January 2009

Profiled foam fillers,

tapes and sealants

FILLERS
Brett Martin Daylight Systems supply Europes leading range of rooflight options, which are
complemented by our large range of foam fillers, used in common or specialised roof structures
in both new and refurbishment projects.

FILLER MATERIAL OPTIONS

PEL FOAM

FOAM

PE foam is a closed cell physically cross-linked polyethylene

laminated with strengthening interfaces, weighing 30kg/m.3
PE foam fillers are the most widely used and cost effective
for standard applications.

Supaseal foam is an innovative new physically cross-linked

material, blending two flexible polymers into a closed cell foam.
It is superior to PE foam (including Metallocene grades) in every
respect, and is as flexible as EPDM foam, allowing excellent gap
filling ability at low compressive forces, ideal properties for a filler.
It is as durable as EPDM foam, and can be stretched further
before failure, but is not as heavy nor as strong as EPDM foam.

EPDM FOAM
EPDM foam is a synthetic rubber (Ethylene Propylene Diene
Monomer) long established as the best filler material available
for applications where extreme durability is required. It offers
enhanced resistance to high temperatures, long term UV
exposure and attack from birds and vermin.

Any PE, Supaseal or EPDM foam fillers can be vented to order

by having tops removed, nicks to base or mesh venting (see
page 2). Use of an adhesive/mastic is recommended to achieve
a permanent fix and prevent fillers being moved by birds or other
outside influences. This can be factory applied when required.

MATERIAL GUIDE
MATERIAL

CODE

DURABILITY

TEMP RANGE

THICKNESS

DENSITY

COLOUR

PE foam
PE foam
PE foam
EPDM foam
EPDM foam
Supaseal foam
Firestop
Cavity Barrier

O625
O630
O650
O825
O850
1025
O740
O711

Standard
Standard
Standard
High
High
High
Standard
Standard

-70
-70
-70
-45
-45
-45
-20

25mm
30mm
50mm
25mm
50mm
25mm

30kg/m3
30kg/m3
30kg/m3
150kg/m3
150kg/m3
30kg/m3
Clay bonded natural rock fibre

(W)
(W)
(W)
(W)
(W)
(W)

to
to
to
to
to
to
to

+70
+70
+70
+120
+120
+70
+900

(B) (L)
(B) (L)
(B) (L)
(B)
(B)
(B)

MATERIAL PERFORMANCE
Heres an easy-reference guide to how Brett Martin Daylight Systems filler material options compare
across a range of performance criteria.
STRENGTH

Tensile strength (kPa)

10
8
6
4
2
0
PE

Supaseal

EPDM

TEAR STRENGTH

Change in tensile strength

after UV exposure (%)

Tear strength (N/m)

2000
1500
1000
500
0

PE

Supaseal

Supaseal

EPDM

3
2
1
0
-1
-2
-3
-4
-5
-6
-7
PE

Supaseal

250
200
150
100
50
0

EPDM

REDUCTION IN STRENGTH AFTER UV EXPOSURE

2500

PE

450
400
350
300
250
200
150
100
50
0

PE

EPDM

Supaseal

EPDM

REDUCTION IN ELASTICITY AFTER UV EXPOSURE

Change in max. elongation

after UV exposure (%)

Deflection at 20kPa (%)

12

ELASTICITY
Elongation before failure (%)

COMPRESSIBILITY (SOFTNESS)

5
0
-5
-10
-15
-20
-25
-30
PE

Supaseal

EPDM

FILLER
VENTILATION
Unique precision cutting machinery produces fillers to exceptionally high levels of accuracy, optimising
seals and minimising energy loss. It also allows us to manufacture bespoke fillers for eaves, ridges and
intermediate roof positions, plus angle cut fillers for hip and valley applications.

PROFILES

Large Flute

Virtually every roofing and cladding profile is held on our database and others can be
quickly added. A direct reference to tooling ensures that fillers are always precision
matched to sheeting panels. Sheet manufacturer name or reference can identify the
correct profile or profile drawings can accurately match dimensions.

FLUTE

Small Flute

The choice of flute depends on which side of the profiled sheet is to be filled. See Fig 1.

LARGE

SMALL

Typically used at the ridge, filling the

inter-profile between ridge cap and
corrugated roof sheet, this filler fits
downwards into the valley. For a
reverse profile the large flute filler
goes under the sheet.

Typically used under the roof sheet at

the eaves, filling the inter-profile cavity
between sheet and structure, the small
flute is fitted to the opposite side of the
sheet compared to the large flute and
fits upwards into the crown.

Pair

FIG 1

Standard Base

Extended
Base

SELF ADHESIVE FILLERS

Bonded butyl sealants can be applied to the profile, the base or both,
offering easier location and improved weather seal.

BASE
Large and small flute fillers are manufactured with a standard 6mm base.
Extended base depth available on request. Please see Fig 2.
Extended Base
& Liner Profile
FIG 2

FILLER ANGLE
ANGLE CUT / RAKED FILLERS
Fillers to be fitted along roof hips and valleys must be cut to the angle formed by the flashing or valley
and short dimension of the profiled sheet *(true angle). It must also be determined if the filler is left or
right handed. Please refer to the plan drawing Fig 3 Handing, flute size and angle cut.
*This depends on both the plan angle and pitch of the roof; we can calculate this if required.

Hip (under capping)

VENTILATED FILLERS
TRIMMED PROFILE - SMALL FLUTE

RHLF

V shaped nicks in the foam allow condensation forming on the

ridge flashing to run down over the top of the filler.

MESH INSERTS - LARGE & SMALL FLUTES

gle

e
Tru

Allows condensation forming on the under side of the sheet to

run down over the top of the filler.

VENTILATION CHANNELS - LARGE FLUTE

LHLF

Made to order in widths up to 1200mm FIRE STOP 0740

is designed to be fitted above compartment walls and into
corrugations where complete resistance to fire is required.
CAVITY BARRIER 0711 is a lighter weight natural fibre product
with low binder content made in various widths up to
1200mm. We also offer a full range of Fire Rated Sealants
and tapes used in conjunction with Fire Stop Blocks.

An

Left hand
small flute (LHSF)

Right hand small

flute (RHSF)

Valley (under sheet)

FIG 3 HANDING, FLUTE SIZE AND ANGLE CUT

Trimmed
Profile

19mm mesh vents situated in the body of the flute prevent

insects entering the void. Please see Fig 4.

FIRE STOP FILLERS

Right hand large

flute (RHLF)

Left hand large flute (LHLF)

Mesh Inserts

Ventilation
Channels

Mesh Inserts

FIG 4 VENTILATION OPTIONS

SEALANTS
Brett Martin Daylight Systems comprehensive range of sealants offers a suitable solution for virtually
any roof sheeting or cladding application. By observing the market closely and using our considerable
purchasing power, we will continue to offer high quality brands at competitive prices.

BUTYL STRIP SEALANTS

Butyl strip sealants are a blend of synthetic rubber plasticisers, fillers and resins extruded in various sizes.
They are usually fitted within a lap, using compression of the sealant to achieve a good seal.
Butyl sealants are generally extruded as rectangular/round beads with varying dimensions. Round, square
and U sections fill bigger gaps and compress more easily, conforming to gaps of varying thickness.
Higher performance Class A variants (as defined in NFRC Technical Bulletin 36), renowned for ease of
application and long life, are recommended for extended life and for particularly demanding joints.
PRODUCT

CLASSIFIED AS HIGHER
PERFORMANCE (CLASS A)
IN ACCORDANCE WITH NFRC
TECHNICAL BULLETIN 36

DURABILITY

COLOUR

SERVICE
TEMP

APPLICATION
TEMP

SHELF
LIFE

Hodgson HP500 / GCA

20+ Years

(W)(B)

-40 to 110

>4C

1 Year @ 20C

(Covered by Hodgsons
Class A 12 year warranty)

Detail guidance on use of butyl strip sealants is given in MCRMA Technical paper No. 16 Guidance
for effective sealing of end lap details in metal roofing constructions, which includes the following
recommendations.
Built-up systems

Two lines of sealant (central or asymmetric primary fixing position)

Profiled metal to metal

combinations

A single run of 6x5mm or 6mm

end of the lap.

Profiled metal to GRP

rooflight combinations

Two lines of sealant (asymmetric primary fixing position)

bead sealant positioned 15mm from each

A single run of 6x5mm or 6mm bead sealant positioned approximately

10-15mm either side of the primary fixing*
Or alternatively,
Three lines of sealant (central primary fixing position)
A single run of 6x5mm, 6 or 8mm bead sealant positioned 15mm from
each end of the lap with an 18x4 or 22x5mm U-section positioned beneath
the line of the primary fixing.

Composite systems

Size, shape and position of sealant(s)

Composite panel to panel

combinations

Three lines of sealant (asymmetric primary fixing position)

Composite panel to
factory assembled GRP
rooflight combinations

Two lines of sealant (asymmetric primary fixing position)

A single run of 6x5mm or 6mm bead sealant positioned approximately

10-15mm either side of the primary fixing with a third seal positioned 15mm
from the bottom of the lap.

A single run of 6x5mm or 6mm bead sealant positioned approximately

10-15mm either side of the primary fixing*.

*Where a seal is required at the bottom of the lap to keep out dirt and trapped water a bead of premium qulity neutral cure silicone sealant positioned
approximately 15mm from the bottom of the lap is suggested. The silicaone sealant should ideally conform to classification ISO 11600 - F - 25 LM or
BS EN ISO 11600: 2003 and adhesion to the substrates involved verified.

FILM BACKED BUTYL SEALANTS

Film backed butyl sealants are developed especially for sealing laps in liner panels on site assembled
metal walls and roofs to reduce condensation and increase air-tightness in buildings.
Polyband is a simple answer to creating an efficient and durable

air leakage test. Correct sealing of liners is essential for achieving

vapour barrier in twin skin metal roofing systems.

an optimum air-tight seal as well as a good vapour check,

They are dual purpose; a robust and effective means of

providing:

thus ensuring compliance with Building Regulations Approved

Document L2. In response to the mandatory requirements Brett
Martin Daylight Systems offer the correct sealant for every

an air seal at lap joints in roof and wall liners to improve the

roofing and cladding project.

air-tightness of the building fabric.

Film backed butyl sealants can be used as recommended in

a moisture barrier to provide an effective method of reducing

the MCRMA Technical Paper No 14 Guidance for the design of

the level of interstitial condensation which can otherwise

metal roofing and cladding to comply with approved document

occur between the metal roof liner and insulation layer in built

L2:2001 and are recommended for use in NFRC Technical

up roof systems.

Bulletin 36 Performance Standards for butyl strip sealants in

The effectiveness of film backed butyl sealants applied over lap

metal clad buildings.

joints in metal liner panels has been verified by independent

PLEASE NOTE: *Revisions to Part L2 of the Building Regulations

testing by BRE.

have put a greater onus on build quality as well as insulation

The specification and use of dual purpose film backed butyl

levels. Careful installation of cladding is necessary to meet heat

sealants will ultimately contribute to avoiding the costly and time

loss and air-tightness requirements.

consuming remedial works which can result if a building fails an

FEATURES

Economical and environmentally friendly, film

backed butyl sealants create an extremely
efficient vapour barrier

Aid thermal conservation and reduce air leakage,

essential in meeting the latest revisions to Part L
of the Building Regulations

Dual purpose air seal and moisture barrier

to improve air-tightness and reduce risk of
condensation

Half the price of traditionally fitted vapour barrier

membranes

Simply applied over liner panel side and end

laps

BRE tests show sealing of laps using film

backed butyl tapes is the most efficient method
of creating a vapour seal

Film backed butyl sealants will not split during

panel flex or movement

Large areas of liner panel can be sealed prior to

laying insulation and weather sheet

MULTI PURPOSE TAPES AND SEALANTS

The extensive range of multi purpose tapes and sealants complement the large range of profiled sheet
used in common and specialised roof structures for refurbishment and new build projects.
ALUMINIUM FOIL TAPE
BARRIER TAPE /
EPDM FOAM TAPE
COLD BRIDGING TAPE
EXPANDING TAPE
CLOTH JOINTING TAPE
HIGH STRENGTH GAP
FILLING ADHESIVE
HIGH AND LOW
MODULUS SILICONE
POLYURETHANE
SEALANT
HODGSON FR FOAM
FIRESTOP SEALANTS

THE COMPLETE RANGE

In Plane Site Assembled Rooflights

Site assembled rooflights, manufactured in both GRP and polycarbonate,
are quick and easy to install. All sheets achieve the highest levels of
profile accuracy and cover a range of options, including safety levels,
U values and fire ratings. Single, double and triple skin rooflights are
available for a huge variety of applications from canopies to warehouses
and factories to retail and leisure facilities.

FAIR
Factory Assembled Insulating Rooflights manufactured to suit a customers
exact specification. Delivered to site as a complete ready to install unit.
A cost-effective rooflight option that can be incorporated into most new or
refurbished roofs. Manufactured in both GRP and polycarbonate in formats
to suit all of the commonly encountered sandwich panel roof coverings.

Modular Vault Rooflights

Comprehensive range of modular length, double skin vault rooflights
available in GRP and polycarbonate. Suitable for either flat, pitched or
curved roofs, Multivaults are a cost-effective range of vaulted rooflight
options that are easily incorporated into new or refurbished roofs.

Vault Rooflight Systems

Continuous run vault rooflights ideal for use on sports halls, assembly
halls and over corridors. Marvault HF is a vault rooflight system with a
maximum span of 9m and hidden fixings, which can achieve U values as
low as 1.6W/m2K. Marvault RL barrel vaults provide long term reliability
and high quality detailing, with different ventilation options available.

Skylights
Attractive glazing bar systems, with excellent weather resistance and
durability, widely specified where reliability is paramount. With many
ventilation and solar control options and double glazed in either
glass or polycarbonate, this is the ideal system for large area glazing
up to 5m span and any length.

Panel Glazing Systems

Continuous run rooflights. These versatile
interlocking panel glazing systems are ideal for
the creation of covered play areas and walkways.
Panels are fully factory assembled for fast and
simple site installation, without the need for
glazing experience. With up to 41/2m span
between supports, top hung vents and a nonfragile option, this is a highly affordable system.

Solid Polycarbonate Sheet

Solid polycarbonate sheet with shatter
resistance up to 200 times that of glass, ideal
for canopy glazing applications.Marlon FSX
Longlife has co-extruded UV protection on
both sides to cut out 98% of harmful UV
radiation, and offers excellent resistance to
weather and atmospheric conditions.

Multi-wall Polycarbonate Sheet

Multi-wall polycarbonate sheet with a
shatter resistance up to 200 times that
of glass. Available in five structures and
nine tints, to provide a range of thermal
performance and light transmission options.
Co-extruded UV protection cuts out 98%
of harmful UV radiation.

Industrial Rainwater Systems

An extensive range of rainwater
management systems to suit every
designers needs.

ACCESSORIES
Dome Rooflights
A range of modular pyramid and dome rooflights with unique security
and water-proofing features. These are reliable, safe, secure and
well insulated rooflights. Suits new build or refurbishment projects,
replacing just the glazing or the whole unit.

A comprehensive range of accessories

including foam fillers, available in a wide
range of options, and tapes, sealants and
adhesives, manufactured and sourced from
the best in the industry.

BRETT MARTIN DAYLIGHT SYSTEMS

Sandford Close
Aldermans Green Industrial Estate
Coventry
West Midlands
CV2 2QU
TEL: 024 7660 2022
FAX: 024 7660 2745
Email: daylight@brettmartin.com

www.daylightsystems.com
798RP04051

All reasonable care has been taken in the compilation of the information
contained within this literature. All recommendations on the use of our
products are made without guarantee as conditions of use are beyond
the control of Brett Martin. It is the customers responsibility to ensure
that the product is fit for its intended purpose and that the actual
conditions of use are suitable. Brett Martin pursues a policy of continuous
product development and reserves the right to amend specifications
without prior notice.