Kestrel Aluminium Systems Limited. Product Manual Section 13 60mm Polyamide Window System - Fabrication. Manual Version

Transcription

1 Limited Product Manual Section 13 60mm - Fabrication Manual Version

2 Section Fabrication Guidelines for cutting and prepping sheet 1 General guidelines for cutting and bar preparation Section 13 Contents Section Fabrication sheet 1 Mitre cutting KS661, KS662 and KS sheet 2 Mitre cutting KS664, KS666 and KS sheet 3 Mitre cutting KS668 and KS sheet 1 Cutting/shouldering of KS sheet 1 Glazing beads cutting/mastering Square beads KS631, 633 and KS sheet 2 Glazing beads cutting/mastering Bevel beads KS632, 634 and KS636 Section Fabrication Drain slot preparations sheet 1 Drain slot preparations External beads to fixed lights sheet 1 Drain slot preparations External beads and vent frame KS sheet 1 Drain slot preparations External beads and vent frame KS sheet 1 Drain slot preparations Internal bead frames sheet 1 Drain slot preparations dapter frame KS sheet 1 Drain slot preparations Vent frame KS667 Section Fabrication Trickle vent preparations sheet 1 KS231 trickle vent preparation KS663/ sheet 2 KS231 trickle vent preparation KS sheet 3 KS231 trickle vent preparation KS663/ sheet 4 KS231 trickle vent preparation KS661/666/ sheet 5 KS231 trickle vent preparation KS663/666/ sheet 6 KS231 trickle vent preparation KS663/652/669 Section Fabrication Inline handles sheet 1 KS240 inline espag handle with KS sheet 1 KS240 inline espag handle with KS669 Section Fabrication Butt hinge on KS sheet 1 KS228 preparation on KS669 Section Fabrication Bar preparation before assembly sheet 1 Bar preparation before assembly Sheet

3 Section Fabrication ssembly Section 13 Contents sheet 1 Corner assembly chevron & cleat locations sheet 2 Corner assembly chevron & cleat locations sheet 1 Corner assembly Crimping 60mm window profiles sheet 2 Corner assembly Crimping 60mm window profiles assembly sequence sheet 1 Corner assembly KS227 Centre mechanical cleat sheet 2 Corner assembly KS227 Offset mechanical cleat in KS sheet 3 Corner assembly KS227 Offset mechanical cleat in KS sheet 4 Corner assembly KS227 Offset mechanical cleat in KS sheet 5 Corner assembly KS227 Offset mechanical cleat in KS sheet 1 Corner assembly KS666 vent adapter sheet 1 Corner assembly KS230 C mechanical chevrons sheet 1 ssembly KS665 mullion/transom with screw ports sheet 2 ssembly KS665 mullion/transom with cruciform block KS230 CB sheet 3 ssembly KS665 mullion/transom full cruciform block KS230 CB sheet 1 ssembly Gasket joints KS sheet 2 ssembly Gasket joints KS286 Section Fabrication Hardware sheet 1 Friction Hinge details KS246 T & KS246 S sheet 2 Friction Hinge ID KS sheet 3 Friction hinges KS246 S 12" with KS668 vent sheet 4 Friction hinges KS246 T 12" with KS668 vent sheet 5 Friction hinges KS246 S 12" with KS669 vent sheet 6 Friction hinges KS246 T 12" with KS669 vent sheet 1 Friction Hinge details KS247 T & KS247 S sheet 2 Friction Hinge ID KS sheet 3 Friction hinges KS247 S 12" with KS668 vent sheet 4 Friction hinges KS247 T 12" with KS668 vent sheet 5 Friction hinges KS247 S 12" with KS669 vent sheet 6 Friction hinges KS247 T 12" with KS669 vent sheet 7 Notes for friction hinge fitting sheet 1 KS228 butt hinge with KS sheet 2 KS228 butt hinge with KS665/666/668 SH vent sheet 3 KS228 butt hinge with KS sheet 1 KS240 inline espag handle with KS sheet 2 KS240 inline espag handle with KS sheet 1 KS241 cockspur handle with KS sheet 2 KS241 cockspur handle with KS sheet 1 Friction hinge details KS248T & KS248S (sterling) sheet 2 Fabrication Friction hinge ID (sterling) sheet 3 Fabrication Bar preparation Friction hinge KS248S sheet 4 Fabrication Bar preparation Friction hinge KS248T Sheet

4 Section Glazing sheet 1 Glazing Setting and location blocks Casements sheet 2 Glazing Setting and location blocks TBT sheet 3 Glazing Sealing of gaskets sheet 4 Glazing Sealing of beads sheet 5 Glazing Sealing of wedge gaskets Section 13 Contents Section Fabrication Hardware TBT sheet 1 TBT Hardware ID KS233 TBT Base kit sheet 2 TBT Hardware ID KS233 TBT T S, M, L Top rms sheet 3 TBT Hardware ID KS233 R sheet 4 TBT Hardware ID KS233 TBT HS Hinge parts base kit and colour parts sheet 5 TBT Hardware ID KS233 CLS, KS233 W, KS233 Stay (small/medium/large) sheet 1 TBT Hardware ID Handles and handing sheet 1 TBT Hardware ID Handle preparation sheet 1 TBT Hardware ID Euro groove preparation sheet 1 TBT Hardware assembly Check rod sizes sheet 1 TBT Hardware assembly Follow number sequence sheet 1 KS283 gasket jointing and sealing Sheet

5 Fabrication - Guidelines for cutting and prepping General guidelines for cutting and bar preparation: For further reading on cutting, preparation and workmanship please refer to BS 8118: Part 2: Storage and transportation: Store aluminium in a dry place, clear of the ground. void contact with other metals and with materials such as cement and damp timber. Protect aluminium extrusion surfaces with low tack removable tapes while danger of damage exists. Pack aluminium during transportation to avoid mechanical damage, abrasion and contact by agents liable to cause surface corrosion or staining. Fabrication tolerance: See corresponding sheets for each section type Marking out: Fine scribing lines must not be used on critically stressed ares of thin material. Where subsequent welding is involved paint, chalk, graphite or other marking materials likely to contaminate must not be used. Cutting: Cutting can be by circular saw or band saw and both must have a tooth form and pitch to suite the thickness of the material to be cut. Cut edges should be smooth, square and free from burrs, distortion and other irregularities. Care must be taken to avoid the use of tools contaminated by other metals, particulary copper or brass. Great care must be taken when working with mitred end cuts to avoid impact damage to ends (ideally bars should not be stored or transported vertically without corner protection). Drilling, punching and preparation: Holes can be made by either drilling, drilling and reaming or by punching. Drill holes should be smooth and free from burrs, distortion and other irregularities. Drainage slots must be of the correct diameter and length and positioned correctly. t all times prepared bars should be free from general debris and cutting/drilling swarf. ssembly: ll joint surfaces should be free of dirt,grease and cutting/drilling debris. ll joints shall be sealed against the entry of water by use of a high quality silicone sealant. NB Small gap joint sealant is NOT to be used on painted material - only anodised or mill finish profile. Be careful not to handle or transport frames in such a way as to disturb or open joints by excessive movement or bending of frames etc Sheet

6 Fabrication - Mitre cuts 45 KS KS Saw block (Not by Kestrel) 56 KS Sheet

7 Fabrication - Mitre cuts KS Saw block (Not by Kestrel) Saw block (Not by Kestrel) KS Saw block (Not by Kestrel) KS Sheet

8 56 Fabrication - Mitre cuts Saw block (Not by Kestrel) KS Saw block (Not by Kestrel) 45 KS Sheet

9 4 60 KS665 Mullion/Transom end preparation 20 Shoulder detail used on LL mullion/transom ends Shoulder prep to each end of KS665 Prep for mullion or transom Cut length 4.0mm deep x 20.0mm long shoulder 4 20 Cut length Sheet

10 Fabrication - Cutting of glazing beads KS631/KS633/KS635 KS633 Vertical bead Horzontal beads square cut and run through full width Vertical beads square cut between as shown 20 KS661 Horizontal bead KS631 Glazing beads mastered as above Run horizontal beads full width unless there is a specific reason otherwise KS635 NB Glazing beads can be used internally or externally. We recommend sloping beads externally as these may be less of a water/dirt trap See _1 and _2 for glazing bead options Sheet

11 Fabrication - Cutting of glazing beads KS632/KS634/KS KS634 Vertical bead Horzontal beads square cut and run through full width Vertical beads mitre cut as shown KS661 Horizontal bead KS632 KS KS661 KS661 Glazing beads mastered as above Run horizontal beads full width unless there is a specific reason otherwise llow extra clearance at ends of vertical beads to help the rotation of the section before clipping in place NB Glazing beads can be used internally or externally. We recommend sloping beads externally as these may be less of a water/dirt trap See _1 and _2 for glazing bead options Sheet

12 Drain slot preparations - External beads to fixed lights 25 Type 5 Drain prep to upstand leg for external bead frames Use Kestrel TC903 punch tool ll externally beaded frames (KS661 shown as example) 100 Drain Slot Location Distance Inbetween Slots 600mm Max. Cut back KS282 on vee as shown Notch bead legs where drain preparation occurs on outer frame profiles - Fixed light glazing only. Not required on external beads to KS669 vent frame. 30 KS487 drain hole cover Sheet

13 Drain slot preparations - External beads and vent frame KS Type 5 Drain prep to upstand leg for external bead frames Use Kestrel TC903 punch tool ll externally beaded frames (KS661 shown as example) 100 KS668 vent Drain Slot Location Distance Inbetween Slots 600mm Max. Route drain slots through polyamide as shown minimum of two per vent Cut back KS286 to clear outer frame drain slot as shown Sheet

14 Drain slot preparations - External beads and vent frame KS Type 5 Drain prep to upstand leg for external bead frames Use Kestrel TC903 punch tool ll externally beaded frames (KS661 shown as example) 100 Drain Slot Location Distance Inbetween Slots 600mm Max. KS669 vent Route drain slots through polyamide as shown minimum of two per vent Cut back KS287 to clear outer frame drain slot as shown Sheet

15 Drain slot preparations - internal bead frames 30 Type 4 Drain prep to rebate leg internal bead frames Use Kestrel TC903 punch tool ll internally beaded frames (KS661 shown as example) 100 Drain Slot Location Distance Inbetween Slots 600mm Max. Cut back KS282 on vee as shown at drain slot locations KS487 drain hole cover Sheet

16 Drain slot preparations - dapter frame KS Type 5 Drain prep to upstand leg for KS666 Use Kestrel TC903 punch tool 100 KS668 vent Drain Slot Location Distance Inbetween Slots 600mm Max. See see _1 for drain slot preparation KS666 adapter Seal with rbosil 1096 around perimeter as shown No.6 x 25mm pan head 300 ctrs (avoid KS243N keeps!) KS487 drain hole cover Sheet

17 Drain slot preparations - Vent frame KS lterrnative to Routed drain slot is to use Type 4 Drain prep to rebate leg internal bead frames Drain Slot Location Distance Inbetween Slots 600mm Max. Use Kestrel TC903 punch tool See sheet _1 KS667 vent Route drain slot as shown minimum of two per vent KS487 drain hole cover Sheet

18 Fabrication - KS231 Trickle vent preparation 60 KS652 Head extension No. 8 x 32mm s/steel pan head self tapping screw KS663 Typical SlimLine E trickle vent with 10mm slot Outside KS Gives 2500mm2 Equivalent rea (E) 375mm Overall Vent 345mm x 10mm Slot 18 Open Closed KS Gives 5000mm2 Equivalent rea (E) 745mm Overall Vent mm x 10mm Slot 345mm x 10mm Slot 10mm bridge Equivalent rea (E) = TTF Slimline data as per BS : Sheet

19 Fabrication - KS231 Trickle vent preparation 60 Outside KS663 Typical SlimLine E trickle vent with 10mm slot 28 KS Gives 2500mm2 Equivalent rea (E) 375mm Overall Vent 345mm x 10mm Slot 18 Open Closed KS Gives 5000mm2 Equivalent rea (E) 745mm Overall Vent mm x 10mm Slot 345mm x 10mm Slot 10mm bridge Equivalent rea (E) = TTF Slimline data as per BS : Sheet

20 Fabrication - KS231 Trickle vent preparation 60 KS KS Trim back legs here Typical SlimLine E trickle vent with 10mm slot 52 KS668 Outside KS Gives 2500mm2 Equivalent rea (E) 375mm Overall Vent 345mm x 10mm Slot 18 Open Closed KS Gives 5000mm2 Equivalent rea (E) 745mm Overall Vent mm x 10mm Slot 345mm x 10mm Slot 10mm bridge Equivalent rea (E) = TTF Slimline data as per BS : Sheet

21 Fabrication - KS231 Trickle vent preparation 60 KS661 Outside 40 KS Trim back legs here KS Typical SlimLine E trickle vent with 10mm slot KS668 KS Gives 2500mm2 Equivalent rea (E) Open Closed 375mm Overall Vent mm x 10mm Slot KS Gives 5000mm2 Equivalent rea (E) 745mm Overall Vent mm x 10mm Slot 345mm x 10mm Slot 10mm bridge Equivalent rea (E) = TTF Slimline data as per BS : Sheet

22 Fabrication - KS231 Trickle vent preparation 60 KS Outside 58 KS219 KS668 Trim back legs here KS Typical SlimLine E trickle vent with 10mm slot KS Gives 2500mm2 Equivalent rea (E) Open Closed 375mm Overall Vent mm x 10mm Slot KS Gives 5000mm2 Equivalent rea (E) 745mm Overall Vent mm x 10mm Slot 345mm x 10mm Slot 10mm bridge Equivalent rea (E) = TTF Slimline data as per BS : Sheet

23 Typical SlimLine E trickle vent with 10mm slot Fabrication - KS231 Trickle vent preparation KS652 Head extension 21 No. 8 x 32mm s/steel pan head self tapping screw Outside KS669 KS663 KS Gives 2500mm2 Equivalent rea (E) 28 Open Closed 375mm Overall Vent mm x 10mm Slot KS Gives 5000mm2 Equivalent rea (E) 745mm Overall Vent mm x 10mm Slot 345mm x 10mm Slot 10mm bridge Equivalent rea (E) = TTF Slimline data as per BS : Sheet

24 Fabrication - KS240 inline espag handle with KS KS668 Ø12 Ø Ø minimum 62 KS243 or KS245 gear box & handle preparation on vent 12mm x 62mm (50mm minimum) slot for gear box Jig KST110 vailable for this prep. Plan view on KS KS240 Inline handle (15mm spindle length) No 8 x 22mm long csk head B S/Steel Self tapping screw to fix esgag bar to KS668 or KS669 KS243 (Inline) or KS245 (Bi-Part) - shown Sheet Rev

25 Fabrication - KS240 inline espag handle with KS Ø12 Ø10 KS Ø minimum 62 KS243 or KS245 gear box & handle preparation on vent 12mm x 62mm (50mm minimum) slot for gear box Route slot first to make drilling easier Jig KST110 available for this prep. Plan view on KS KS240 Inline handle (15mm spindle length) No 8 x 22mm long csk head B S/Steel Self tapping screw to fix esgag bar to KS668 or KS669 KS243 (Inline) or KS245 (Bi-Part) - shown Sheet Rev

26 Fabrication - KS228 Haps butt hinge with KS669 KS228 - KS669 KS669 NB Remove nib as indicated for 53.00mm to clear hinge (cranked vent leaf) Plan view on KS669 Set out hinges and mark locations - Remove nib before vent frame assembly Outside Sheet

27 Fabrication - Bar preparation before assembly Important note; Previous pages in this part of the manual detail typical routing and drilling details that should be completed before the individual bars are assembled into window outer frame and vent frames. The schedule of preparation details is based on our standard offering of window accessories, but does not show all possible hardware types and preparation options etc. Please ensure window hardware is checked for correct fit and function, and all preparation details are considered before final assembly. ssembly of window frames; The polyamide window system can be assembled in two ways. 1. Crimped corners using pre-cut extruded corner cleats - Uses and dedicated tool set on the MDG Crest crimper base. 2. Mechanical two part die-cast corner cleats in conjunction with the Kestrel TC903 pheumatic punch tool centre. Requires compressed air at bar. 3. ll mullion/transom joints use the same connection principles regardless of corner assembly. ssembly - see details on following pages ll joint surfaces should be free of dirt,grease and cutting/drilling debris. ll joints shall be sealed against the entry of water by use of a high quality silicone sealant. Use rbosil 1096 or equal product. NB Small gap joint sealant is NOT to be used on painted material - only anodised or mill finish profile. Be careful not to handle or transport frames in such a way as to disturb or open joints by excessive movement or bending of frames etc Sheet

28 Corner assembly - chevron & cleat locations Mechanical Crimped Chevron Chevron B Chevron C KS661 KS227-Centre KS KS230-C Ragni x x mm FUJI 2000 BREVETTTO KS662 KS227-Centre KS KS230-C KS230-CGR Ragni x x mm FUJI 2000 BREVETTTO B KS663 KS227-Centre KS KS230-C KS230-CGR KS230-CGR Ragni x x mm FUJI 2000 BREVETTTO B C KS664 KS227-Centre KS KS230-C KS230-CGR Ragni x x mm FUJI 2000 BREVETTTO B KS665 Cruciform block Joint piece Joint piece B KS230-CB B No.8 pan head x SX 1701 DX KS230-JL KS230-JR KS666 KS KS230-C 15.20mm FUJI 2000 No.8 csk head x 2 BREVETTTO Scale Sheet

29 Corner assembly - chevron & cleat locations Mechanical Crimped Chevron Chevron B Chevron C KS667 KS227-Centre KS KS230-C Ragni x x mm FUJI 2000 BREVETTTO KS668 KS227-Offset KS KS230-C KS230-CGR Ragni x x mm FUJI 2000 BREVETTTO B KS669 B KS227-Offset KS KS225 KS230-CGR Ragni x x mm No.8 pan head Scale Sheet

30 Shim behind Vee block Corner assembly - Crimping 60mm window profiles Clamp sits here Crest Crimper base Kestrel V4 H2 H2 Thrust washers required here (2mm or 3mm) Top/front 2mm H2 Head DOWN KS mm 2.5mm shim total KS661 KS662 KS663 KS664 LL outer frame and vent profiles use; Insert V4 Kestrel V4 2mm H2 Head DOWN KS mm 2.5mm shim total KS667 Heads H2 UP or DOWN H2 DOWN H2 UP 3mm thrust washer behind head H2 2mm H2 Head UP KS mm 2.5mm shim total KS669 2mm thrust washer behind head H2 Shims - various thickness combinations to do 1.5mm, 2.5mm and 3mm 2mm H2 Head DOWN KS mm 1.5mm shim total KS668 3mm H2 Head UP KS mm shim total KS Sheet

31 Corner assembly - Crimping 60mm window profiles ssembly Sequence pply rbosil 1096 silicone sealant to one of the mitre cut faces. Cover LL of the cut face. 2. Insert the chevron KS230-CGR if required - see separate sheets to show locations 3. Insert the corner cleat 4. Offer the first adjoining bar onto the corner cleat/chevrons and push together Offer the second adjoining bar onto the corner cleat/chevrons and push together Offer the third adjoining bar onto the corner cleat/chevrons and push together When ll corners are together position each corner over the insert, clamp, check and crimp Test crimper settings on off-cuts FIRST! Kestrel V4 Crimped corner joint: Use rbo small gap sealant on anodised or mill finish profiles only. Centre clamp pad over crimp as shown Do not over tighten clamp ll joints must be fully sealed against water ingress. Clean off any excess sealant immediately Sheet

32 Corner assembly - KS227-Centre KS227-Centre - use on KS661, 662, 663, 664 and KS667 Monticelli 0410 Ragni x x 14.3 KS227-Centre is non handed, so access to bolt head can be punched as required either side of mitre Punch holes and slot using prep TYPE 1 Insert M8 pin on chain to include slot and hole togehter 41 Remove M8 pin on chain to punch hole only mm allen key required 6Ø 10Ø BEFORE MKING THE JOINT Ensure mitre faces have been buttered with rbosil 1096 silicone sealant. Complete joint and remove excess sealant. If you need KS230-CGR on long leg or odd leg o/frames - insert before assembly!! Punch Type 1 Hinge top and bottom plates out of the way - use middle two only lways push mitre cut section upto tool stop KS661 shown for info Sheet

33 Corner assembly - KS227-Offset KS227- Offset - use on KS668 and KS669 Monticelli x 13.8 Ragni x 14.2 KS227-Offset is handed, so access to bolt head must be punched as shown, See sheet 2 for opposite hand Punch holes and slot using prep TYPE 2 Insert M8 pin on chain to include slot and hole togehter KS230-CGR Remove M8 pin on chain to punch hole only 5mm allen key required 10 10Ø Ø BEFORE MKING THE JOINT Ensure mitre faces have been buttered with rbosil 1096 silicone sealant. Insert KS230-CGR. Complete joint and remove excess sealant. KS230-C can be fitted later. KS230-CGR Punch Type 2 Hinge bottom two plates out of the way - use top two only lways push mitre cut section upto tool stop KS Sheet

34 Corner assembly - KS227-Offset KS227- Offset - use on KS668 and KS669 Monticelli 0355 Ragni x x 14.2 KS227-Offset is handed Punch holes and slot using prep TYPE 2 Insert M8 pin on chain to include slot and hole togehter Remove M8 pin on chain to punch hole only KS230-CGR mm allen key required 10 10Ø Ø BEFORE MKING THE JOINT Ensure mitre faces have been buttered with rbosil 1096 silicone sealant. Insert KS230-CGR. Complete joint and remove excess sealant. KS230-C can be fitted later. Punch Type 2 Hinge top two plates out of the way - use bottom two only KS230-CGR lways push mitre cut section upto tool stop KS Sheet

35 Corner assembly - KS227-Offset KS227- Offset - use on KS668 and KS669 Monticelli x 13.8 Ragni x 14.2 KS227-Offset is handed, so access to bolt head must be punched as sheet 2 for opposite hand Punch holes and slot using prep TYPE 2 Insert M8 pin on chain to include slot and hole togehter Remove M8 pin on chain to punch hole only 5mm allen key required Ø 10Ø BEFORE MKING THE JOINT Ensure mitre faces have been buttered with rbosil 1096 silicone sealant. Insert KS225 & KS230-CGR. Complete joint and remove excess sealant dd No8 x 22mm stainless steel pozi pan head self tapping screw no8 KS230-CGR KS225 Punch Type 2 Hinge top two plates out of the way - use bottom two only lways push mitre cut section upto tool stop KS Sheet

36 Corner assembly - KS227-Offset KS227- Offset - use on KS668 and KS669 Monticelli x 13.8 Ragni x 14.2 KS227-Offset is handed, so access to bolt head must be punched as shown. Punch holes and slot using prep TYPE 2 Insert M8 pin on chain to include slot and hole togehter Remove M8 pin on chain to punch hole only mm allen key required Ø 10Ø BEFORE MKING THE JOINT Ensure mitre faces have been buttered with rbosil 1096 silicone sealant. Insert KS225 & KS230-CGR. Complete joint and remove excess sealant. dd No8 x 22mm stainless steel pozi pan head self tapping screw no8 Punch Type 2 KS230-CGR KS225 Hinge bottom two plates out of the way - use top two only lways push mitre cut section upto tool stop KS Sheet

37 Corner assembly - KS666 vent adaptor BEFORE MKING THE JOINT Ensure mitre faces have been buttered with rbosil 1096 silicone sealant. Complete joint and remove excess sealant. KS230-C can be fitted later. No.8 csk self tapping screws Backset for screw 'B' 16.4 Chevron is used to align faces only backset for screw '' 14.5 BREVETTTO FUJI 2000 BREVETTTO FUJI 2000 KS221_15.2 corner cleat KS230-C Drop and push chevron into corner with elliptical grippers retracted. Use 3mm allen key to secure. Tighten up each side equally and in stages. Centre for screw '' on this Vee groove KS666 Centre for screw 'B' on this Vee groove KS221_ Sheet

38 Corner assembly - KS230-C chevrons Chevron is used to align faces only FUJI 2000 FUJI 2000 BREVETTTO BREVETTTO KS230-C Drop and push chevron into corner with elliptical grippers retracted. Use 3mm allen key to secure. Tighten up each side equally and in stages. KS661, KS662, KS663 and KS664 KS667 KS230-CGR KS668 KS Sheet

39 KS665 Mullion/Transom with screw ports ll joints to be sealed against the entry of water with rbo small gap sealer (Mill or ano) or 1096 silicone (powder coated) See sheet _1 for end prep 68 Drill 2 x 4.20mmØ holes for No 8 Drill 2 x 9mmØ holes for clearance to No 8 screw heads KS230-JL SX KS230-JR 1701 DX 1 3/4" No. 8 pan head self S/Steel self tapping screws Screw ports used for all NON cruciform connections KS230-JR KS230-JL DX 1701 SX Front alignment pieces with elliptical allen key locking - Use on LL mullion/transom joints KS230-JR KS230-JL 1701 DX 1701 SX Drill 2 x 4.20mmØ holes for No 8 2 x 1 1/4" No. 8 self tapping screws (Stainless steel) Drill 2 x 9mmØ holes for clearance to No 8 screw heads Use Vee grooves for drilling guide Sheet

40 KS665 Mullion/Transom with cruciform block KS230-CB KS230-CB Cruciform block used on one or both sides of a full cruciform joint Use Vee grooves for drilling guide Notch to front 1 3/4" No. 8 pan head self S/Steel self tapping screws mm from mullion/transom end will give 0.50mm draw on screws into cruciform block (11.50mm pilot hole for No 8) Remove this extrusion leg See prep below 2 x 3.0mmØ pilot holes for No. 8 self tapping screws Prep (Route) 14.5 Clearance holes holes for No. 8 self tapping screws if only using block on 1 side KS230-CB Cruciform block used on one or both sides of a full cruciform joint 38 See sheet _1 for end prep Sheet

41 KS665 Mullion/Transom - Full cruciform with KS230-CB ll joints to be sealed against the entry of water with rbo small gap sealer (Mill or ano) or 1096 silicone (powder coated) See sheet _1 for end prep Drill 2 x 3.00mmØ pilot holes for No 8 screws Drill 2 x 4.20mmØ holes for No 8 (Csk) KS230-JL KS230-JR 1701 DX 1701 SX 1701 DX 1 3/4" No. 8 pan head self S/Steel self tapping screws 1701 SX 2 x 1/2" No. 8 Csk self tapping screws - oppose as shown (Stainless steel) KS230-CB Cruciform block used on one or both sides of a full cruciform joint Notch to front Block Transom KS230-JR KS230-JL 12.00mm from mullion/transom end will give 0.50mm draw on screws into cruciform block (11.50mm pilot hole for No 8) KS230-JR KS230-JL 1701 DX 1701 SX Front alignment pieces with elliptical allen key locking - Use on LL mullion/transom joints DX 1701 SX Drill 2 x 4.20mmØ holes for No 8 2 x 1 1/4" No. 8 self tapping screws (Stainless steel) Drill 2 x 9mmØ holes for clearance to No 8 screw heads Use Vee grooves for drilling guide Sheet

42 Gasket joints - KS287 KS287 Cut with gasket snips at 45 - but do not stretch gasket Glue corners together with Loctite Super Glue Ultra Gel or similar flexible isocyanurate glue - make sure gasket faces align. KS Sheet

43 Gasket joints - KS286 Use gasket shears to cut leg as shown on external/internal corners to allow bubble to turn through 90 Inner rebate seal joint gasket centrally at head Butt joint gasket so each end is in compression Butt joint of KS286 gasket on mullion or transom ends should be in compression also - seal joint to outer frame KS286 gasket Typical outer frame Typical vent frame Outer rebate seal joint gasket to match drain slot preparation - see _1 as example Sheet

44 Friction Hinge details KS246-T & KS246-S KS246-T08 Top and Side Hung ventilators are hung on 13mm stack height concealed variable geometry friction hinges non-restricted. Hinge Dimn 'L' When hinge fully open KS668 KS669 Vent Size Vent Size Opening ngle Side hung vent should NOT exceed 1300mm in height Top Hung Ventilators Top hung vent should NOT exceed 1200mm in width Part Reference Hinge Length Maximum Vent Weight Maximum Vent Height Minimum Vent Height Hinge Dim 'L' Opening ngle KS246-T08 8"/209mm 12Kg 350mm 260mm 119mm 65 KS246-T10 10"/259mm 16Kg 400mm 310mm 131mm 80 KS246-T12 12"/310mm 20Kg 550mm 365mm 163mm 80 KS246-T16 16"/412mm 21Kg 780mm 500mm 237mm 80 KS246-T20 20"/513mm 26Kg 1100mm 700mm 200mm 50 KS246-T24 24"/615mm 40Kg 1300mm 850mm 154mm 37.5 Side Hung Ventilators Part Reference Hinge Length Maximum Vent Weight Maximum Vent Width Minimum Vent Width Hinge Dim 'L' Opening ngle KS246-S12 12"/310mm 22Kg 600mm 360mm 166mm 60 KS246-S16 16"/412mm 24Kg 700mm 470mm 174mm Sheet

45 Fabrication - Friction hinge ID KS246 KS246-S12 KS246-S16 KS246-T8 KS246-T10 KS246-T12 KS246-T16 KS246-T20 KS246-T Side Hung NB Side hung hinges have longer vent arms and lift blocks Top Hung Use correct hinge for each application Data sheets for each hinge can be provided if required Scale Sheet

46 Friction hinges KS246-S 12" with KS668 vent Important Note: KS288 and KS289 hinge packers set position of the hinge to outer frame and vent Only setting out of first hole is necessary - see below Butt the Stay Body Tightly into KS289 and to the top of the frame and Drill through the Centre of the Slotted djustment Holes Drilling and hole setting out is for KS 246-S (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 13.50mm +/- 0.50mm View on back of hinge Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B Use Drill Jig KST mm Drill bit C B Side hung hinges have lift block here B D View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening LL Pilot holes to be 3mmØ for No 8 fixings (frame side and vent side) Sheet

47 Friction hinges KS246-T 12" with KS668 vent Important Note: Butt the Stay Body Tightly into KS289 and to the top of the frame and Drill through the Centre of the Slotted djustment Holes KS288 and KS289 hinge packers set position of the hinge to outer frame and vent Only setting out of first hole is necessary - see below Drilling and hole setting out is for KS 246-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 13.50mm +/- 0.50mm View on back of hinge Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining B C Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B Use Drill Jig KST mm Drill bit 304 D B View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening LL Pilot holes to be 3mmØ for No 8 fixings (frame side and vent side) Sheet

48 Friction hinges KS246-S 12" with KS669 vent Important Note: KS288 and KS289 hinge packers set position of the hinge to outer frame and vent Only setting out of first hole is necessary - see below Butt the Stay Body Tightly into KS289 and to the top of the frame and Drill through the Centre of the Slotted djustment Holes Drilling and hole setting out is for KS 246-S (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 13.50mm +/- 0.50mm View on back of hinge Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B Use Drill Jig KST mm Drill bit C B Side hung hinges have lift block here B D View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening Pilot holes to be 3mmØ for No 8 fixings (frame side) and 2.5mm Ø for KS fixings (vent side) Sheet

49 Friction hinges KS246-T 12" with KS669 vent Important Note: Butt the Stay Body Tightly into KS289 and to the top of the frame and Drill through the Centre of the Slotted djustment Holes KS288 and KS289 hinge packers set position of the hinge to outer frame and vent Only setting out of first hole is necessary - see below Drilling and hole setting out is for KS 246-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 13.50mm +/- 0.50mm View on back of hinge Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining B C Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B Use Drill Jig KST mm Drill bit 304 D B View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening Pilot holes to be 3mmØ for No 8 fixings (frame side) and 2.5mm Ø for KS fixings (vent side) Sheet

50 KS247-T12 Friction Hinge details KS247-T & KS247-S Top and Side Hung ventilators are hung on 13mm stack height concealed variable geometry friction hinges with integral restrictor mechanism. KS668 KS669 Vent Size Vent Size Restricted ngle Opening ngle Side hung vent should NOT exceed 1300mm in height Top Hung Ventilators Top hung vent should NOT exceed 1200mm in width Part Reference Hinge Length Maximum Vent Weight Maximum Vent Height Minimum Vent Height Maximum Opening ngle Restricted Opening ngle KS247-T12 12"/310mm 20Kg 550mm 365mm KS247-T16 16"/412mm 21Kg 780mm 500mm KS247-T20 20"/513mm 26Kg 1100mm 700mm 50 8 KS247-T24 24"/615mm 40Kg 1300mm 850mm Side Hung Ventilators Part Reference Hinge Length Maximum Vent Weight Maximum Vent Width Minimum Vent Width Maximum Opening ngle Restricted Opening ngle KS247-S12L 12"/310mm 22Kg 600mm 360mm KS247-S12R 12"/310mm 22Kg 600mm 360mm KS247-S16L 16"/412mm 24Kg 700mm 470mm KS247-S16R 16"/412mm 24Kg 700mm 470mm Sheet

51 Fabrication - Friction hinge ID (Restricted) KS247 KS247-S12 KS247-S16 KS247-T12 KS247-T16 KS247-T20 KS247-T Side Hung NB Side hung hinges have longer vent arms Use correct hinge for each application Data sheets for each hinge can be provided if required 8" and 10" hinges NOT available in restricted type Top Hung NB Only use one restricted hinge per pair Typically the bottom hinge of a side hung window, left or right hand of top hung window as specified Scale Sheet

52 21.75 Friction hinges KS247-S 12" with KS668 vent Important Note: Butt the Stay Body Tightly into KS289 and to the top of the frame and Drill through the Centre of the Slotted djustment Holes KS288 and KS289 hinge packers set position of the hinge to outer frame and vent Only setting out of first hole is necessary - see below Drilling and hole setting out is for KS 247-S (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 13.50mm +/- 0.50mm View on back of hinge Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B C B B 13 Restricted View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening LL Pilot holes to be 3mmØ for No 8 fixings (frame side and vent side) D Sheet

53 Friction hinges KS247-T 12" with KS668 vent Important Note: Butt the Stay Body Tightly into KS289 and to the top of the frame and Drill through the Centre of the Slotted djustment Holes KS288 and KS289 hinge packers set position of the hinge to outer frame and vent Only setting out of first hole is necessary - see below Drilling and hole setting out is for KS 247-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 13.50mm +/- 0.50mm View on back of hinge 23.5 Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B C B D B View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening 14 Restricted LL Pilot holes to be 3mmØ for No 8 fixings (frame side and vent side) Sheet

54 21.75 Friction hinges KS247-S 12" with KS669 vent Important Note: Butt the Stay Body Tightly into KS289 and to the top of the frame and Drill through the Centre of the Slotted djustment Holes KS288 and KS289 hinge packers set position of the hinge to outer frame and vent Only setting out of first hole is necessary - see below Drilling and hole setting out is for KS 247-S (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 13.50mm +/- 0.50mm View on back of hinge Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B C B B 13 Restricted View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening Pilot holes to be 3mmØ for No 8 fixings (frame side) and 2.5mm Ø for KS fixings (vent side) D Sheet

55 Friction hinges KS247-T 12" with KS669 vent Important Note: Butt the Stay Body Tightly into KS289 and to the top of the frame and Drill through the Centre of the Slotted djustment Holes KS288 and KS289 hinge packers set position of the hinge to outer frame and vent Only setting out of first hole is necessary - see below Drilling and hole setting out is for KS 247-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 13.50mm +/- 0.50mm View on back of hinge 31.8 Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B C B D B View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening 14 Restricted Pilot holes to be 3mmØ for No 8 fixings (frame side) and 2.5mm Ø for KS fixings (vent side) Sheet

56 Fabrication - Notes for friction hinge fitting KS286 KS KS KS287 ** KS665 KS287 KS669 KS286 ** NB Check hinge to transom/mullion fixing screw is not longer than 12.7mm (1/2") when fixing back to back hinges to avoid screw points clashing (Length is from underside of head) Sheet

57 Fabrication - KS228 Butt Hinge with KS668 Hinge packer 3 Elevation on KS Cut back KS286 gasket for width of hinge (Vent part) NB dd 4mm packer to set correct cavity between vent and outer frame (Part KS ) Fix hinge base on packer (supplied) with No8 x 13 csk pozi head S/Steel self tapping B screws Outside KS C B Use KS fixing screw in holes B - pilot hole not required 20 Ignore Holes and drill new holes C (4mmØ) C B Use No8 x 22mm pozi pan head s/steel self tapping B screw in holes C - drill 3.00mmØ pilot hole through polyamide and extrusion leg Plan view on KS Sheet

58 Fabrication - KS228 butt hinge SH vent KS666 KS KS Face width of KS665 Mullion 68mm Cut back KS286 gasket for width of hinge (Vent part) Outside KS668 NB dd 4mm packer to set correct cavity between vent and outer frame (Part KS ) Fix hinge base on packer (supplied) with No8 x 13 csk pozi head S/Steel self tapping B screws B C Outside C B Side View on KS668 KS Use KS fixing screw in holes B - pilot hole not required Ignore Holes and drill new holes C (4mm ) Use No8 x 22mm pozi pan head s/steel self tapping B screw in holes C - drill 3.00mm pilot hole through polyamide and extrusion leg Sheet

59 Fabrication - KS228 Butt Hinge with KS669 Hinge packer 6.50 Elevation on KS661 5 Cut line in KS287 gasket either side of hinge See _1 Fix hinge base on packer (supplied) with No8 x 13 csk pozi head S/Steel self tapping B screws 8 21 Outside KS B B 53 Use KS fixing screw in holes - pilot hole not required Use No8 x 13mm pozi csk head s/steel self tapping B screw in holes B - drill 3.00mmØ pilot holes Plan view on KS Sheet

60 Fabrication - KS228 Butt Hinge with KS669 Use KS670 if vent over vent Hinge packer 6.50 Elevation on KS665 5 Cut line in KS287 gasket either side of hinge See _1 Fix hinge base on packer (supplied) with No8 x 13 csk pozi head S/Steel self tapping B screws 8 21 Outside KS B B 53 Use KS fixing screw in holes - pilot hole not required Use No8 x 13mm pozi csk head s/steel self tapping B screw in holes B - drill 3.00mmØ pilot holes Plan view on KS Sheet

61 Fabrication - KS240 inline espag handle with KS668 KS243N Keep (profile specific) KS KS661 KS243N Keep fixing screws (2.5mm Ø pilot) Position keep and locate at front edge as shown lign to centres of locking points to suit relevant espag bar Ensure position is correct for simple single direction item (KS243) or Bi-part item (KS245) KS240 Inline handle (15mm spindle length) KS668 Position espag and fix via KS240 handle with 2 x M5 x 25mm Csk machine screws Fix bars with screws as shown Final adjustment of compression is via the mushroom pins for each locking point (+/- 1.00mm) No 8 x 22mm long csk head B S/Steel Self tapping screw to fix esgag bar to KS668 or KS Sheet

62 Fabrication - KS240 inline espag handle with KS669 KS243N Keep (profile specific) KS KS661 KS243N Keep fixing screws (2.5mm Ø pilot) Position keep and locate at front edge as shown lign to centres of locking points to suit relevant espag bar Ensure position is correct for simple single direction item (KS243) or Bi-part item (KS245) KS240 Inline handle (15mm spindle length) KS669 Position espag and fix via KS240 handle with 2 x M5 x 25mm Csk machine screws Fix bars with screws as shown Final adjustment of compression is via the mushroom pins for each locking point (+/- 1.00mm) No 8 x 22mm long csk head B S/Steel Self tapping screw to fix esgag bar to KS668 or KS Sheet

63 Fabrication - KS241 cockspur handle - KS668 KS KS KS241-W Cockspur Handle Wedge (3mm) KS KS661 Single cockspur on vent/outer frame centreline Single cockspur on vents upto 800mm KS Fix handle on packer (supplied) with No8 x 13 csk pozi head S/Steel self tapping B screws (4 total) Finish with screw cover KS241-P Cockspur Handle Packer (2mm) Side hung vent should NOT exceed 1300mm in height Top hung vent should NOT exceed 1200mm in width KS241 Cockspur Handle (9mm backset) LEFT hand shown Sheet

64 Fabrication - KS241 cockspur handle - KS669 KS KS KS241-W Cockspur Handle Wedge (3mm) KS KS661 Single cockspur on vent/outer frame centreline Single cockspur on vents upto 800mm KS Fix handle on packer (supplied) with No8 x 13 csk pozi head S/Steel self tapping B screws (4 total) Finish with screw cover KS241-P Cockspur Handle Packer (2mm) Side hung vent should NOT exceed 1300mm in height Top hung vent should NOT exceed 1200mm in width KS241 Cockspur Handle (9mm backset) LEFT hand shown Sheet

65 Friction Hinge details KS248-T & KS248-S (Sterling) Dim 'L' when hinge is fully open Top and Side Hung ventilators are hung on 17mm stack height concealed variable geometry friction hinges with adjustable stop for top hung hinges Hinges to be used with KS290 packer. KS669 KS668 Vent Size Vent Size Opening ngle Top Hung Ventilators Part Reference Hinge Length Maximum Vent Weight Maximum Vent Height Minimum Vent Height Opening ngle Hinge Dim 'L' KS248-T10 10"/262mm 40Kg 635mm 310mm mm KS248-T12 12"/313mm 50Kg 787mm 635mm mm KS248-T16 16"/415mm 65Kg 1090mm 787mm mm KS248-T22 22"/567mm 75Kg 1500mm 1090mm mm KS248-T26 26"/680mm 100Kg 2000mm 1270mm 20 85mm Side Hung Ventilators Part Reference Hinge Length Maximum Vent Weight Maximum Vent Width Minimum Vent Width Opening ngle Hinge Dim 'L' KS248-S10 10"/262mm 38Kg 660mm 310mm mm KS248-S16 16"/415mm 55Kg 838mm 470mm mm Side hung vent should NOT exceed 1300mm in height Top hung vent should NOT exceed 1200mm in width Sheet

66 Fabrication - Friction hinge ID (Sterling) KS248-S10 KS248-S16 KS248-T10 KS248-T12 KS248-T16 KS248-T22 KS248-T Side Hung NB Side hung hinges have different vent arm geometry Use correct hinge for each application Data sheets for each hinge can be provided if required Top Hung 8" hinges NOT available in Sterling type Important Note: Sterling hinge is wider than defender type - DO NOT use defender setting out. Himge needs to be installed with KS290 packer. KS290 New Sterling hinge support profile Black UPVC Scale Sheet

67 Fabrication - Bar preparation - Friction hinges KS248-S 10" Important Note: 28 KS635 View on back of hinge KS290 packer KS661 shown as example KS668 No No Sterling Hinge to be fixed with M5 or No. 10 self tapping screws Frame fixing: M5 x 16mm or No. 10 x 16mm S/Steel Vent fixing: M5 x 20mm or No. 10 x 19mm S/Steel Cross or Torx pan head Note: Vent to be manufactured 4mm smaller in height than normal to allow for 17mm stack height of hinge. Position the Stay Body correctly and Drill through the Centre of the Slotted djustment Holes Drilling and hole setting out is for KS 248-S (10") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 17.00mm mm mm Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B C B D B View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening KS290 New Sterling hinge support profile Black UPVC Important Note: * Sterling hinge is wider than defender type - DO NOT use defender setting out Sheet

68 Fabrication - Bar preparation - Friction hinges KS248-T 12" Important Note: 28 KS635 View on back of hinge KS290 packer KS661 shown as example KS668 No No Sterling Hinge to be fixed with M5 or No. 10 self tapping screws Frame fixing: M5 x 16mm or No. 10 x 16mm S/Steel Vent fixing: M5 x 20mm or No. 10 x 19mm S/Steel Cross or Torx pan head Note: Vent to be manufactured 4mm smaller in width than normal to allow for 17mm stack height of hinge. Position the Stay Body correctly and Drill through the Centre of the Slotted djustment Holes Drilling and hole setting out is for KS 248-T (12") ONLY do not use with other hinge types or NON Kestrel supplied hinges. See drawing sheet 2 for hinge details supplied by Kestrel Tolerance on cavity: 17.00mm mm mm Once the Hinge Position is Determined by the Fixings in the Holes Marked C Drill through the Centre of the Remaining Slotted Holes D and pply Fixings Close the Window and Check the lignment djust as Necessary and then Drill and pply Fixings to the Dead Fixing Holes B C B D B View on front of hinge (on vent arm) Note: rrow on arm shows direction of opening KS290 New Sterling hinge support profile Black UPVC Important Note: * Sterling hinge is wider than defender type - DO NOT use defender setting out Sheet