FILON PRODUCTS LTD
UNIT 3 RING ROAD
ZONE 2
BURNTWOOD BUSINESS PARK
BURNTWOOD
STAFFORDSHIRE WS7 3JQ
Tel: 01543 687300
Fax:
Suppliers of: GRP Rooflights GRP profiled Sheets, Corrugated Roofing sheets, Profiled Roofing Sheets, GRP Cladding, GRP Over-Roofing Sheets, Roof Refurbishment, Translucent Roofing Panels, GRP Skylights
Profiled GRP rooflights and roof sheets, flat roofing products and components, valley gutters and accessories for domestic housing, flat sheet products for signage and other applications… Filon Products is a leader and innovator in GRP products for building and construction as well as other specialist markets including oil and gas, chemicals, marine, transportation and others. You may know us for our famous range of GRP profiled roofing products, but there’s so much more to Filon Products than that.
GRP Rooflights and Profiled Sheets
FILON has been supplying high-quality, industrial rooflights to the building and construction industry for more than 60 years. Our profiled rooflights are made from glass reinforced polyester resin (GRP) – also known as fibreglass – with unique light diffusing additives that scatter light to provide effective daylighting without hot spots, excessive glare or shadow. Available in over 900 different profiles, our products are designed to match all current and most discontinued asbestos cement and metal roofing profiles.
STANDARD RANGE:
FILON STANDARD PROFILED GRP ROOFLIGHTS AND SHEETS
ENHANCED REINFORCEMENT RANGE:
FILON STANDARD PROFILED GRP ROOFLIGHTS AND SHEETS
INSULATING ROOFLIGHTS:
FILON FAIRs GRP factory assembled insulating rooflights are manufactured using high-quality FILON Glass Reinforced Polyester (GRP) to provide a simple in-plane rooflight solution in composite panel roofs and walls. They are designed to provide high levels of natural light, with double and triple skin rooflights available to provide a range of insulation values. FILON GRP sheets scatter transmitted light, to ensure even light distribution without internal glare, excessive shadow or hot spots.
INTERNAL ROOFLIGHTS / LAYLIGHTS:
Internal rooflights, commonly known as laylights, are often required when working with discontinued roofing systems within older industrial buildings. In order to create seamless light transmission and insulation while not compromising existing traditional construction, we created Filon Filites – a smart, modern-day laylight solution for discontinued roofing systems. Filon Filites are factory-assembled double-skin translucent internal rooflights manufactured from Filon GRP sheets. Designed for internal linings and used with suspended ceilings and purlin linings, our double-skin GRP box rooflights work seamlessly with external rooflights, allowing natural light to pass through whilst maintaining balanced insulation levels.
GRP BARREL VAULTS:
Filon Monarch-F GRP Barrel Vault Rooflights are a series of arched, barrel-shaped rooflights set in a parallel configuration to create a continuous vaulted rooflight that provides exceptional light transmission and durability. Our GRP Barrel Vaults are designed for use on standing seam and secret fix roofing systems, continuous ridge applications and flat roofs – making them an ideal choice for a wide range of commercial and industrial roofing applications, such as factories, warehouses and retail spaces. They are also suitable for shallow roof pitches and curved roofs down to a minimum 25m radius. Known for its extreme durability, high impact resistance and ease of handling, we’re proud to manufacture our Filon Monarch-F Barrel Vault Rooflights from high-quality glass-reinforced plastic (GRP) to ensure maximum efficiency and effectiveness from day one until years to come.
CITADEL SHEETS:
FILON Citadel sheets serve as a durable substitute for steel sheets in hostile settings that promote the decay and corrosion of metals. This makes it ideal for construction projects such as galvanizing plants, aluminium smelting works, fertiliser plants, composting facilities, coastal and marine buildings, chemical works, and many other similar applications. FILON Citadel is utilised extensively in these aggressive and corrosive environments as a roofing and wall cladding solution, and is offered in a broad variety of profiles, along with translucent and opaque colours and tints.
HORTICULTURAL SHEETS:
Filon Fotolite Profiled GRP sheets have been designed to meet the diverse demands of the horticulture industry and help you create the most ideal growing environment. This cost-effective, long-lasting and reliable roofing application maximises balanced light diffusion whilst protecting your products from the elements. Manufactured from specially developed glass-reinforced plastic (GRP) using polyester resins and glass reinforcement matting, our Filon Fotolite GRP sheets boast the unrivalled benefits of this specialised composite material.
ROOF REFURBISHMENT AND OVER-ROOFING SYSTEM:
The patented FILON Over-roofing system has an incredible range of benefits for building refurbishment – from time and cost savings to reduced environmental impact and more. Our refurb over-roofing products have been proven in countless diverse applications throughout the UK and Ireland – from factories and industrial units to leisure centres, retail stores and local authority housing. Utilising durable profiled GRP sheets, FILON Over-roofing is designed to provide a quick, trouble-free and economical solution for a new waterproof skin over an existing roof, whatever its condition.
FILON REFURBISHMENT SHEETS:
Filon DR Refurb GRP sheets are available in translucent or opaque colours as a replacement for old or damaged profiled roofing sheets – including profiles which have been discontinued. Contact us today to find out more or to make an enquiry. You can also take a look at our roof refurbishment magazine to discover the benefits of refurbishment sheets for your roof.
FIXSAFE – SAFETY FIXING SYSTEM
Figures published by the Health & Safety Executive show that falls through fragile roofing could equate to nearly 30% of fatal accidents in the construction industry. The Filon Fixsafe safety fixing system has been developed to address this problem, to safely replace GRP roof sheets and rooflights from inside a building, avoiding the need to access the roof from above.
NEW HERITAGE VALLEY - GRP ROOF VALLEY TROUGH:
Heritage Valley by Filon is a ground-breaking, patent-pending GRP valley trough that creates a close-mitred valley appearance using cost-effective and simple methods. Designed for use on slate and plain-tiled roofs, Heritage Valley is installed beneath roof tiles and slates, eliminating the need for expensive lead soakers. The one-of-a-kind, innovative ‘S’ design creates a wider drainage channel whilst maintaining narrow tile support ledges, significantly reducing the number of slate and a half and tile and a half that are needed going into the valley. These combined qualities ensure Filon contractors and clients can enjoy the desirable heritage aesthetic for less cost than a normal dry fix or open valley trough.
V-FLOW VALLEY TROUGHS:
Filon V-Flow Valley Troughs have been designed as a lightweight, durable and cost-effective alternative to traditional lead roof gutters, providing an efficient channel to direct and collect water run-off. Manufactured from glass-reinforced plastic (GRP), our GRP Roof Valley Troughs boast the unrivalled benefits of this fantastic composite material.
FILON MULTICLAD:
Filon Multiclad is an opaque white glass reinforced polyester (GRP) panel with a tough, wear-resistant ‘cracked ice’ embossed finish for wall cladding applications. It’s non-toxic and compliant with Code of Practice for use in food preparation areas. The surface is highly scratch and stain resistant and is unaffected by blood, detergents, antiseptics or steam cleaning making it the perfect hygienic cladding material for food preparation areas and abattoirs. The depth of embossing is insufficient to retain dirt but enough to prevent direct ‘run off’ during cleaning. This enables the surface to be more easily and antiseptically cleansed.
Further Technical information is available to Download from the BPI Download Library or from the Manufacturer’s own website.
Filon Products - The Science of GRP: What is GRP?
The Science of GRP
GRP, which stands for glass reinforced polyester, is a material that is known for its lightweight nature and durability. But, what’s under the surface and why has it become such a popular material choice? Let’s find out.
What is GRP?
Glass reinforced polyester, also known as fibreglass or FRP, is a composite material composed of both fibres and resin. The two components coming together create a desirable material that has many characteristics which make the material versatile and ideal for various applications.
When we say versatile, we mean that it works well across a variety of industries such as construction, automotive, aerospace, rail, and renewable energy (wind farm turbines), to name a few.
How is GRP made?
GRP is made from glass fibres and polyester resin, making it a composite material. Explore the process of Filon GRP sheets and profiles being made and dive into the applications that it is chosen for time and time again.
How are Filon GRP Products made?
The manufacturing process is called pultrusion and we firstly create a flat laminate on a wide carrier film that is ‘pulled’ through the production line. The process is as follows:
Polyester resin is poured onto the carrier film to a specific thickness, we then lay onto the resin a glass fibre mat which is produced online by chopping glass strands into shorter lengths and spread evenly, to a controlled weight. Nylon threads are then laid at tension, on top of the glass strands known as rovings, to create a glass mat of even thickness. Then we apply a top film which for external sheet use is normally UV absorbing to ensure a lengthy lifespan. To ensure the glass is fully impregnated into the resin, the laminate passes through a series of fluted rollers which impregnate the glass into the resin and it then makes its way to the forming section and ovens.
The forming section involves a series of formers, or shoes, that take the laminate into the required sheet shape or profile. This happens through a number of ovens which effectively ‘cook’ the sheet and lock in the required profile. This ‘cooking’ involves a chemical exothermic reaction, which generates heat, and the oven and sheet temperatures are carefully controlled before the sheet goes through the saw section where it is cut to the necessary width and length before being quality checked for profile, thickness, light transmission and other critical characteristics. When the quality control checks approve the sheet for use it is then labelled, packed, and delivered.
What is GRP known for?
There are so many characteristics and benefits to this material, here are a few of them. GRP does not melt, and has a high energy absorption and resistance to both chemicals and corrosion, too. It’s easy to shape and has a known durability, offering an extremely high strength to weight ratio. Plus, it is durable, hard-wearing, and can stand the test of time. Filon translucent sheets are highly diffusing, spreading the light passing through it in a wide angle, reducing the likelihood of hot spots, shadows, and glare.
What is GRP made for?
GRP is an ideal material because it is so durable and long-lasting, which makes it a popular choice in many settings that we see. From tent poles to tool handles, ladders to lamp posts, baths to boats, and just about everything in between, GRP is a widely adopted material that acts as a chameleon in its environment. At Filon, we use GRP especially for rooflights, valley trough gutters, and flat sheet applications to name a few.
What is the difference between GRP, FRP and Fibreglass?
They are one and the same, so you may see the material being referred to as one of these.
GRP in Rooflights
GRP is the go-to choice for industrial rooflights, mainly because they are durable and lightweight, but also because they are incredibly energy-efficient and a simple direct replacement for the main opaque roof sheets.
At Filon, we have been developing GRP profiled sheets since the late 1950s, and have become the go-to manufacturer and supplier for this material, especially for rooflight applications.
Our sheets have a lifespan of around 30 years, meaning that the need for replacement and maintenance is minimal, a desirable trait when installing rooflights. The natural composition of them also offers up to 92% light transmission, reducing the need for artificial lights and reducing the energy usage, too. They’re a popular choice for industrial and agricultural settings, and the GRP composite is always a firm choice with customers.
If you’d like to discover more about GRP and our solutions, please get in touch with a member of the team and we will be more than happy to help.
Filon Products : How to Safely Replace Rooflights in a Fragile Roof
Posing an inherent safety risk to construction workers, the replacement of rooflight installations can be a daunting task, especially on fragile roofs.
Person falling through a rooflight in a fragile industrial roof
Figures published by the Health & Safety Executive show that falls from height is the lead cause of worker fatalities and equates to 36% of all fatal workplace accidents.
Making the final hook bolt connections with the Filon Fixsafe rooflight replacement system
However, the Filon Fixsafe system offers a revolutionary solution that mitigates the requirement for external roof access, ensuring a safer working environment and removing the complexity of this otherwise dangerous endeavour.
Technical Considerations for Rooflight Replacement
There are several key technical factors to consider before changing a rooflight in a fragile roof.
Identify the required roof sheet profile. See our blog.
Determine the required sheet length.
Identify the necessary fire grade. Filon Technical Information Sheet TIS003 will help.
What is the type of purlin? Cold rolled steel, hot rolled steel, timber, concrete, other?
Adopt a Safer Approach with Filon Fixsafe
The Filon Fixsafe system is a significant advancement in rooflight replacement technology that offers a safer and more efficient alternative to traditional installation methods. By eliminating the need for external roof access, the Fixsafe system significantly reduces the risk of falls and other accidents associated with working on fragile roofs. As roof top access is avoided the risk of further damage to an old and fragile roof is limited, reducing the possibility of additional works becoming necessary.
Employing high-quality GRP sheets specifically designed to match various roof profiles, ensuring a secure and aesthetically pleasing fit, the patented fixing system is engineered to provide a strong and reliable connection between the GRP sheet and existing roof structure.
Step-by-Step Guide to Safe Rooflight Replacement
Assess the Roof: Carefully inspect the fragile roof to identify the areas requiring repair or replacement.
Choose the Right Materials: Select GRP sheets that match the existing profile of your roof and hooks to suit the purlin type.
Prepare the Work Area: Clear the area beneath the rooflight to provide safe working area and prevent unauthorised access.
Remove the Old Rooflight: Carefully remove the existing rooflight, taking care to avoid damaging the surrounding sheets.
Install the New Rooflight: Position the new GRP sheet, with fixings and sealant attached, and secure it using the Fixsafe system.
More detailed information is available at Fixsafe installation guide.
Additional Safety Tips
Always follow safety guidelines – Wear appropriate personal protective equipment (PPE) and follow all safety regulations.
Obtain necessary permits – If required, obtain the necessary permits before starting any work on your roof.
Consult a professional – If you’re unsure about any aspect of rooflight replacement, speak to our Technical Team.
Key Benefits of the Fixsafe System
Enhanced Safety
Perhaps the most significant advantage of the Fixsafe system is its ability to eliminate the need for external roof access. Traditional rooflight replacement methods require workers to access the roof from above, exposing them to the inherent risks associated with working at heights and on fragile roofs. The Fixsafe system, on the other hand, allows for the entire replacement process to be carried out from within the building, removing the risk of falls through a fragile roof.
Increased Efficiency
The Fixsafe system is designed to streamline the rooflight replacement process, resulting in significant time and cost savings. By eliminating the need for expensive scaffolding, internal safety netting and other external preparations, the Fixsafe system can reduce project timelines, the number of trades on site, and minimise disruption to building occupants. This efficiency is particularly valuable in commercial settings where downtime can have a significant impact on operations.
Cost-Effectiveness
In addition to its efficiency benefits, the Fixsafe system can also be more cost-effective than traditional methods. The reduced need for safety equipment and the potential for faster project completion can result in lower overall project costs. Moreover, the long-term benefits of a safer and more efficient rooflight replacement process can outweigh the initial investment.
Versatility
The Fixsafe system is not limited to a specific type of roof. It is adaptable to a wide range of roof types, including asbestos, fibre cement, and metal assemblies. This versatility makes the Fixsafe system a valuable solution for a variety of building applications.
Want to Know More?
If you want to learn how our patented Fixsafe system can improve the safety and efficiency of your rooflight repair and replacement operations, you can find a full technical breakdown by downloading the brochure via the Filon website. https://www.filon.co.uk/
Alternatively, contact our Technical Team today to discuss your requirements. sales@filon.co.uk Tel. +44 (0)1543 687300
