Drainage members for flat roofs and methods of making same

A process of making a one-piece drain sump for drainage of an essentially flat roof, the process comprising:

• feeding a bottom facer in a conveyance direction toward a laminator;
• depositing a foam-forming mixture on the bottom facer;
• feeding a top facer in the conveyance direction toward the laminator whereby the foam-forming mixture is interposed between the bottom facer and the top facer;
• curing the foam-forming mixture in the laminator to form a solidified web;
• using a mold member while the foam-forming mixture is in the laminator to impart a tapered concave cross sectional shape in two orthogonal dimensions to a segment of the solidified web.

A process of making a sloped roofing member for drainage of an essentially flat roof, the process comprising:

• feeding a bottom facer in a conveyance direction toward a laminator;
• depositing a foam-forming mixture on the bottom facer;
• feeding a top facer in the conveyance direction toward the laminator whereby the foam-forming mixture is interposed between the bottom facer and the top facer;
• curing the foam-forming mixture in the laminator to form a solidified web;
• using a mold member while the foam-forming mixture is in the laminator to impart plural non-orthogonally sloped surfaces in a width direction to corresponding plural sloped roofing members, the width direction being orthogonal to the conveyance direction;
• and thereafter,
• cutting the solidified web into the plural sloped roofing members.