We spent the last three days measuring all our Skylight windows so that we can send off for quotations for creating triple glazing units. Now that we have built our new working platform, it meant that we could get the whole job done in one go without interruptions.
We decided that we would use lots of thin insulation boards that we had left-over and proceeded to cut a ‘template’ for each individual window in turn. We found some slightly thicker boards, measuring 40mm thick and also very flat as well, so we could test to how easy, or difficult, it was in moving the template into place, avoiding the various obstacles like the steel cross ties etc.
The proposed triple glazing units are currently selected to be using 4mm thick glass panes with 16mm cavities which makes an overall 44mm in depth. Our 40mm template is a good size to test the installation of the real thing later on, the heaviest glazing unit being at around 40kg each.
Happily, we can report that all 22 windows passed this particular test with flying colours!
Another reason for using a thick foam board, is to also find out to how ‘flat’ our wooden framework is up there in our Skylight that we built all those years ago. The PU foam material is quite stiff and we can detect whether the pseudo glazing unit template sits rock steady or wiggles.
Generally speaking, the majority of each window hole was pretty damn close to being flat and we will be able to get away in using only 3mm or 5mm thick sticky foam tape for the first stage of sealing the units into place. Only one window had a serious wobble, caused by a break in our framing timber. We will have to do some tidy up of the joint and recondition it so it is back to the same original coatings of fibre glass resin.
After the 40mm foam was close to the right size (fits with a little ‘slop’), we made a copy onto 20mm foam and measured and labelled it and inserted it into the skylight. It was quite slow in getting each window done, we didn’t want to rush it as it will cost many £1000s for the windows, especially the triangular ones, four of them at each end of the Skylight.
The list of our windows breaks down into these quantity and approximate sizes:
- Great Room: 4 triangles measuring about 1150mm high by 1100mm wide and 2 rectangular – 1120mm high by 1190mm wide
- Sitting Room: 5 rectangular – 1120mm high by 966mm wide
- Stairs/ Hall: 2 rectangular – 1150mm high by 750mm wide (one of these is a special shape!)
- Study: 2 rectangular – 1145mm high by 1066mm wide
- Work Room: 3 rectangular – 1145mm high by 996mm wide 4 triangular ? about 1140mm high by 1110mm wide
To measure the triangular templates we created a tool from aluminium bars which could hold against all 3 sides and measure the correct size of each edge (the foam is too soft/crumpled to measure directly)
We have sent a request for a quote off to our local manufacturer, based in Norwich. We wait to see what they can do.
We have requested that the outer pane of glass is treated with the infra-red reflective and absorbing treatment so we can reduce the sheer amount of heat that we get during the Summer months! Hopefully, it won’t be too expensive. We will have to have safety glass in one way or another but we may be able to have a lowest pane to be laminated and the other two higher panes can be ordinary glass, to save money of not having it made with toughened glass. We now wait and see ! This expenditure will be the last major outlay for the basic building structure and materials.