In this first example, a Conservatory was being built around a square bay with the added challenge of building it around a boiler flue on the one side.
First a frame is constructed out of 4×2 timbers and fixed securely on all sides to the conservatory, and also to the house. The timber in the center adds to the strength and longevity of the roof and will also catch the plaster board when finished.
OSB board is then used on top for the roof. We then use OSB board, which is very strong and also water-resistant, and a much superior product compared to standard plywood favoured by many installers. The top board is fitted with slight pitch as to allow water to drain off it, and thus not pool up on the roof nor accumulate dirt.
On top of the board we use Code 4 lead, a heavier and more robust option than Code 3 favoured by many companies. The mortar is ground out and the lead is knocked into the mortar to an adequate depth so that it won’t pull out due to weathering or heat expansion. The lead is run down into the guttering to prevent any water finding its way in-between the lead and the board. We always use patination oil on our lead work, the layer of the oil helps protect the lead and prevent carbonate formation on the surface.
Around the flue we used a lead and rubber flue collar and also added some extra flash banding to assure water proofing.
A second and third coat of patination oil is applied to clean off any dust and ensure an even coat of oil. We then apply Everbuild Lead Mate sealant is used to adhere the lead to the mortar.
On the inside insulation is put in between the timbers to provide adequate thermal efficiency.
The same practices are used when making a bow conversion. The main difference in this scenario is that the finishing edge of the lead is on show and also shaped around a multi-sided roof. In this instance we have the option to cut the lead into a pattern if wanted.