INTRODUCTION Tools Required Laminate Washroom Products... 4 DUCT PANELS Fixing the Frame: Fixing the Shadow Panels...

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2 Contents INTRODUCTION... 2 Tools Required... 3 Laminate Washroom Products... 4 DUCT PANELS... 4 Fixing the Frame:... 5 Fixing the Shadow Panels... 9 Fitting the Duct Panels: WASHSTATIONS Fixing the Frame Fitting the Top Fitting the End Panel CUBICLES Assembling Pilasters: Setting Out and Fixing Cleats: Fixing Division Panels: Preparation for Fixing Pilasters: Fixing Pilasters: Fixing Doors: Fixing Accessories... 36

3 INTRODUCTION Thankyou for choosing Trovex range of laminate washroom products. Please follow this guide to ensure these products are installed to a high standard to give you many years of service. This is a guide to installation which will assist the skilled installer to achieve perfect installation. If you need further guidance, please call the technical department on Trovex

4 Tools Required Hammer Drill Cordless Screwdriver Hammer 1200mm (4 ) Level Tape Measure Square Soft Jaw Clamps (for Head Rail) Hacksaw File Pozi Screwdriver no.2 Sharp Pencil Wooden Block (temporary support for Divisions) - 150mm tall for K2:12 & S3:60 and 100mm for X5:80 Packers (temporary support for Divisions) 7mm Masonry Drill 3.5mm HSS drill bit (supplied) 9.5mm HSS drill bit (supplied) Fittings as below: Interbolt Cleat Hinge Pedestal Installation Guide 3

5 Laminate Washroom Products This guide covers the installation of SYSTEM S3:60, SYSTEM K2:12 and SYSTEM X5:80 If you have any questions, the Trovex support team is available on Please take note of the system variations and special features highlighted like this. 4 Trovex

6 DUCT PANELS Fixing the Frame: 1. Consult drawings. 2. Cut a timber to length for the base, place on floor correct distance from wall (refer to drawings) and fix to floor. 3. Mark on the base timber, the positions of uprights and double check with drawings. Framing to be supplied by the contractor Installation Guide 5

7 4. Cut end upright, allowing enough room for a batten to run across the top of the frame. Fix the end uprights. Tip: you may want to fit a few brackets to the wall batten ready for fixing the end panel. Refer to Fitting the Duct Panels, step Trovex

8 5. Cut and fix top batten(s). 6. Working from one end, cut and fix uprights, working to the marks on the base timber, and fix in position. Ensure the battens are plumb. Installation Guide 7

9 7. Cut 9mm ply plinth to length and fix level at 100mm high (not following the floor) along the entire length of the frame. 8. Cut and fix additional supports to the back wall to support uprights. These need to be placed about half way up the height of the upright. 8 Trovex

10 Fixing the Shadow Panels 1. Cut the horizontal top shadow tight between the walls (on an enclosed range) or flush with the end of the frame (on a corner or freestanding range) 2. Fix the top shadow as shown on the diagram below, taking care to place screws where they will be hidden by the duct panels. 3. Once top shadow is fixed, butt the vertical shadows up to it, and mark the shadow length, level with the top of the plinth and cut. 4. Fix the vertical shadows taking care to place screws where they will be hidden by the panels. Installation Guide 9

11 Fitting the Duct Panels: 1. Mark the heights of duct panels near the edge of the shadows. 2. Insert the panel clips into the groove on the shadow as shown using the lines to guide where the clips should be located, and fix with two screws. For Urinals, the bottom panel needs to be on push-in clips 10 Trovex

12 3. Place bottom panels against the duct, spaced out according to drawings, then adjust to equalise the spacing between each panel 4. Mark on the shadow panels either side of each duct panel with a pencil line Installation Guide 11

13 5. Offer the first panel up to the lines you have marked (height and width), and clamp into position, checking it is level and plumb. 6. Using second part of panel clip as a template, mark screw holes for all four clips. 7. Release clamps and fix clips to panel using 4x16 screws for particle board core and 4x12 screws for SGL panels. It is essential that the protective film is REMOVED from the rear of the panel to prevent bowing of the panel. 8. Clip panel into correct position, and check all levels and lines. 9. Repeat process for each bottom panel. 12 Trovex

14 10. Place second panel on top of first and repeat the marking and fixing processes. 11. Repeat for third and fourth rows 12. until the set is complete. Installation Guide 13

15 13. Fit the end panel using corner brackets or push-in clips as appropriate. 14. Your Duct Panel will now look like this. 14 Trovex

16 WASHSTATIONS Fixing the Frame 1. Consult drawings supplied 2. Set out for the frame as detailed on the drawing 3. Check that the panels are numbered on the reverse, and then remove panels from the frame, and set aside 4. Fix supplied floor brackets to the rear of the plinth Installation Guide 15

17 5. Fix frame to the floor and the wall using the setting out marks 6. Fix horizontal batten to the wall, level with the front rail of the frame The wall batten is supplied by the contractor 16 Trovex

18 Fitting the Top 1. Fix small brackets to the front edge of the batten, in line with the upright frame posts. This saves the basin cutouts conflicting with the brackets 2. Sit the top onto the batten and the frame Installation Guide 17

19 3. Fix the back edge of the top through the small brackets using 16mm screws supplied 4. Fix the front of the top though the front rail using 25mm screws supplied 18 Trovex

20 Fitting the End Panel 1. Cut the plinth return to length, scribe to skirting as necessary, and fix using brackets supplied. 2. Fix small brackets to the wall and the frame, to receive the end panel. 3. Fit the end panel to the brackets using the screws supplied. If the panels are SGL, then a pilot hole will need to be drilled. Use 3.5mm drill bit supplied. Installation Guide 19

21 CAUTION! Do not drill right through the panel! Max drill depth 11mm. 4. Refit the front panels by carefully pushing each numbered panel back into the correct numbered location, firmly onto its clips. 20 Trovex

22 CUBICLES Assembling Pilasters: For Inward opening doors Assemble the pilasters as shown. For Outward opening doors on Inline cubicles To ensure the door does not foul the top of the pedestal, these need to be fitted either: a) At least 60mm (to centre of pedestal) from edge of door opening, or b) On the inside of pilaster. A standard pilaster will be okay with an outward opening door. For wall end pilasters, check whether a pedestal will sit neatly on the floor before drilling the fixing holes narrow end pilasters and a coved vinyl floor often mean that the pedestal won t sit on the floor properly. Fittings You will need Pilaster Pack CU51201H for each pilaster fixed to a division, and packs CU51202H & CU51213H for each end pilaster fixed to the wall. Method 1. Drill holes through pilaster for pedestal fixings in centre of width 2. Fit 3 cleats into predrilled holes using an interbolt and a taptite screw for each 3. Fit 2 hinges into predrilled holes with an interbolt and a taptite screw for each 4. Fit 2 door buffers as required into predrilled holes using 4.0x13mm screws 5. Fit pedestal into holes drilled by installer using the fixings supplied with the pedestal Do not drill out or deepen any existing holes provided! Installation Guide 21

23 S3:60 & K2:12 X5:80 S3:60 & K2:12 X5:80 For SYSTEM X5:80, the pedestal must be fitted to the division panel, not the pilaster! Pilasters over 300mm wide may require 2 pedestals! Please refer to job specific layout drawing which will indicate how many pedestals are required for each pilaster (75mm from the edge of the pilaster). 22 Trovex

24 Setting Out and Fixing Cleats: Set out cubicle centres on rear wall or ductwork as per Trovex drawings and fix wall cleats (pack CU51202H) with 5x50 countersunk screws and plugs if fixing to wall, or 5x25 countersunk screws if fixing to duct panel system. Fix at heights to match the heights of the cleats on the pilasters. (The standard heights for wall cleats are 300mm, 1100mm and 1890mm to the top of the cleat.) For K2:12 cubicles with cutout division panels, you will only need the lower two wall cleats! Check before you fix! Installation Guide 23

25 Panel-to-wall cleats CU51202H 24 Trovex

26 Fixing Division Panels: Floor Levels will need to be assessed before setting out each Cubicle Range. It is advisable to set out starting from the highest point in the room. 1. Offer division up to wall cleats and support with 155mm high wooden blocks and packers as necessary to ensure the blocks are level with each other (for X5:80, the division will be supported and adjusted with the 100mm pedestal on the division see inset). Pedestal fixed to division for X5:80 2. Check that the front edge of the division is plumb using packers on the wooden blocks as necessary. 3. Fix the division to the wall cleat by drilling through the cleat and the panel with the 9.5mm HSS drill bit provided. (When drilling, it is advisable to position a wooden block to the reverse face to prevent laminate breakout.) 4. Insert interbolts and tighten using allen key provided. Installation Guide 25

27 5. Repeat the above operation for all other divisions checking that each division is level with the previous one, and plumb on the front edge. 26 Trovex

28 Preparation for Fixing Pilasters: 1. Stand first pilaster upside down (pedestal uppermost) in front of the first division (numbered to correspond with drawing) 2. Wind out foot until top of pilaster is level with the top of the division panel. Lock adjustable foot by tightening the upper grub screw. 3. Turn the pilaster the right way up, and place in position on front of division. 4. Drill centre cleat hole only, using 9.5mm drill and insert interbolt this only needs to be fingertight. Installation Guide 27

29 5. Repeat this process for each division panel. 6. Mark up for cleats to hold end pilasters, using a straight edge across the front of the other pilasters, ensuring that the pilaster is pushed against the division, as per diagram below. Check wall cleats are plumb. This line will represent the outside edge of the pilaster panel not the fixing centre line see cleat diagram below. Follow steps 1-4 above to position the end pilaster. 28 Trovex

30 7. Fix the three wall cleats using appropriate wall fixings at the same heights as all the other cleats, so that the end pilaster is in line with the other pilasters. Panel-to-wall cleats CU51202H 8. Fit the end pilaster using the same process as above, and make sure it is level with the next one. Installation Guide 29

31 9. Equalise the door openings (as detailed on the layout drawings) by measuring the opening near to the bottom of the pilasters and adjusting the position of each pilaster till all the door openings are equal. 10. Mark the floor around each pedestal using a pencil, ensuring that the pilaster is pushed against the division. 11. Remove the pilasters from the division panels by releasing the central interbolt, and set aside. 30 Trovex

32 Fixing Pilasters: 1. Drill floor fixing holes in the center of each mark on the floor, and fix the locator plug to the floor. 2. Stand pilasters over the locator plugs. Replace interbolt through the central pilaster cleat. Installation Guide 31

33 3. Drill remaining interbolt holes making sure that each pilaster is pushed tight against the division. 4. Insert all interbolts and tighten. 5. Fix pedestal to locator plug by tightening the lower grub screw. 32 Trovex

34 6. Cut head rail exactly to length. Offer up and clamp headrail to wall end pilaster(s). Drill through headrail screw holes in end pilasters from inside the cubicle and just into the headrail, using 3.5mm drill bit. 7. Fix with 4 x 30 pan-head self-tapping stainless steel screws included in the Pilaster fitting pack. 8. Adjust each centre pilaster so that it is vertical and then it clamp to the headrail. Drill and fix pilaster to headrail as above. 9. Repeat this for each pilaster. Installation Guide 33

35 10. Fix head rail end cap(s) (CU512/808H) where required. Headrail end cap CU512/808H 11. Your cubicle range will now look like this. 34 Trovex

36 Fixing Doors: Assemble the cubicle door lock Turn round For inward-opening doors use fitting pack CU51202H, with long end of shoot bolt into keep For outward-opening doors use fitting pack CU51204H, with short end of shoot bolt into keep 1. Fit the hinges to the door using the interbolts provided. 2. Hang the doors. The plastic insert in the hinge assembly can be set to either fall open or fall closed. Make sure all the plastic inserts are facing the same direction. 3. Standing inside the cubicle when the door is shut, check that the lock is level and fix the top of the indicator bolt using the screws provided. For SGL doors, a pilot hole will be required. Use 3.5mm drill bit supplied. CAUTION! Do not drill right through the door! Max depth 11mm Installation Guide 35

37 4. Mark the position of the keep onto the pilaster, leaving at least a 4mm gap between the open position of the bolt and the keep. Drill the large hole with a 10mm bit right through the panel (using a block of timber on the far side to prevent breakout) and drill the small hole with a 5mm bit only 8mm deep. WARNING: Do not drill right through the panel! 5. Your cubicle range should now look like this. Fixing Accessories 1. Finally, fix toilet roll holders (CU51212H) to partitions (back-to-back for strength) and fix coat hooks (CU51211H) to division panels (not the door) in clear swing of the door. 2. Check that all fixings including interbolts and pedestal adjustment screws are secure. 36 Trovex

38 Notes Call for installation advice or technical support. Installation Guide 37

39 2014 Focus Trovex LLP. All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing it in any medium by electronic means and whether or not transiently, or incidentally to some other use of this publication) without the written permission of the copyright owner. Application for the copyright owner s permission to reproduce any part of this publication should be addressed to Trovex. Trovex reserves the right to alter specification and designs without prior notice. 38 Trovex

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