and secure thick thermal insulation to the inside surface of the panel tray. Furthermore, we cut this insulation to the same shape as the inner dimensions and angles. As a result, the entire inside of your new panel has complete, durable and thermal-rich insulation. It is this insulation helping to keep your conservatory cool in the summer and warm in the winter.
Finally, the finished panel is pressed together fully sealing it and ready to install in your conservatory. Once again, these panels remain fully protected throughout. The protection is removed only when the panels are fitted in your conservatory roof.
The video below illustrates all the above processes.
Get in touch today for a free quote and transform your conservatory.
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