MOUNTING INSTRUCTIONS CONCRETE PURLIN BRACKET

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1 CONCRETE PURLIN BRACKET VERSION MARCH 2015

2 GENERAL INSTRUCTIONS Safety: Systems may only be installed and operated by properly trained and technically suitable people (i.e. MCS accredited installers). Installers must at all times adhere to the site s safety procedures and also working at height safety procedures. Information about working safely at heights can be found at All systems should not be installed during adverse weather conditions. Regulations: National and local building regulations, standards, environmental regulations, and planning laws must always be adhered. For on-roof systems the load bearing capacity of the roof must be checked by qualified personnel prior to installation. It is recommended for all ground mounted systems that a geological survey is conducted by qualified personnel prior to installation. Design: SUNFIXINGS Ltd require a fully completed checklist in order to issue a copy of the snow and wind loading results. These checklists can be found at SUNFIXINGS Ltd will inform the installer of any specialist requirements, for example the required amount of fixings and minimum/maximum spacing between fixings supplied by SUNFIXINGS Ltd. SUNFIXINGS Ltd must be informed prior to the design process of any module manufacturer s specifications that may affect the installation of the mounting system. The mounting instructions of the module manufacturer should always be adhered to. Prior to Install: It is recommended that all orders are checked upon delivery and any discrepancies or queries are reported to SUNFIXINGS Ltd within 48 hours of accepting the delivery. Asbestos: SUNFIXINGS Ltd does not endorse the drilling into asbestos material. This is solely the responsibility of the installer or other qualified personnel. Torque: The recommended torque settings apply to the following: Middle and Corner Clamp: 12Nm Fixed Connector, Cross Connector, Flexible Connector: 25Nm M10 Screw (A2): 30Nm M12 Screw (A2): 52Nm M12 (zinc plated): 75Nm Flexible Connectors: these must be used after approximately every 18m to allow thermal expansion of the mounting rails 40x40, 40x60, and 40x80 profiles. To install the Flexible Connectors, leave a 20mm gap between the mounting rails and ensure that the middle of the Flexible Connector sits in line with the middle of the gap. Flexible Connectors are not required for the Mounting Rail Direct or Domestic profile; instead break the module array after every 18 th module in a row to leave a 20mm gap before starting the next array of modules. Do not mount modules over the thermal expansion gap. Page 2 of 13

3 Ground Mounted: It is highly recommended that additional Zinc Galvanising Spray is used on any scratches, cuts, or additional holes drilled into the Park Tegra ground mounted range of frames. For the Park Tegra Ground Anchor system it is recommended that a 2.5 tonne cylinder head Hydraulic auger unit with twin flow application is used to install the Ground Anchors. Ballasted Systems: For ballasted systems, ensure that the correct ballast is applied in the correct position and that wind deflectors/wind bracing has been installed correctly. EPDM: For systems that require the use of EPDM tape, ensure that the surface is cleaned prior to sticking so that it is free of dirt, dust, and grease etc. If it is not possible for the EPDM tape to adhere successfully to the roof, it is possible to fix the EPDM tape to the mounting rail. It is highly recommended that where fixing into roofing cladding with troughs and crowns that the fixings are fixed through the top of the crown. For steel roof cladding, it should be pre-drilled 2 sizes bigger than the diameter of the fixing. Roof Tiles: Roofing tiles may be brushed or grinded to gain a better fit for the Roof Hook system, however it is not recommended to drill into any roofing tiles. To further weather protect the Roof Hook system, use a UV and water resistant sealant around and underneath the Roof Hook. Each Roof Hook should be fixed with a minimum of 2x SUNFIXINGS wood screws. End Caps: The End Caps for the mounting rails are optional and are available upon request at the point of order. During the winter months it may be necessary to keep the End Caps inside a warm environment to maintain elasticity for installation. System Removal: The system can be dismantled and removed by reversing the steps of this document. These mounting instructions are subject to change without prior notice, therefore please contact SUNFIXINGS Ltd to ensure you have the current version. SUNFIXINGS Ltd reserves the right to refuse liability if it is found that these general and mounting instructions have not been adhered to. Maintenance: The system should be properly maintained annually. The use of third party components, including screws, will invalidate the system warranty. For more information about our Terms and Conditions and Warranties, please visit Page 3 of 13

SUNFIXINGS MOUNTING RAIL TYPES 40 X 40 40 X

T Bolts into the relevant side channels of

and lock into place by twisting it until

4 SUNFIXINGS MOUNTING RAIL TYPES 40 X X X 80 MOUNTING RAIL DIRECT DOMESTIC The type of mounting rail supplied will depend on the system location. This will be indicated on the layout provided by SUNFIXINGS Ltd, however if you are unsure of which type you require, please check with SUNFIXINGS Ltd before installation to confirm. USING THE MOUNTING RAIL CHANNELS Insert the T Bolts into the relevant side channels of the SUNFIXINGS Ltd range of mounting rails and lock into place by twisting it until the line marked into the bottom of the bolt is perpendicular to the direction of the channel. Page 4 of 13

MODULE CLAMP ASSEMBLY All module clamps and components are pre-assembled with the T Bolts.

turn the bolt clockwise until it locks. Then secure module by tightening the top nut.

5 MODULE CLAMP ASSEMBLY All module clamps and components are pre-assembled with the T Bolts. CORNER CLAMP Adjust the height of the Corner Clamp to match the depth of the module as shown above. Fix the clamp into position by sliding the T Bolt into the top channel of the mounting rail then turn the bolt clockwise until it locks. Then secure module by tightening the top nut. MIDDLE CLAMP Fix the clamp into position by sliding the T Bolt into the top channel of the mounting rail then turn the bolt clockwise until it locks. Then secure module by tightening the top nut. Page 5 of 13

COMPONENTS ASSEMBLY FIXED CONNECTOR (40X40, 40X60, 40X80) Fix the Fixed Connector into position by sliding the T Bolts into the side channel of the mounting rail then turn the bolts clockwise until

6 COMPONENTS ASSEMBLY FIXED CONNECTOR (40X40, 40X60, 40X80) Fix the Fixed Connector into position by sliding the T Bolts into the side channel of the mounting rail then turn the bolts clockwise until they lock. Then secure by tightening the serrated nuts. Ensure there are 2x T Bolts either side of the joining point and the centre of the Fixed Connector is positioned in line with the join. FIXED CONNECTOR (MOUNTING RAIL DIRECT) Ensure the centre of the Fixed Connector is positioned over the join. Fix either side of the join with 1x Hexagon Head Drilling Screw. FIXED CONNECTOR (DOMESTIC RAIL) Fix the Fixed Connector into position by sliding the T Bolts into the side channel of the mounting rail then turn the bolts clockwise until they lock. Then secure by tightening the serrated nuts. Ensure there are 1x T Bolt either side of the joining point and the centre of the Fixed Connector is positioned in line with the join. Page 6 of 13

FLEXIBLE CONNECTOR (40X40, 40X60, 40X80) The Flexible Connector is identified by the orange circle. Leave 20mm between rails.

Slide the 2x T Bolts on the opposite side of the orange circle into side channel of the rail and turn clockwise until they lock, then secure them

Flexible Connectors are not required for Mounting Rail Direct or Domestic rails, leave 20mm expansion gap between rails.

CROSS CONNECTOR Fix the Cross Connector into position as shown above by sliding the T Bolt into side channel of the mounting rail then turn the

7 FLEXIBLE CONNECTOR (40X40, 40X60, 40X80) The Flexible Connector is identified by the orange circle. Leave 20mm between rails. Slide the 2x T Bolts on the orange circle side into side channel of the rail but do not tighten. Slide the 2x T Bolts on the opposite side of the orange circle into side channel of the rail and turn clockwise until they lock, then secure them by tightening the serrated nuts as shown above. Flexible Connectors are not required for Mounting Rail Direct or Domestic rails, leave 20mm expansion gap between rails. Do not mount modules over the expansion gap. CROSS CONNECTOR Fix the Cross Connector into position as shown above by sliding the T Bolt into side channel of the mounting rail then turn the bolt clockwise until it locks. Then secure by tightening the serrated nut. CROSS CONNECTION Use for projects where base rail and module rail is required. Place the module mounting rail perpendicular on top of the base mounting rail. Fix 1x Cross Connector C into position as shown above. Slide 1x T Bolt into side and top channels of the rail and turn clockwise until they lock into place. Secure them by tightening the serrated nuts. Page 7 of 13

ITEMS a MIDDLE CLAMP b CORNER CLAMP c MOUNTING RAIL

CAP (OPTIONAL) (for 40x40, 40x60, 40x80) g CONCRETE

8 ITEMS a MIDDLE CLAMP b CORNER CLAMP c MOUNTING RAIL Depends on type specified (see page 4) d FIXED CONNECTOR (For 40x40, 40x60, 40x80) e FLEXIBLE CONNECTOR (identified by the orange label) f END CAP (OPTIONAL) (for 40x40, 40x60, 40x80) g CONCRETE PURLIN BRACKET h EPDM WASHER i M12 SERRATED NUT Page 8 of 13

9 j CROSS CONNECTOR Page 9 of 13

10 M12 Threaded Bar M10 Threaded Bar Page 10 of 13

m bigger than the size of the threaded bar. 2.

11 1. Fit the Concrete Purlin Bracket (g) around the purlin as shown on page 10. Pre-drill the roofing sheet 2mm bigger than the size of the threaded bar. 2. Once the M12 threaded bar has been threaded through the roofing sheet, fit the EPDM Washer (h) over the threaded bar and push down against the roofing cover to provide the weatherproof seal. Tighten 1x M12 Serrated Nut (i) over the top of the EPDM Washer (h). 3. Place 1x M12 Serrated Nut (i) over the threaded bar, together with 1x Cross Connector (j) and another 1x M12 Serrated Nut (i), as shown below. Page 11 of 13

12 4. Attach the Cross Connector (j) to the Mounting Rail (d) by sliding the T Bolt into the side channel of the Mounting Rail (d) and turn clockwise until it locks, then secure it by tightening the serrated nut. Page 12 of 13

13 Page 13 of 13

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