Kestrel Aluminium Systems Limited. Product Manual Section 3 Shop Front System - Fabrication. Manual Version

Transcription

1 Limited Product Manual Section 3 - Fabrication Manual Version

2 Section 3 Contents Section 3.01 Fabrication - Guidelines for cutting and prepping sheet 1 General guidelines for cutting and bar preparation Section 3.02 Fabrication frame sections sheet 1 Fabrication SG frame sections KAS1, KAS78 and KAS sheet 1 Fabrication DG frame sections KAS41, KAS48 and KAS sheet 1 Fabrication KAS25 door header bar sheet 1 Fabrication KAS93 door header bar sheet 2 Application of KAS sheet 1 Fabrication KAS2, KAS51, KAS40 and KAS sheet 1 Fabrication KAS80 and KAS sheet 1 Fabrication KAS18, 19, 63, 86 and KAS90 Threshold sections sheet 1 Fabrication KAS88, 89 and KAS sheet 1 Fabrication KAS24 and KAS25 sections sheet 1 Fabrication KAS18, 19, 86 Thresholds sheet 1 Fabrication KAS90 Threshold sheet 1 Fabrication KAS65, 69, 95 sections Section 3.03 Fabrication door sections sheet 1 Fabrication KAS14 into framing SG/DG sheet 1 Fabrication KAS34 into framing SG/DG sheet 1 Fabrication KAS13 into framing SG/DG sheet 1 Fabrication KAS33 into framing SG/DG sheet 1 Fabrication Door Leafs - KAS12 and KAS13 rail to stile sheet 1 Fabrication Door Leafs - KAS13 and KAS33 rail to stile sheet 1 Fabrication Door Leafs - KAS77 and KAS85 rail to stile sheet 1 Fabrication Door Leafs - KAS14 and KAS34 rail to stile sheet 1 Fabrication Door Leafs KAS58 rail to and KAS sheet 1 Fabrication Door Leafs KAS58 rail to stile sheet 1 Fabrication Door Leafs KAS58 rail to mid-rail sheet 1 Fabrication Door Leafs KAS59 lay-bar Section 3.04 Fabrication door hardware sheet 1 Fabrication Door hardware COC general view sheet 1 Fabrication Door hardware COC types sheet 1 Fabrication Door hardware COC top arm options sheet 1 Fabrication Door hardware COC disk supports sheet 2 Fabrication Door hardware COC disk supports sheet 1 Fabrication Standard side load top arm prep sheet 2 Fabrication Standard side load top arm assembly sheet 1 Fabrication Standard end load top arm prep sheet 2 Fabrication Standard end load top arm assembly sheet 1 Fabrication Standard short side load top arm prep sheet 2 Fabrication Standard short side load top arm assembly sheet 1 Fabrication Standard side load top arm prep with 100mm stiles sheet 1 Fabrication Bottom pivot in KAS87 with KAS29, KAS sheet 1 Fabrication Bottom pivot in KAS87 with KAS27, KAS sheet 1 Fabrication Bottom pivot in KAS87 with KAS21, KAS Sheet

3 Section 3.05 Face applied closer sheet 1 Face applied closer KAS sheet 2 Face applied closer KAS576 setting out on leaf Section 3 Contents Section 3.06 Butt hinges sheet 1 Haps butt hinge KAS405H 2D sheet 2 Haps butt hinge KAS405H Positions on stile sheet 3 Haps butt hinge KAS405H 3D sheet 1 AFL stainless butt hinge KAS sheet 2 AFL stainless butt hinge KAS409 tap plate detail Section 3.07 Top centre sheet 1 Top centre KAS sheet 2 Top centre KAS568 in finger guard door sheet 3 Top centre KAS568 in pivot door Section 3.08 Flush Bolt sheet 1 Flush Bolt KAS571 details Section 3.09 Letter plate sheet 1 Letter Plate KAS403 details Section 3.10 Handles sheet 1 Pad Handles KAS401 and KAS sheet 1 Pole handle KAS412 on 54mm stiles sheet 1 Pole handle KAS412c on 100mm stiles sheet 1 Flush pull KAS554 on 54mm and 100mm stiles sheet 1 KAS416, KAS417 and KAS418 tubular handles Section 3.11 Door Locks sheet 1 KAS502b lock prep details BAR BOLT (round cylinder) sheet 2 KAS502h lock prep details HOOK BOLT (round cylinder) sheet 1 KAS504b lock prep details BAR BOLT 25mm B/S (profile cylinder) sheet 2 KAS504h lock prep details HOOK BOLT 25mm B/S (profile cylinder) sheet 3 KAS504b lock prep details BAR BOLT 30mm B/S (profile cylinder) sheet 4 KAS504h lock prep details HOOK BOLT 30mm B/S (profile cylinder) sheet 4a KAS Sentinel 6 HOOK BOLT 30mm B/S (profile cylinder) sheet 5 KAS504h lock prep details HOOK BOLT 40mm B/S (profile cylinder) sheet 1 KAS505r lock prep details latch lock 28.6mm B/S (round cylinder) sheet 2 KAS505r lock prep details latch lock 38.1mm B/S (round cylinder) sheet 3 KAS505p lock prep details latch lock 28mm B/S (profile cylinder) sheet 4 KAS505p lock prep details latch lock 37mm B/S (profile cylinder) sheet 1 KAS536 NPLL Nemef latch lock 30mm B/S (profile cylinder) Sheet

4 Section 3 Contents Section 3.12 Electric strikes UltraLine series sheet 1 KAS540 (single doors) detail on KAS sheet 2 KAS540 (single doors) detail on KAS1 prep sizes sheet 3 KAS540 (single doors) detail on KAS sheet 4 KAS540 (single doors) detail on KAS41 prep sizes sheet 5 KAS540 (single doors) detail on KAS sheet 6 KAS540 (single doors) detail on KAS2 prep sizes sheet 1 KAS540 (double doors) detail on KAS sheet 2 KAS540 (double doors) detail on KAS28 prep sizes sheet 3 KAS540 (double doors) detail on KAS sheet 4 KAS540 (double doors) detail on KAS10 prep sizes Section 3.13 Maglocks sheet 1 KAS451 (261 armlock) magnet and brackets Section 3.14 Code Lock sheet 1 KAS446 (255 Code Lock) prep details to KAS sheet 1 KAS557 (Simplex 3000) product specification only sheet 2 KAS557 (Simplex 3000) isometric detail Section 3.15 Door exit devices sheet 1 Door exit devices Classifications sheet 1 KAS432 (940 mortice exit device) part prep sheet 1 KAS433 (960 CVR exit device) stile prep sheet 2 KAS433 (960 CVR exit device) header/threshold prep sheet 1 KAS577 (294 Exidor exit device) prep on wide stiles sheet 2 KAS577 (294 Exidor exit device) top/bottom keeps sheet 1 KAS578 (PJ 1085 exit device) prep on KAS sheet 2 KAS578 (PJ 1085 exit device) lock prep on KAS29/ sheet 3 KAS578 (PJ 1085 exit device) lever prep on KAS29/ sheet 4 KAS578 (PJ 1085 exit device) header/threshold prep Section 3.16 Gasket, Wool-pile and Brush ID sheet 1 Gasket, wool-pile and brush strip ID chart Section 3.17 Sliding Folding Door sheet 1 Stile preparation for KAS532T (Top guide) sheet 2 Stile preparation for KAS532B (Bottom Roller) sheet 1 Shoot bolt guides for open in and open out doors sheet 1 Shoot bolt track prep for sliding folding doors (KAS69 and KAS95) Section 3.18 Installation sheet 1 Commercial frames and doors Installation, glazing, cleaning and maintenance notes 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. 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

6 Fabrication - SG frame sections KAS5 KAS 1 No 10 KAS1 45 Drill: 2 x 5mmØ holes Screw: 2 x KAS KAS Drill: 3 x 5mmØ holes 25 Screw: 3 x KAS No 10 KAS6 KAS78 KAS6 4.7 No 10 KAS6 KAS 3 KAS3 45 Drill: 2 x 5mmØ holes KAS5 22 Screw: 2 x KAS Scale Sheet

7 Fabrication - DG frame sections KAS5 KAS 41 No 10 KAS41 45 Drill: 2 x 5mmØ holes Screw: 2 x KAS KAS Drill: 3 x 5mmØ holes 25 Screw: 3 x KAS No 10 KAS44 KAS48 KAS No 10 KAS44 KAS 42 KAS42 45 Drill: 2 x 5mmØ holes KAS5 22 Screw: 2 x KAS Scale Sheet

8 Fabrication - KAS25 door header bar KAS25 13 KAS Drill: 4 x 5mmØ holes (Clearance for M5) KAS24 (shown for info only) Screw: Fit 'F' bracket with 4 M5 x 25mm screws, washers and nuts from COC fixing pack KAS25 KAS24 (shown for info only) KAS569 M6 KAS 25 Repeat for NON closer end on SINGLE DOOR for fitting of 'F' bracket KAS 569 (fix header bar to jamb via 'F' bracket with 2 x M6 csk machine screws from COC fixing pack) KAS 25 9 Drill & Csk: 2 x 6mmØ (Clearance for M6) KAS25 viewed on plan Repeat for NON closer end on SINGLE DOOR (fix header bar to jamb via 'F' bracket with 2 x M6 csk machine screws from COC fixing pack) Scale Sheet

9 Fabrication - KAS93 door header bar KAS 93 KAS Drill: 4 x 5mmØ holes (Clearance for M5) KAS24 (shown for info only) Screw: Fit 'F' bracket with 4 M5 x 25mm screws, washers and nuts from COC fixing pack KAS93 KAS 93 No Drill: 2 x 5mmØ holes (Clearance for M5) Screw: 2 x KAS KAS24 (shown for info only) NON closer end on SINGLE DOOR KAS Drill & Csk: 2 x 6mmØ (Clearance for M6) Closer end on SINGLE DOOR (fix header bar to jamb via 'F' bracket with 2 x M6 csk machine screws from COC fixing pack) KAS93 viewed on plan Scale Sheet

10 Application of KAS To top of KAS23 or KAS93 M6 M6 No 10 No 10 No 10 No 10 7 To top of KAS25 NEW Channel adapter for door header bars KAS23, 25 and KAS93 to clip in all standard pocket plates Screw ports used at jamb, csk M6 machine screw and nut used at intermediate fixing points KAS 94 Glass Glazing bead 22.5 KAS93 shown as example M6 KAS94 Use M6 fixing at approximate 600mm centres Screw into KAS94 at jambs KAS24 (dotted) No 10 Screw into KAS1 mullion through KAS4 plate Door (Centre hung pivot) KAS4 KAS1 KAS1/4 shown as example KAS4 Glass 45 Scale Sheet

11 Fabrication - KAS40, 70, 2, 51 sections KAS No 10 KAS Drill: 2 x 5mmØ holes Screw: 2 x KAS KAS No 10 KAS Drill: 2 x 5mmØ holes Screw: 2 x KAS KAS2 4.7 No 10 KAS 2 Drill: 2 x 5mmØ holes 45 Screw: 2 x KAS KAS No 10 KAS 51 Drill: 2 x 5mmØ holes 45 Screw: 2 x KAS Scale Sheet

12 Fabrication - KAS80, 83 sections No 10 KAS 80 Drill: 4 x 5mmØ holes 100 Screw: 4 x KAS KAS 83 No Drill: 6 x 5mmØ holes Screw: 6 x KAS KAS KAS83 Scale Sheet

13 Fabrication - KAS18, 19, 86, 63, 90 Threshold sections No 10 KAS 18 KAS Drill: 2 x 5mmØ holes Screw: 2 x KAS No 10 KAS 19 KAS Drill: 2 x 5mmØ holes Screw: 2 x KAS No 10 KAS 86 KAS Drill: 2 x 5mmØ holes Screw: 2 x KAS KAS63 No KAS 63 Drill: 2 x 5mmØ holes Screw: 2 x KAS No 10 KAS90 15 KAS 90 Drill: 2 x 5mmØ holes Screw: 2 x KAS Scale Sheet

14 Fabrication - KAS88, 89 & 81 sections KAS88 KAS 88 & 89 Drill: 2 x 5mmØ holes Screw: 2 x KAS KAS No 10 NB - KAS 88 & 89 may not line up with the 100mm mullion profiles on all occassions KAS Scale Sheet

15 KAS24 (KAS 586 pre-machined) Fabrication - KAS24 & 25 sections Cutaway 9 6 Clear Csk. Holes Ø 50 Cutaway Hole for Closer Pivot Spindle Access Hole for Closing Speed Regulator Screw Length of KAS25 = Overall door Frame Width - 90mm 318 Pivot Jamb End applicable to:- Single Doors Double Doors Access Hole for Latching Speed Regulator Screw KAS 25 only Plan of Closer Plate applicable to:- All Single Pivot Doors All Double Pivot Doors KAS 482 Weatherstripping Lock Jamb End - Single Doors Plan of Frame Head applicable to:- Single Pivot Doors with No Fanlight Double Pivot Doors with No Fanlight KAS24 Cut Away these Legs at Positions Shown Above KAS Sheet

16 100 Fabrication - KAS18, 19 & 86 thresholds Clear Csk. Hole Mild steel plated tapping block 12mm x M6 pozi csk. machine screw Clear Hole Bottom pivot and lock nut O/A threshold (As header bar) Plan of Threshold applicable to:- Single Doors Screw Port Centres (See drg ) Double Doors The above preparation is required at both ends of the threshold KAS18 KAS19 Use No10 self tapping screws for fasterning the frame jambs and threshold profiles together KAS Sheet

17 Fabrication - KAS90 threshold 35 6 Clear Csk. Hole Mild steel plated tapping block 12mm x M6 pozi csk. machine screw 35 approx 200 ctrs approx 200 ctrs approx 200ctrs Centres of Drain Holes in the face and top recess of the threshold Drill 13 Clear Hole straight through Bottom pivot and lock nut 2mm thick 13 ID x 19 OD split washer 35 Plan of Threshold applicable to:- Single Doors Double Doors The above pivot preparation is required at both ends of the threshold Bottom pivot and lock nut 2mm thick 13 ID x 19 OD split washer 6mm Ø Clear Holes for Drainage Mild steel plated tapping block Sheet

18 Fabrication - KAS65, KAS69 & KAS95 sections No 10 KAS Drill: 3 x 5mmØ holes 4.65 Screw: 3 x KAS No KAS 95 Drill: 2 x 5mmØ holes Screw: 2 x KAS No KAS 69 Drill: 2 x 5mmØ holes Screw: 2 x KAS Scale Sheet

19 Fabrication - KAS14 into framing SG/DG Modified KAS Cleat KAS Single glazed frames = 41mm centres Drill and Csk to suit No.10 x 25 Csk Screws at Both Top and Bottom of the Midrail NB Use csk M6 x 32mm machine screws flush in profile so screw heads in box and plates do not clash Double glazed frames = 39.5mm centres Drill and Csk to suit No.10 x 25 Csk Screws at Both Top and Bottom of the Midrail NB Use csk M6 x 32mm machine screws flush in profile so screw heads in box and plates do not clash Sheet

20 Fabrication - KAS34 into framing SG/DG Use off cut of profile to spot holes KAS Drill & csk 2 x clearance holes for No10 fixing (5mmØ) on centres shown (same detail for box or plate) 45 Single glazed example Double glazed example NB Use csk No10 x 38mm self tapping screws flush in profile so screw heads in box and plates do not clash (same detail for single or double glazed sections) Sheet

21 Fabrication - KAS13 into framing SG/DG Modified KAS Cleat *Lines through with rail in door KAS KAS482 woolpile KAS39 Floor Level Single glazed frames = 41mm centres 22* Seal between KAS39 & KAS18 KAS Drill and Csk to suit No.10 x 25 Csk Screws at top of the bottom rail NB Use csk M6 x 32mm machine screws flush in profile so screw heads in box and plates do not clash Double glazed frames = 39.5mm centres Drill and Csk to suit No.10 x 25 Csk Screws at top of the bottom rail NB Use csk M6 x 32mm machine screws flush in profile so screw heads in box and plates do not clash Sheet

22 Fabrication - KAS33 into framing SG/DG *Lines through with rail in door Use off cut of profile to spot holes KAS KAS482 woolpile KAS39 Drill & csk 2 x clearance holes for No10 fixing (5mmØ) on centres shown (same detail for box or plate) Floor Level 22* Seal between KAS39 & KAS18 KAS18 Single glazed example Double glazed example NB Use csk No10 x 38mm self tapping screws flush in profile so screw heads in box and plates do not clash (same detail for single or double glazed sections) Sheet

23 Top of STILE View on Bead Table Fabrication - Door leafs - KAS12 & 13 rail to stile Sectional Elevation at Top of STILE Elevation of Stile to Rail Junction Pilot Hole for No.10 x 25 Twinfast Self Tapping Screw KAS Cleat KAS12 10 dia M10 Threaded Tie Rod with Nyloc Nuts and 25mm OD, 10mm ID Form C Penny Washers Tie Rod Length = Rail Length + 40mm Fitting the cleats Slide the cleat into the stile Use an off-cut of the rail profile to position the cleat Spot drill through the cleat for the No10 screw Slide the cleat away and drill the pilot hole Re-position the cleat and secure with screw Check rail alignment with stile Drill 10mmØ hole through cleat for the tie rod Tie Rod Preparation Cut the tie rod to the required length Dress and bevel the ends on a grind stone Wind the M10 nuts onto the rod to ease the nylon grip Remove the nut and keep to hand Use Draper Expert 17mm Reversible Gear Wrench for tightening the M10 nylock nuts Pilot Hole for No.10 x 32 Twinfast Self Tapping Screw Used for Holding Cleat in Required Position Prior to Assembly KAS Cleat dia. Clear Hole for Tie Rod KAS13 Bottom of STILE View on Bead Table Sectional Elevation at Bottom of STILE Elevation M10 STILE Holes in this Face Only Sectional Plan of STILE/RAIL Junction Sheet

24 Top of STILE View on Bead Table Fabrication - Door leafs - KAS13 & 33 rail to stile Sectional Elevation at Top of STILE Elevation KAS13 10 dia KAS Cleat Pilot Hole for No.10 x 32 Twinfast Self Tapping Screw M10 Threaded Tie Rod with Nyloc Nuts and 25mm OD, 10mm ID Form C Penny Washers Tie Rod Length = Rail Length + 40mm Fitting the cleats Slide the cleat into the stile Use an off-cut of the rail profile to position the cleat Spot drill through the cleat for the No10 screw Slide the cleat away and drill the pilot hole Re-position the cleat and secure with screw Check rail alignment with stile Drill 10mmØ hole through cleat for the tie rod Tie Rod Preparation Cut the tie rod to the required length Dress and bevel the ends on a grind stone Wind the M10 nuts onto the rod to ease the nylon grip Remove the nut and keep to hand Use Draper Expert 17mm Reversible Gear Wrench for tightening the M10 nylock nuts Pilot Hole for No.10 x 32 Twinfast Self Tapping Screw KAS Cleat KAS dia. Clear Hole for Tie Rod M10 STILE Plan Holes in this Face Only Sectional Plan of STILE/RAIL Junction Sheet

25 Top of STILE View on Bead Table Fabrication - Door leafs - KAS77 & 85 rail to stile Sectional Elevation at Top of STILE Elevation of Stile to Rail Junction 35.4 KAS Cleat KAS77 Pilot Hole for No.10 x 32 Twinfast Self Tapping Screw Used for Holding Cleat in Required Position Prior to Assembly 10 dia. Clear Hole for Tie Rod dia 46.7 M10 Threaded Tie Rod with Nyloc Nuts and 25mm OD, 10mm ID Form C Penny Washers Tie Rod Length = Rail Length + 40mm Fitting the cleats Slide the cleat into the stile Use an off-cut of the rail profile to position the cleat Spot drill through the cleat for the No10 screw Slide the cleat away and drill the pilot hole Re-position the cleat and secure with screw Check rail alignment with stile Drill 10mmØ hole through cleat for the tie rod Tie Rod Preparation Cut the tie rod to the required length Dress and bevel the ends on a grind stone Wind the M10 nuts onto the rod to ease the nylon grip Remove the nut and keep to hand Use Draper Expert 17mm Reversible Gear Wrench for tightening the M10 nylock nuts 24.5 KAS Cleat KAS85 Top of STILE View on Bead Table Sectional Elevation at Top of STILE Elevation M10 STILE Plan Holes in this Face Only Sectional Plan of STILE/RAIL Junction Sheet

26 View on Bead Table Fabrication - Door leafs - KAS14 & 34 rail to stile Sectional Elevation on Midrails Elevation of Stile to Rail Junction KAS Cleat KAS Slide the Cleat into the Stile Use an Offcut of the Rail Profiles to Position the Cleat Spot drill Thro. the Cleat for the No. 10 Screw Slide the Cleat Away and Drill the Pilot Hole Re-position the Cleat and Secure with No10 x 32 Screw 170 Drill and Csk to suit No.10 x 25 Csk Screws at Both Top and Bottom 52 of the Midrail Pilot Hole for No.10 x 32 Twinfast Self Tapping Screw Used for Holding Cleat in Position Prior to Assembly KAS Cleat KAS34 Fitting the Cleats STILE Plan Holes in this Face Only Sectional Plan of STILE/RAIL Junction Plan of Drilling Prep. at Midrail Ends Sheet

27 Fabrication - Door leafs - KAS58 rail to KAS55 Method 1 Drill 4.2 Ø Pilot Hole at 18mm ctr. Use 32 x No.10 Csk Head Self Tapping Screws Cleat fixing hole is offset from the centre line of the KAS58 muntin by 2.5mm KAS Cleat KAS58 Drill M6 Clear Holes at 18mm ctr. Drill M6 Clear Hole at 18mm ctr. Tap the 5 Ø Hole in the Cleat M6 Tap the 5 Ø Hole in the Cleat M6 Use M6 x 20 Cap Head Socket Use M6 x 20 Hexagon Head Screw and Washer. Screw and Washer. Tighten with Hexagon Wrench via Tighten with Ring Spanner via 6mm dia.hole in Opposite Wall the Open end of the Profile M6 KAS Cleat M6 KAS KAS KAS58 Method 2 2 no. Clear Csk Hole to Allow 16mm No.10 Self Tapping Screws to Pass Method 3 KAS55 KAS55 KAS58 6 M6 M6 2 no. Clear Csk Hole to Allow 16mm No.10 Self Tapping Screws to Pass Sheet

28 Fabrication - Door leafs - KAS58 rail to stile Sectional Elevation of Stile to Lay Bar Junction View on Bead Table Fitting the cleats Slide the cleat into the stile Use an off-cut of the rail profile to position the cleat Spot drill through the cleat for the No10 screw Slide the cleat away and drill the pilot hole Re-position the cleat and secure with screw Check rail alignment with stile Drill 10mmØ hole through cleat for the tie rod Cleat fixing hole is offset from the centre line of the KAS58 muntin by 2.5mm KAS Cleat KAS58 Pilot Hole for No.10 x 32 Twinfast Self Tapping Screw Drill and Csk to suit No.10 x 13 Csk Screws at Both Top and Bottom 51.5 of the Midrail STILE Plan Holes in this Face Only Sectional Plan of STILE/RAIL Junction Plan of Drilling Prep. at Midrail Ends Sheet

29 Fabrication - Door leafs - KAS58 rail to mid-rail Cleat fixing hole is offset from the centre line of the KAS58 muntin by 2.5mm KAS Drill 4.2 Ø Pilot Hole at 18mm ctr. Use 32 x No.10 Csk Head Self Tapping Screws KAS Cleat 52 KAS no. Clear Csk Hole to Allow 13mm No.10 Self Tapping Screws to Pass Centre Line of KAS58 Muntin & Centre Line of Door Rails KAS Sheet

30 Fabrication - Door leafs - KAS59 laybar KAS59 Drill 4 x 4.2 Ø Pilot Hole at 15mm ctr. through angle bracket Use 12 x No.10 Csk Head Self Tapping Screws 15 Ex KAS305a cut 11.00mm wide Note projecting screw points and reduced glass clearance when using these brackets File off screw points flush to laybar to prevent damage to glass/igu NB On full cruciform, brackets can only be on opposing diagonal - (dotted line) - so screws do not clash Typical arrangement of KAS 59 (10mm Laybar) Face fitted angle brackets NOT supplied by Kestrel Aluminium Systems Limited Scale Sheet

31 Fabrication - Door Hardware - COC general view 'F' bracket fixed to hinge jamb KAS 25 or KAS 93 fits to bracket COC transom closer - see chart on sheet for types and strengths. COC transom closer - All Kestrel pivot doors use 70mm pivot point Transom closer support bracket fixed to KAS25 or KAS93 Standard side load arm set for NON finger guard door jambs Standard end load arm set for finger guard door jambs NB Short side load arm is alternative fitting for finger guard doors See sheet for detailed view of each top arm type and application Bottom pivot assembly, use with all pivot door types. Allows for threshold fitting or direct to floor level fitting Scale n/a Sheet

32 Fabrication - Door Hardware - COC closer types 90 HO Closer Identification Numbers 25 = Size 2 Non-Hold Open 35 = Size 3 Non-Hold Open 45 = Size 4 Non-Hold Open 26 = Size 2 Hold Open 36 = Size 3 Hold Open 46 = Size 4 Hold Open Date of Manufacture e.g = Week 25 Year 2006 KAS No. Size Function Arm KAS573 KAS573.HO Adj. HO Standard Side Load Adjustable Closer KAS573.NHO Adj. NHO or End Load KAS574.2HO 2 HO Standard Side Load KAS574.2HO-E 2 HO End Load KAS574.2NHO 2 NHO Standard Side Load KAS574.2NHO-E 2 NHO End Load KAS574.3HO 3 HO Standard Side Load KAS574 KAS574.3HO-E 3 HO End Load Transom Closer KAS574.3NHO 3 NHO Standard Side Load KAS574.3NHO-E 3 NHO End Load KAS574.4HO 4 HO Standard Side Load KAS5784.4HO-E 4 HO End Load KAS574.4NHO 4 NHO Standard Side Load KAS574.4NHO-E 4 NHO End Load KAS575 KAS575 - DUMMY Standard Side Load Dummy Closer KAS575E - DUMMY End Load Scale n/a Sheet

33 Fabrication - Door Hardware - COC top arm options KAS No. KAS561.S Description Standard Side Load Top Arm Standard Side Load Drive Arm KAS No. KAS561.E Description End Load Arm (Finger guard door jamb) End Load Drive Arm KAS No. KAS561.SS Description Short Side Load Top Arm (Finger guard door jamb) Short Side Load Drive Arm Scale n/a Sheet

34 Fabrication - Door Hardware - COC Disk supports Top Pivot Arm Support Disc The Aluminum Alloy Component is Intended for use with our Anti Finger Trap and Wide Door Stiles It is Compatible with most Top Pivot Arm Support Brackets Profile ref. KAS27 KAS585 Full Disc Profile Ref. KAS67 KAS585L Left Hand Disc Profile Ref. KAS67 KAS585R Right Hand Disc Profile Ref. KAS31 KAS585W Wide Stile Disc Outside Sheet

35 Fabrication - Door Hardware - COC Disk supports The Aluminum Alloy Component is Intended for use with our Anti Finger Trap and Wide Door Stiles It is Compatible with most Top Pivot Arm Support Brackets The Support Bracket Should be Secured to the Casting via Hole A with a M6 x 12mm Csk Head Screw Profile ref. KAS27 Full Disc KAS585 Hole A Profile Ref. KAS67 LH Disc KAS585L Hole B Profile Ref. KAS67 RH Disc KAS585R Disc Support Bracket KAS591 Cleat Profile Ref. KAS31 Wide Stile Disc KAS585W M10 Threaded Tie Rod with Nyloc Nuts and 25mm OD, 10mm ID Form C Penny Washers Tie Rod Length = Rail Length + 40mm M10 20 When using Tie Rods with KAS12 Top Rails the Rail Cleat should be Positioned as Shown Above By Connecting the Top Arm Support Bracket to the Casting this can be used as a jig to position the remaining 3 Fixings, after the Door is Assembled. (It is Recommended that Rivnuts should be used at these 3 Locations in which case One leg of the Rail Cleat should be Cut Off to Avoid Interference at Hole B) Sheet

36 Fabrication - Standard side load top arm prep Sectional Inside Elevation at Top of Stile Stile to Rail Junction To give Access to the Closer Arm Clamping Block Machine Leg as Shown * M6 Threaded Inserts to be Fitted to the Top Rail before Assembling the Door Outside face KAS11 23 KAS12 KAS29 Plan at Top of STILE Showing Centres of Threaded Inserts Required for Top Arm Fixing RAIL LENGTH To give Access to the Closer Arm Clamping Block Machine Leg as Shown Inside face * 4 M6 Threaded Inserts to be Fitted to the Top Rail before Assembling the Door Outside face Hatched Area of Cleat to be Cut Away to Allow M6 Threaded Insert to pass the cleat on assembly Cutaway Plan of STILE/RAIL Junction Showing Modification Required to Top Rail Cleat Sheet

37 Plan of Door Leaf Clamping Screw Fabrication - Standard side load top arm assembly Inside face Spindle Clamping Block Winding this hexagon m/c screw out and winding the opposite screw in will adjust the alignment anti-clockwise. Vice versa for the clockwise adjustment. M6 Csk Screw KAS29 Slotted grub screw with loctite 65 M6 Csk Socket Head Screw Washer Side Load Arm By Relaxing this M6 Socket Head Screw and adjusting the Slotted Grub Screw it is Possible to Tilt the Door Leaf Slightly. Arm Channel Underside view of transom header Round Head Screw with serrated washer 70 Adjustment can be made without removing KAS24 plate closer. Clockwise turn - slower speed. Anti-clockwise turn - faster speed. 2 TURNS MAXIMUM. in either direction. 1 - Closing speed, 2 - Latching speed. Hexagon Screw M6 Csk Screw and serrated washer M6 Hexagon Nut 90 HO 1 2 Closer Jamb Connection Bracket HO - Hold Open NHO - Non Hold Open 90 - Opening Angle Header Bar Closer B Washer M6 Header Bar Closer Connection Bracket Sheet

38 Fabrication - Standard end load top arm prep Sectional Elevation at Top of STILE Elevation of Stile to Rail Junction M6 Threaded Inserts see drawing sheets 1 & 2 for support disks KAS591 Cleat KAS12 To give Access to the Closer Arm Clamping Block Machine as Shown Plan at Top of STILE Showing Centres of Threaded Inserts Required for Top Arm Fixing M6 Threaded Inserts 40 * KAS27 KAS67 Hatched Area of Cleat to be Cut Away to Allow M6 Threaded Insert to be Used at this Location Cutaway Plan of STILE/RAIL Junction Showing Modification Required to Top Rail Cleat Sheet

39 Fabrication - Standard end load top arm assembly Plan Looking down onto Top Rail of Door Leaf Clamping Screw KAS26 Spindle Clamping Block M6 Csk * Socket Head Screw KAS27 Winding this hexagon m/c screw out and winding the opposite screw in will adjust the alignment anti-clockwise. Vice versa for the clockwise adjustment. Both Screws must be fully wound out as illustrated M6 Socket Head Alignment screw Slacken off screw Re-tighten screw after adjustment * and adjust this screw to tilt the door within the opening aperture * 70 Round Head Screw with serrated washer Washer To Fix top Arm Channel to Top Rail Use M6 Screws Provided into M6 Threaded Inserts Underside View of Header Bar (with Closer Plate Removed) Arm Channel End Load Arm Adjustment can be made without removing KAS24 plate closer. Clockwise turn - slower speed. Anti-clockwise turn - faster speed. 2 turns max. in either direction. 1 - Closing speed, 2 - Latching speed. M6 Csk Screw This Locknut must be Fully Tightened following the Adjustment of the M6 Socket Head Alignment Screw Hexagon Screw M6 Csk Screw and serrated washer M6 Hexagon Nut 90' HO 1 2 Closer Jamb Connection Bracket HO - Hold Open NHO - Non Hold Open 90 - Opening Angle Header Bar Closer B Washer M6 Header Bar Closer Connection Bracket Sheet

40 Fabrication - Short side load top arm prep Sectional Elevation at Top of STILE Elevation of Stile to Rail Junction M6 Threaded Inserts To give Access to the Closer Arm Clamping Block Machine as Shown INSIDE FACE OF STILE ONLY KAS591 Cleat KAS Plan at Top of STILE Showing Centres of Threaded Inserts Required for Top Arm Fixing M6 Threaded Inserts see drawing sheets 1 & 2 for support disks * KAS27 KAS67 Hatched Area of Cleat to be Cut Away to Allow M6 Threaded Insert to be Used at this Location Cutaway Plan of STILE/RAIL Junction Showing Modification Required to Top Rail Cleat Sheet

41 Fabrication - Short side load top arm assembly Plan Looking down onto Top Rail of Door Leaf Winding this hexagon m/c screw out and winding the opposite screw in will adjust the alignment Clamping Screw KAS26 Spindle Clamping Block M6 Csk * Socket Head Screw KAS27 anti-clockwise. Vice versa for the clockwise adjustment. Both Screws must be fully wound out as illustrated M6 Socket Head Alignment screw Slacken off screw * and adjust this screw to tilt the door within the opening aperture Re-tighten screw after adjustment * KAS480A 70 Round Head Screw with serrated washer Washer To Fix top Arm Channel to Top Rail Use M6 Screws Provided into M6 Threaded Inserts Underside View of Header Bar (with Closer Plate Removed) Arm Channel End Load Arm Adjustment can be made without removing KAS24 plate closer. Clockwise turn - slower speed. Anti-clockwise turn - faster speed. 2 turns max. in either direction. 1 - Closing speed, 2 - Latching speed. M6 Csk Screw This Locknut must be Fully Tightened following the Adjustment of the M6 Socket Head Alignment Screw Hexagon Screw M6 Csk Screw and serrated washer M6 Hexagon Nut 90 HO 1 2 Closer Jamb Connection Bracket HO - Hold Open NHO - Non Hold Open 90 - Opening Angle Header Bar Closer B Washer M6 Header Bar Closer Connection Bracket Sheet

42 Fabrication - Standard side load top arm prep with 100mm stiles 40 Sectional Inside Elevation at Top of Stile Stile to Rail Junction 60 To give Access to the Closer Arm Clamping Block Machine Leg as Shown * see drawing sheets 1 & 2 for support disks M6 Threaded Inserts to be Fitted to the Top Rail before Assembling the Door NB: 100mm stiles use Standard side load arm - See drg _2 Plan at Top of STILE Showing Centres of Threaded Inserts Required for Top Arm Fixing RAIL LENGTH 179 To give Access to the Closer Arm Clamping Block Machine Leg as Shown M6 Threaded Inserts to be Fitted to the Top Rail before Assembling the Door Outside face 4 * Inside face KAS21 KAS30 KAS31 Hatched Area of Cleat to be Cut Away to Allow M6 Threaded Insert to pass the cleat on assembly Cutaway Plan of STILE/RAIL Junction Showing Modification Required to Top Rail Cleat Sheet

43 Fabrication - Bottom pivot KAS 87 with KAS29, 11 Sectional Elevation KAS13 20 x M6 Csk Pozi BZP Set Screws with M6 Nyloc Nuts and Serrated Washers M6 M6 KAS87 KAS87 Weatherstrip Profile Cut to Fit the Full Width of the Door after Assembly KAS KAS29 Pivot C L Once the Door Alignment is Finalized it is Advised that the Door Leaf Should be Removed in Order to Apply a Dead Fixing Screw to the Centre Hole of the Pivot Shoe Fix KAS87 Profile to Bottom Rail with 25 x No.10 Self Tapping Screws at approx 150mm Centres, Staggered about the Centre Line of the Profile KAS7 M6 M Door Leaf - View from Underside with KAS87 KAS33 Use detail with KAS11 & KAS 29 55mm door stiles Use detail with KAS 13 or KAS 33 bottom rails KAS Sheet

44 Fabrication - Bottom pivot KAS 87 with KAS27, 67 Sectional Elevation KAS13 M6 M6 Secure KAS87 into Bottom Rail of Door with No.10 x 25mm Twinfast self Tapping Screws M6 KAS87 KAS87 Weatherstrip Profile Cut to Fit the Full Internal Width of the Door after Assembly KAS KAS27 44 Once the Door Aligment is Finalized it is Advised that the Door Leaf Should be Removed in Order to Apply a Dead Fixing Screw to the Centre Hole of the Pivot Shoe KAS26 KAS7 M6 M6 Door Leaf - View from Underside KAS33 Use detail with KAS27 & KAS 67 Finger guard door stiles Use detail with KAS 13 or KAS 33 bottom rails KAS Sheet

45 Fabrication - Bottom pivot KAS 87 with KAS21, Sectional Elevation KAS13 Fix KAS87 Profile to Bottom Rail with 25 x No.10 Self Tapping Screws at approx 150mm Centres, Staggered about the Centre Line of the Profile M6 M6 M6 KAS87 20 X M6 Csk Head Screws with Hexagon Nuts and Serrated Washers KAS87 Weatherstrip Profile Cut to Fit the Full Internal Width of the Door after Assembly KAS1 70 KAS Once the Door Aligment is Finalized it is Advised that the Door Leaf Should be Removed in Order to Apply a Dead Fixing Screw to the Centre Hole of the Pivot Shoe KAS7 M6 11 Door Leaf - View from Underside KAS33 Use detail with KAS31 & KAS mm door stiles Use detail with KAS 13 or KAS 33 bottom rails KAS Sheet

46 KAS 576 Face fix closer KAS 576.DP drop plate Face applied closer KAS 576 Parallel arm 100 KAS KAS61 KAS1 KAS219 5 Packing block for parallel arm application KAS77 M M KAS 576.DP drop plate fixed to door rail with M6 csk screws via 6 holes as shown See drg sheet 2 for horizontal setting out csk Packing block available to special order KAS 576.DP KAS 576.DP (Drop Plate) Sheet

47 KAS 576 Face fix closer Face applied closer KAS 576 setting out on leaf KAS 576.DP drop plate Parallel arm For 120 max opening 220mm For 180 max opening 185mm KAS77 top rail Cover not shown For 120 max opening 117mm For 180 max opening 82mm 283 Internal elevation of rebated open out door 45 Hinge jamb (55mm stile shown as example only) Sheet

48 Haps butt hinge KAS 405H 45 KAS 405 H Knuckle Hinge KAS5 KAS1 2 part hinge with gasket pressure adjustment. Includes 2 backing plates with spring clips and all necessary main fixings Maximum door leaf weight if 2 hinges used: 120 kg Maximum door leaf weight if 3 hinges used: 140 kg Maximum door leaf sizes: 1250mm wide x 2100mm high 100 KAS61 KAS461 KAS KAS480 Gasket pressure adjustment = +/- 0.75mm Hinges are available from stock in Mill Finish Silver anodised Finish White powder coat Finish Centre line of complete hinge Drill 11.00mm Ø Holes as shown Be accurate!!! Drill jig available as special order See sheet 2 for recommeded hinge positions Scale Sheet

49 Haps butt hinge KAS 405H - Positions on stile Dimensions are taken to the Centre Line of the Hinge Prep and from ends of stile both top and bottom NB!! NB!! Important - Check you have correct clearances top and bottom of stiles before any drilling NB!! KAS12 (or KAS77) KAS13 (or KAS33) Recommended Hinge Positions Scale n/a Sheet

50 3D adjustable Haps butt hinge KAS 405H 45 KAS 405 H Knuckle Hinge KAS5 KAS1 2 part hinge with 3 way adjustment (3D). Includes 2 backing plates with spring clips and all necessary main fixings Maximum door leaf weight if 2 hinges used: 120 kg Maximum door leaf weight if 3 hinges used: 140 kg Maximum door leaf sizes: 1250mm wide x 2100mm high 100 KAS61 KAS461 KAS KAS Horizontal adjustment = +/- 3mm Gasket pressure adjustment = +/- 0.75mm Hinges are available from stock in Mill Finish Silver anodised Finish White powder coat Finish 6 8 Drill holes as shown Be accurate!!! Drill jig available as special order 20 Centre line of complete hinge Height adjustment = - 1mm + 4mm See sheet 2 for recommeded hinge positions Scale Sheet

51 KAS5 45 KAS1 AFL Stainless butt hinge KAS 409 KAS 409 Butt Hinge 100mm stainless steel butt hinge Fit to tap plates with M6 short csk hd screws 6 Use 1" x 1/4" aluminium bar for tap plates (KAS 397) Allow 6mm between door stile & jamb mullion 100 KAS61 KAS461 KAS29 KAS480A Packing piece Remove screw port for length of tap plate Remove section as shown prep 102mm long for fitting of hinge plate KAS29 KAS61 KAS Tap plate Scale Sheet

52 AFL Stainless butt hinge KAS 409 tap plate detail KAS KAS61 KAS Drill & tap 8 holes as shown for M6 machine screw Csk holes in mullion and stile to recieve M6 above and below hinge 47 Tap plate NON handed (Not by Kestrel) 100 M6 Scale Sheet

53 KAS 568 Top Centre 25mm maximum pin extension (less 4mm for thickness of KAS 24) NB. May not be able to retract pin fully as top will hit under side of KAS 25 Pin approx 45mm o/a Top Centre KAS 568 Sectional Elevation 15 Top Centre Housed Centrally on the Inside Face of the KAS24 on 2mm packs 15 KAS24 to be 250mm Long and fixed to 2No. 38 x 25 x 3mm Channels 70 Fix KAS 568 to KAS24 with M5 csk machines screws supplied in kit Add shake proof washers and lock nuts (not by Kestrel) 4 locations as shown Csk for M5 typ mm pack Hinge jamb (pivot) Drill clearance holes for 15mm pivot pin and adjustment screw Plan view M6 M6 Once the Door Aligment is Finalized it is Advised that the Door Leaf Should be Removed in Order to Apply a Dead Fixing Screw to the Centre Hole of the Pivot Shoe Eccentric Cam Bush gives 0.75 or 1.5mm Lateral Adjustment when Rotated thro. 90 or 180 degrees Respectively 30 Hinge jamb 70 (pivot) Pivot shoe installed in top rail See separate sheets for various applications by door type, stile/ rail combinations Sheet

54 Top Centre KAS 569 pivot shoe in Finger guard door Top Centre Shoe Fitted to finger guard door and KAS12 top rail Door Leaf - Section elevation M6 M6 Top centre Shoe Fixed to the Aluminium Strap with 15 x M6 Csk Head Machine Screws and Serrated Washers KAS12 KAS12 38 x 8mm Thick Solid Aluminium Strap Securly Fixed to the Top Rail of the Door KAS27 KAS5 45 KAS1 KAS26 Notch stile to allow plate & shoe to pass KAS27 Once the Door Aligment is Finalized it is Advised that the Door Leaf Should be Removed in Order to Apply a Dead Fixing Screw to the Centre Hole of the Pivot Shoe KAS Hinge jamb 70 (pivot) Pivot shoe KAS 27 or KAS 67 Finger guard door stiles KAS 12 top rail Door Leaf - Plan View Sheet

55 Top Centre KAS 569 pivot shoe in pivot door Top Centre Shoe Fitted to standard pivot door and KAS13 top rail Door Leaf - Section elevation Top centre Shoe Fixed to the Aluminium Strap with 15 x M6 Csk Head Machine Screws and Serrated Washers 40.2 M6 M KAS13 KAS13 38 x 8mm Thick Solid Aluminium Strap Securly Fixed to the Top Rail of the Door KAS29 KAS5 45 KAS1 5 Notch stile to allow plate & shoe to pass Once the Door Aligment is Finalized it is Advised that the Door Leaf Should be Removed in Order to Apply a Dead Fixing Screw to the Centre Hole of the Pivot Shoe KAS29 KAS Hinge jamb 70 (pivot) Pivot shoe KAS 29 or KAS 11 pivot door stiles KAS 13 top rail Door Leaf - Plan View Sheet

56 Flush bolt KAS 571 details KAS 571 Flush bolts - Satin chrome finish Flush bolt KAS 571.F (FLAT) for KAS 28, 84, 30 Flush bolt KAS 571.R (RADIUS) for KAS 10 Flush bolt KAS 571.G (Guide) Top of SLAVE STILE END VIEW 47 Guide Throw of bolt = 18mm 240 (NTS) Drill & csk for M5 fixings x 2 as shown (for guide) Top of SLAVE STILE SIDE VIEW Route with 5Ø bit to give 2.5mm corner radii Flush bolt preparation repeats for top and bottom of slave stile 23 Drill & csk for M5 fixings x 2 as shown (for flush bolt) Sheet

57 Letter Plate KAS 403 KAS14 Midrail 130mm mm Not to Scale 262mm Not to Scale R8 70 KAS KAS34 Midrail 170mm 45 8 R R4 KAS33 Bottom Rail 150mm R4 KAS mm Not to Scale mm Not to Scale mm Not to Scale 262mm Not to Scale All Letterplates feature; Sprung face plates (mill, silver & white) Brush piles internally Internal aperature 253mm w x 38mm h R4 R8 70 KAS Sheet

58 mm Diameter Clear Holes Pad Handles KAS 401 & KAS 401 8" Pad handle (200mm long) complete with 70mm long M6 stud and dome nuts KAS " Pad handle (300mm long) complete with 70mm long M6 stud and dome nuts 46 KAS 402 = 300 KAS 401 = 200 Vertical position of Pad Handles 25 There is NO set criteria for positions of handles in Building Regulations Approved Document M, we would suggest referal to the building's Access Statement for clarification, or follow guidlines for hand-rails; Position between 900mm and 1100mm from floor level KAS29 KAS 401 8" Pad handle (200mm long) Hole centres 150mm KAS " Pad handle (300mm long) Hole centres 250mm Drill 8mm Diameter Clear Holes at centres shown Sheet

59 Pole Handles KAS 412 on 54mm stiles KAS 412 Pole Handles (45mm Ø) tube 2134mm in height Brackets available from stock; Mill finish Silver anodised finish White powder coat finish Polished (stainless) finish M8 M KAS KAS KAS29 Outside Drill M8 clearance holes as shown 65 Fix brackets with M8 stud and dome nuts (Not by Kestrel) 45 M10 KAS 12 KAS KAS13 M10 30 KAS Sheet

60 Pole Handles KAS 412c on 100mm stiles KAS 412 Pole Handles (45mm Ø) tube 2134mm in height Brackets (cranked) available from stock; Mill finish Silver anodised finish White powder coat finish Polished (stainless) finish KAS 412 c CRANKED M10 M KAS KAS KAS31 Outside Drill M8 clearance holes as shown Drilling of cleat necessary Fix brackets with M8 stud and dome nuts (Not by Kestrel) M10 KAS 12 KAS KAS13 M10 30 KAS Sheet

61 33 Flush pull KAS 554 on 55mm & 100mm stiles KAS 554 Flush pull (Pair) Available from stock in; Mill finish Anodised finish White powder coat finish 48 SCALE KAS KAS 554 Flush pull Requires slot 35mm w x 85mm h - proposed setting out shown for 55mm stiles and 100mm stiles Fix with 4 x no 6 csk head self tapping screws SCALE 1.1 KAS & Sheet

62 KAS 416/17/18 tubular handles NB Do not use straight handles on 55mm stiles as these may cause finger trap or injury against jamb or meeting stiles - Always use 'D' or 'C' types set out as below KAS 416 Straight handle KAS 417 'D' handle KAS 418 'C' handle Vertical position of tubular Handles There is NO set criteria for positions of handles in Building Regulations Approved Document M, we would suggest referal to the building's Access Statement for clarification, or follow guidlines for hand-rails; Position between 900mm and 1100mm from floor level. Threaded handle outside KAS29 KAS31 47 Drill clearance holes for stud at 300mm centres M12 or M8 Grub screw handle inside KAS 417 'D' handle or KAS 418 'C' handle Sheet

63 Slave stile (Double door) KAS 502b lock prep details BAR BOLT Lock stile (Double or single door) Bar Route for bar keep 17mm w x 86mm h 4mm corner rad See also; Armour Strike KAS 508.RB Trim Strike KAS 509.RB KAS 502 B ( Bar bolt) 28.6mm (1 1/8) backset 45.2mm o/a lock case depth Drill 32mmØ holes for lock cylinder Hole per face per cylinder See also; KAS 521 KAS 522 Route for lock case 26mm w x 175mm h 4mm corner rad drill 2 x csk clearance holes for M5 fixing for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 512.BF (KAS29,31) KAS 512.BR (KAS11,21) Sheet

64 KAS 502h lock prep details HOOK BOLT Slave stile (Double door) Lock stile (Double or single door) Hook Route for bar keep 17mm w x 49mm h 4mm corner rad See also; Armour Strike KAS 508.RH Trim Strike KAS 509.RH KAS 502 H ( Hook bolt) 28.6mm (1 1/8) backset 45.2mm o/a lock case depth Drill 32mmØ holes for lock cylinder Hole per face per cylinder See also; KAS 521 KAS 522 Route for lock case 26mm w x 175mm h 4mm corner rad drill 2 x csk clearance holes for M5 fixing for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 512.HF (KAS29,31) KAS 512.HR (KAS11,21) Sheet

65 KAS 504b lock prep details BAR BOLT 25mm b/s Slave stile (Double door) Lock stile (Double or single door) Bar 10.5 Route for bar keep 15mm w x 70mm h 4mm corner rad See also; KAS 504 B ( Bar bolt) 25.0mm backset 41.0mm o/a lock case depth Armour Strike KAS 508.PB Trim Strike KAS 509.PB Drill 17.5mmØ & 10.5mmØ holes for lock cylinder Hole per face per cylinder Escutecheons KAS 520 See also; KAS 523 KAS 524 KAS 527 KAS 528 Route for lock case 26mm w x 197mm h 4mm corner rad drill 2 x csk clearance holes for M5 fixing for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 514.BF (KAS29,31) KAS 514.BR (KAS11,21) Sheet

66 Slave stile (Double door) KAS 504h lock prep details HOOK BOLT 25mm b/s Lock stile (Double or single door) Hook 10.5 Route for bar keep 15mm w x 48mm h 4mm corner rad See also; Armour Strike KAS 508.PH Trim Strike KAS 509.PH Trim Strike KAS 509K (SG frames) Trim Strike KAS 509K (DG frames) KAS 504 H (Hook bolt) 25.0mm backset 41.0mm o/a lock case depth Drill 17.5mmØ & 10.5mmØ holes for lock cylinder Hole per face per cylinder Escutcheons KAS 520 See also; KAS 523 KAS 524 KAS 527 KAS 528 Route for lock case 26mm w x 197mm h 4mm corner rad drill 2 x csk clearance holes for M5 fixing for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 514.HF (KAS29,31) KAS 514.HR (KAS11,21) Sheet

67 Slave stile (Double door) KAS 504b lock prep details BAR BOLT 30mm b/s Lock stile (Double or single door) Bar 10.5 Route for bar keep 15mm w x 70mm h 4mm corner rad See also; KAS 504 B ( Bar bolt) 30.0mm backset 46.0mm o/a lock case depth Armour Strike KAS 508.PB Trim Strike KAS 509.PB Drill 17.5mmØ & 10.5mmØ holes for lock cylinder Hole per face per cylinder Escutecheons KAS 520 See also; KAS 523 KAS 524 KAS 527 KAS 528 Route for lock case 26mm w x 197mm h 4mm corner rad drill 2 x csk clearance holes for M5 fixing for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 514.BF (KAS29,31) KAS 514.BR (KAS11,21) Sheet

68 Slave stile (Double door) KAS 504h lock prep details HOOK BOLT 30mm b/s Lock stile (Double or single door) Hook Route for bar keep 15mm w x 48mm h 4mm corner rad See also; Armour Strike KAS 508.PH Trim Strike KAS 509.PH Trim Strike KAS 509K (SG frames) Trim Strike KAS 509K (DG frames) KAS 504 H (Hook bolt) 30.0mm backset 46.0mm o/a lock case depth Drill 17.5mmØ & 10.5mmØ holes for lock cylinder Hole per face per cylinder Escutcheons KAS 520 See also; KAS 523 KAS 524 KAS 527 KAS 528 Route for lock case 26mm w x 197mm h 4mm corner rad drill 2 x csk clearance holes for M5 fixing for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 514.HF (KAS29,31) KAS 514.HR (KAS11,21) Sheet

69 Slave stile (Double door) KAS lock prep details AR Sentinel 6 30mm b/s Lock stile (Double or single door) ** Hook ** ** Ø17.5 Ø ** Route for bar keep 11mm w x 57mm h 4mm corner rad See also; Armour Strike KAS 508.S Trim Strike KAS 509.SF (Flat) Trim Strike KAS 509.SR (Radius) Drill 17.5mmø & 10.5mmø holes for lock cylinder Hole per face per cylinder ** See separate details for cyinder guards and escutcheons available for this lock type Route for lock case 26mm w x 197mm h 4mm corner rad drill 2 x csk clearance holes for M5 fixing for lock tabs in lock kit Spot tab centres with lock & tabs in place KAS (Hook bolt) 30.0mm backset 47.5mm o/a lock case depth Face plates: KAS 513.F (KAS29,31) KAS 513.R (KAS11,21) Sheet 4a

70 Slave stile (Double door) KAS 504h lock prep details HOOK BOLT 40mm b/s Lock stile (Double or single door) Use 100mm stiles with this lock case Hook Route for bar keep 15mm w x 48mm h 4mm corner rad See also; Armour Strike KAS 508.PH Trim Strike KAS 509.PH Trim Strike KAS 509K (SG frames) Trim Strike KAS 509K (DG frames) KAS 504 H (Hook bolt) 40.0mm backset 56.0mm o/a lock case depth Drill 17.5mmØ & 10.5mmØ holes for lock cylinder Hole per face per cylinder Escutcheons KAS 520 See also; KAS 523 KAS 524 KAS 527 KAS 528 Route for lock case 26mm w x 197mm h 4mm corner rad drill 2 x csk clearance holes for M5 fixing for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 514.HF (KAS29,31) KAS 514.HR (KAS11,21) Sheet

71 Slave stile (Double door) KAS 505r lock prep details latch lock 28.6mm b/s Lock stile (Double or single door) Standard strike (not electric release) KAS528T alternative to mounting tubes Route for latch strike 35mm w x 67mm h 4mm corner rad as shown See also; Latch Strike KAS 506.S (centre hung single door on to 100mm frame) Latch Strike KAS 506.D (applied to slave leaf stile as shown) KAS 505.R (Latch lock) 28.6mm backset 44.7mm o/a lock case depth Drill 32mmØ holes for lock cylinder Hole per face per cylinder See also; KAS 521 KAS 522 Route for lock case 26mm w x 175mm h 4mm corner rad drill & tap 2 x holes for M5 fixing through mounting tubes or drill separate M5 csk clearance holes for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 515.F (KAS29,31) KAS 515.R (KAS11,21) Sheet

72 Slave stile (Double door) KAS 505r lock prep details latch lock 38.1mm b/s Lock stile (Double or single door) Standard strike (not electric release) Remove mounting tubes - Use lock fixing tabs Route for latch strike 35mm w x 67mm h 4mm corner rad as shown See also; Latch Strike KAS 506.S (centre hung single door on to 100mm frame) Latch Strike KAS 506.D (applied to slave leaf stile as shown) KAS 505.R (Latch lock) 38.1mm backset 54.36mm o/a lock case depth Drill 32mmØ holes for lock cylinder Hole per face per cylinder See also; KAS 521 KAS 522 Route for lock case 26mm w x 175mm h 4mm corner rad drill M5 csk clearance holes for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 515.F (KAS29,31) KAS 515.R (KAS11,21) Sheet

73 Slave stile (Double door) 12.7 KAS 505p lock prep details latch lock 28mm b/s Lock stile (Double or single door) Standard strike (not electric release) Route for latch strike 35mm w x 67mm h 4mm corner rad as shown See also; Latch Strike KAS 506.S (centre hung single door on to 100mm frame) Latch Strike KAS 506.D (applied to slave leaf stile as shown) KAS 505.P (Latch lock) 28mm backset 44.7mm o/a lock case depth Drill 17.5mmØ & 10.5mmØ holes for lock cylinder Hole per face per cylinder Escutecheons KAS 520 See also; KAS 523 KAS 524 KAS 527 KAS 528 Route for lock case 26mm w x 175mm h 4mm corner rad drill M5 csk clearance holes for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 515.F (KAS29,31) KAS 515.R (KAS11,21) Sheet

74 Slave stile (Double door) 12.7 KAS 505p lock prep details latch lock 37mm b/s Lock stile (Double or single door) Standard strike (not electric release) Route for latch strike 35mm w x 67mm h 4mm corner rad as shown See also; Latch Strike KAS 506.S (centre hung single door on to 100mm frame) Latch Strike KAS 506.D (applied to slave leaf stile as shown) KAS 505.P (Latch lock) 37mm backset 54.4mm o/a lock case depth Drill 17.5mmØ & 10.5mmØ holes for lock cylinder Hole per face per cylinder Escutecheons KAS 520 See also; KAS 523 KAS 524 KAS 527 KAS 528 Route for lock case 26mm w x 175mm h 4mm corner rad drill M5 csk clearance holes for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates: KAS 515.F (KAS29,31) KAS 515.R (KAS11,21) Sheet

75 Locking jamb (Single door) Slave stile (Double door) 12.6 KAS536 NPLL Nemef 9600 Latch Lock 30mm b/s Lock stile (Double or single door) 67 70mm lock cylinder required. See KAS mm pack required here or use flat tab Bolt strike KAS 536 NBS Latch strike with ramp KAS 536 NLS KAS536 HTLH Lever/Lever handle set mm pack required here or use flat tab KAS 536 NPLL ( Nemef Latch Lock) 30.0mm backset 45.0mm o/a lock case depth Stainless Steel Forend Drill 17.5mmØ & 10.5mmØ holes for lock cylinder & 16.0mmØ hole for handle spindle, 2 x 6.0mmØ holes for M5 handle fixings (122.0mm centres) Repeat both sides See also; KAS537 35/35 cylinder variants (70mm) KAS536 HTLH Lever/Lever handle set (silver finish only) Route for lock case 25.5mm w x 245mm h no corner rad drill 2 x csk clearance holes for M5 fixing for lock tabs KAS 528T Spot tab centres with lock & tabs in place Face plates = lock forend Sheet

76 45 KAS540.S Bead glaze here KAS540 KAS 540 (single doors) detail on KAS1 KAS52 KAS1 Important Note: If glazing required to door side light at locking jamb - Pocket glazing sections CANNOT be used. Use KAS KAS 5 plain plate will NOT hit KAS 540 when used on NON glazed lock jambs KAS7 Extension KAS540 KAS540.S KAS540 KAS7 2.4 KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V fail safe or fail secure - field switchable. Scale Sheet

77 KAS 540 (single doors) detail on KAS1 prep sizes DETAIL A 100 Remove glazing pocket for 86mm about centre line as shown on detail A Remove to a depth of 2.5mm for 19mm above and below the 86mm dimension as shown on detail B 16.5 KAS1 R KAS540 C/L of Latch Strike face plate is 2.4mm thick Glazing pocket legs provide support to rear of strike face plate and allow through fixing to glazing pocket base on 105mm centres DETAIL B 32 KAS1 45 Preparation of mullion door jamb KAS1 Pivot door with KAS 540.F electric strike & subcover extension KAS 540.S 2.5 Please be accurate - test route on off cut first! KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V AC/DC Fail safe or fail secure - field switchable Sheet

78 45 KAS540.S KAS540 Bead glaze here KAS 540 (single doors) detail on KAS41 KAS52 KAS41 Important Note: If glazing required to door side light at locking jamb - Pocket glazing sections CANNOT be used. Use KAS KAS 5 plain plate will NOT hit KAS 540 when used on NON glazed lock jambs KAS45 Extension KAS540 KAS540.S KAS540 KAS KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V fail safe or fail secure - field switchable. Scale Sheet

79 KAS 540 (single doors) detail on KAS41 prep sizes DETAIL A 100 Remove glazing pocket for 86mm about centre line as shown on detail A KAS spacer 85.6 KAS C/L of Latch Strike face plate is 2.4mm thick spacer Add spacer blocks with fixing clearance holes 31.75mm wide (1 1/4") x 19mm long x 20mm thick to allow through fixing of strike to glazing pocket base on 105mm centres Preparation of mullion door jamb KAS1 spacer Pivot door with KAS 540.F electric strike & subcover extension KAS 540.S Please be accurate - test route on off cut first! KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V AC/DC Fail safe or fail secure - field switchable Sheet

80 45 KAS540.S Bead glaze here KAS540 KAS 540 (single doors) detail on KAS2 KAS52 KAS2 Important Note: If glazing required to door side light at locking jamb - Pocket glazing sections CANNOT be used. Use KAS KAS 5 plain plate will NOT hit KAS 540 when used on NON glazed lock jambs Mounting clip fixing Extension KAS540 KAS540.S KAS KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V fail safe or fail secure - field switchable. Scale Sheet

81 KAS 540 (single doors) detail on KAS2 prep sizes DETAIL A 100 Remove glazing pocket for 86mm/124mm about centre line as shown on detail A KAS R4 KAS Strike face plate is 2.4mm thick C/L of Latch Use mounting clips as supplied with strike Drill csk clearance holes for M5 on 155.6mm centres Clip 19 fix clips to give 105mm centres using fan washer nuts and pressure sensitive spacers between KAS2 and the clip as shown in detail B Ensure face plate of strike is flush with surface of KAS2 Preparation of mullion door jamb KAS2 DETAIL B Clip KAS2 Pivot door with KAS 540.F electric strike & subcover extension KAS 540.S Spacer Please be accurate - test route on off cut first! KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V AC/DC Fail safe or fail secure - field switchable Sheet

82 KAS 540 (double doors) detail on KAS28 KAS28 Important Note: * 55 KAS540 KAS 28 plain stile with KAS 540 electric strike 47 Mounting clip fixing KAS540.F KAS KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V fail safe or fail secure - field switchable. Scale Sheet

83 KAS 540 (double doors) detail on KAS28 prep sizes DETAIL A 47 KAS28 Remove profile for 86mm/124mm about centre line as shown on detail A R4 KAS Strike face plate is 2.4mm thick C/L of Latch Use mounting clips as supplied with strike Drill csk clearance holes for M5 on 155.6mm centres Clip 19 fix clips to give 105mm centres using fan washer nuts and pressure sensitive spacers between KAS28 and the clip as shown in detail B Ensure face plate of strile is flush with surface of KAS28 DETAIL B KAS28 Preparation of door stile KAS28 Clip Spacer Pivot door with KAS 540 electric strike Please be accurate - test route on off cut first! KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V AC/DC Fail safe or fail secure - field switchable Sheet

84 KAS 540 (double doors) detail on KAS10 KAS541 KAS10 Important Note: * 55 KAS 10 plain radius stile with KAS 540.R electric strike Use radius face plate as supplied 47 * Mounting clip fixing KAS540.F KAS KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V fail safe or fail secure - field switchable. Scale Sheet

85 KAS 540 (double doors) detail on KAS10 prep sizes DETAIL A 47 KAS10 Remove profile for 86mm/124mm about centre line as shown on detail A R4 KAS Strike face plate is 2.4mm thick C/L of Latch Use mounting clips as supplied with strike Drill csk clearance holes for M5 on 155.6mm centres Clip 19 fix clips to give 105mm centres using fan washer nuts and pressure sensitive spacers between KAS10 and the clip as shown in detail B Ensure face plate of strile is flush with surface of KAS10 DETAIL B KAS10 Preparation of door stile KAS10 Clip Spacer Pivot door with KAS 540.R electric strike & radius face plate Please be accurate - test route on off cut first! KAS540.F (flat) KAS540.R (Radius) UltraLine strike - 12/24V AC/DC Fail safe or fail secure - field switchable Sheet

86 KAS 451 (261 Armlock) magnet & brackets Head Structure Adjustable L bracket Armature * 261 Armlock 25 KAS93 50 Non moving part KAS24 L & Z bracket Door opens in * Important - Ensure that the soffit clearance KAS12 is sufficient to allow the door with armature and L & Z brackets to open without fouling. KAS 451: Standard 261 Armlock model = 250mm long Armature = 160mm long = adjustable bracket 48mm x 30mm x 5mm thk and 250mm long (fits Armlock to door header bar) Outside = L & Z brackets 50mm x 50mm x 5mm thk and 160mm long (fits armature to door top rail) 45 NB: Use FULLY rectified DC power supply (magnet will not function on AC supply) Scale Sheet

87 KAS 446 Codelock: Codelock 200 Mechanical 60mm backset (use with 100mm stiles only) KAS 446 (255 codelock) prep details to KAS31 80 KAS31 Barrel must NOT enter strike Codelock body repeats on each side of stile Use KAS 528T lock tab with 3mm thk spacer to fix latch flush to stile face Centre line of latch See template supplied also 100 Scale Sheet

88 KAS 557 (Simplex 3000) product spec only KAS 557 Simplex 3000 key pad Use KAS 505.R (4710) dead latch with 28.6mm (1 1/8") backset - See drg Sheet 1 Important Note - Key pad drive to latch are factory handed - See codes below Elevations viewed on OUTSIDE for open in or open out doors Door hinged on LEFT KAS 557 L Drive assembly required Door hinged on RIGHT KAS 557 R Drive assembly required KAS 557 Simplex 3000 key pad Cardboard drilling template is provided in kit; LH 1 1/8" backset = template code (LH Drive assembly code = 74418) RH 1 1/8" backset = template code (RH Drive assembly code = 74416) Metric conversions: 3/32" = 2.38mm (pilot holes sizes) 3/8" = 9.525mm (Hole A) 7/8" = mm (Hole B) 1/4" = 6.35mm (Hole C) Scale n/a Sheet

89 KAS 557 (Simplex 3000) iso detail KAS 557 shown as example KAS 557 R on open out lock stile part number sheet