Kestrel Aluminium Systems Limited. Product Manual Section 11 Thermal Framing System - Fabrication. Manual Version

Transcription

1 Limited Product Manual Section 11 - Fabrication Manual Version

2 Section Fabrication sheet 1 General guidelines for cutting and bar preparation Section 11 Contents Section Fabrication sheet 1 Frame drill Jig KAS T105 Thermal break frame sections sheet 1 Hole setting out KAS721 and KAS sheet 2 Hole setting out KAS722 and KAS sheet 3 Hole setting out KAS sheet 4 Hole setting out KAS sheet 1 Screw port fixing Section Cill drainage preparation and fixing holes sheet 1 Cill drainage preparation in KAS sheet 1 Fixing holes Sheet

3 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. Avoid 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. At all times prepared bars should be free from general debris and cutting/drilling swarf. Assembly: All joint surfaces should be free of dirt,grease and cutting/drilling debris. All 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. See separate document for installation guidelines Sheet

4 Frame drill Jig KAS T05 Thermal break frame sections KAS721 Plate Middle drill hole handed for KAS 723 KAS T05 KAS721 TOP TOP KAS 721/727 Plate Plate Box KAS726 TOP TOP KAS 723/727 KAS723 KAS T Sheet

5 Fabrication - Hole setting out - KAS721, KAS KAS 723/727 3 x 5mmØ holes KAS x KAS KAS721 KAS 721/ x 5mmØ holes 4 x KAS Use off cut of KAS721 to keep 's parallel when drilling, fix top/bottom transoms in place to keep plates square prior to drilling intermediate transom positions Sheet

6 Fabrication - Hole setting out - KAS722, KAS724 KAS722 KAS x 5mmØ holes 2 x KAS KAS KAS x 5mmØ holes x KAS Use off cut of KAS721 to keep 's parallel when drilling, fix top/bottom transoms in place to keep plates square prior to drilling intermediate transom positions Sheet

7 Fabrication - Hole setting out - KAS717 Use internal screrw ports for securing fixing plates or cover trims KAS KAS x 5mmø holes 2 x KAS Use off cut of KAS721 to keep 's parallel when drilling, fix top/bottom transoms in place to keep plates square prior to drilling intermediate transom positions Sheet

8 Fabrication - Hole setting out - KAS718 KAS x 5mmØ holes 6 x KAS KAS Use off cut of KAS721 to keep 's parallel when drilling, fix top/bottom transoms in place to keep plates square prior to drilling intermediate transom positions Sheet

9 Fabrication - Screw port fixing Transom Mullion (Box) KAS721 Mullion (Plate) Transom Mullion Transom KAS723 Screw port fixing Sheet

10 Fabrication - Cill drainage preparation Mullion KAS Cill end plate Mullion Drain slot position for jamb mullions 55 Slot minimum 5mmØ 30 Cill end plate (fully sealed to KAS725) Mullion Drain slot position for all intermediate mullions Slot minimum 5mmØ Sheet

11 Fabrication - Fixing holes Always put deep glazing pocket inside Fixing length datum Clearance hole Fixing hole Clearance hole (to clear screw head) Fixing hole (8mmØ or 10mmØ typical) Note for fixing of frames Position frame within the opening plumb, level and diagonally square DO NOT TWIST OR BEND THE FRAME as this will damage frame joints. Use KAS729 as continuos filler around perimeter of frame Pack each fixing location with proprietary shims and fix using correct type and size of fixing for structural grounds. Fix from corners approximately 200mm in and then at approximately 500mm centres. Fix threshold to ensure no bowing or sagging. Ensure fixings do not clash with keep locations for flush or panic bolts etc. Check again that the frame is plumb, level and diagonally square Sheet