PRODUCT INFORMATION MANUAL SECTION: 2A TIMBER SHUTTERS TIMBER SHUTTERS
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1 TIMBER SHUTTERS
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3 TIMBER SHUTTERS TECHNICAL MANUAL PAINTED PANELS MATERIAL Made from a low density, light colored hardwood timber, with a fine texture and minimal blemishes. The Shutter panel is finger-jointed and laminated using the latest reverse-grain technology. This process allows for more homogenous strength throughout the profile length and a more efficient yield from the tree, resulting in both a more environmentally friendly and economical finished product. COLOURS The painted panel comes standard in 5 neutral colours. Custom colours are available. Any colour chosen from the Dulux fan-deck specifier 2 will not require a sample; however, all other custom colour requests require a high-quality paint brush out. Custom colours may vary due to sheen levels. CONSTRUCTION Stile to rail joints are constructed with a fluted mortise and tenon engineered dowel system. The tenon dowel is fluted in order to force the glue to cover the entire joined area of the panel, thus creating a rail connection, which will support the panels weight and size. The size of the tenoned dowel will change in accordance with the specified rail dimensions, adding further stability. This, coupled with waterproof Aquadhere glue (warranted against delamination, even in moist areas) will give the connecting points of the panel greater strength than the timber itself. This unique construction process allows larger single spans per panel. This is an important feature as you can often place fewer panels in a window and maximise both the light and view potential of a window. COATING SYSTEM Coated with a specialised Polyurethane system, which includes 3 undercoats and a topcoat. Two undercoats are applied prior to assembly and one coat after assembly, creating a perfectly even surface area to apply the final topcoat. The shutters have a 30% sheen level, which provides the optimal combination between the natural insulation properties, its ease of cleaning and overall aesthetic look and feel. The final product has a uniquely smooth finish. INSTALLATION METHODS Hinged Panel, Framed, Bi-fold, Fixed, Track Bi-fold and Track Sliding. PANEL COLOUR White Silk White Shell Ivory Alabaster HINGE COLOUR White White White Ivory Ivory REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 3 OF 31
4 STAINED PANELS MATERIAL Made from Premium Basswood, which is light in color, has a fine uniform texture and an indistinct straight grain. The specific timber properties of Basswood enhance the stain coloring process, making it the ideal choice for darker panels. Due to the staining process, solid profile lengths are used which have been color matched by order for superior consistency in finish. COLORS Comes standard in 7 Stain finishes. Custom stains are available on request. CONSTRUCTION Using the same fluted mortise and tenon joint system which is employed across the breadth of the entire shutter range, the Basswood shutters can span the largest single solid panel distances in the industry. COATING SYSTEM The Basswood Stain has an NC (nitro-cellulose) sprayed or wiped finish. After the initial machine sanding, the shutter is then detailed, stained, sealed and sanded 3 times prior to the final top coat. This is to keep a smooth and more even finish across the grain and texture lines. INSTALLATION METHODS Hinged Panel, Framed, Bi-fold, Fixed, Track Bi-fold and Track Sliding. PANEL COLOUR Light Oak Golden Oak Cherry Walnut Black Walnut Black Honey Oak HINGE COLOUR Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 4 OF 31
5 SPECIFICATION CHART SPECIFICATION Blade Profile Elliptical Elliptical Flat Urban Block Elliptical Blade Sizes Blade Thickness Stile Sizes BEADED: 35mm, 51mm FLAT: 35mm, 51mm, 65mm, 90mm Stile Depth 26mm Rail Depth 20mm Tilt Rod Centre / Clearview / Offset40 in Traditional LIMITATIONS Maximum Panel Height 3000mm Minimum Panel Height 400mm Minimum Panel Width 200mm Mid 1800mm Second Mid 2700mm MAXIMUM PANEL WIDTHS Hinged/Fixed/Sliding Hinged Bi-Fold 600mm Track Bi-Fold 600mm Joined Panel 2000mm ACCESSORIES Frames L Frames / Z Frames & Face Mount Decorative frames Hinges Non-Mortise / Pivot / Bi-Fold Track Sliding Yes Track Bi-Fold Yes Shaped Shutters Yes Fixed Blades Yes Fixed Panel Yes Solid Panel Yes Bay Window Yes Corner Window Yes T-Posts Yes Mouse Hole Round Timbers/Strips 19 x 19, 33 x 20, 26 x 33, 26 x 40, 26 x 65, 33 x 33 Pelmet Head Sizes 100 x 18, 180 x 18, 220 x18 Pelmet Fascia Sizes 65 x 12, 95 x 12, 140 x 12 REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 5 OF 31
6 BLADE SIZES 64MM ELLIPTICAL BLADE 89MM ELLIPITICAL BLADE 115MM ELLIPTICAL BLADE 89MM URBAN BLOCK BLADE 89MM FLAT BLADE REVEAL CLEARANCE FOR BLADE OPERATION IMPORTANT: Check the depth of the reveal for clearance of the shutter blades (handles, louvres etc) Blade Size Tilt Mechanism Clearance 64mm Centre 47mm 64mm Clearview 54mm 89mm Centre 60mm 89mm Clearview 67mm 115mm Centre 72mm 115mm Clearview 79mm NOTE: Clearance is the measurement from the front of the Panel/Frame to the Rear of Blade/Tilt Rod. Optimal frame choice is 67mm. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 6 OF 31
7 HINGES Number of Hinges Per Panel Panel Height Hinge Quantity < 1220mm mm mm mm mm mm mm 5 Hinge colours HS100 White HS103 Ivory HS200 Chrome HS201 Stainless Steel Hinge Clearances Hinge Type Width Height Non-Mortise 2.5mm n/a HS202 HS203 HS207 Brass Antique Brass Black Pivot 2.5mm 14mm Bi-Fold 2.5mm n/a Hinge colour selection is automatic, unless otherwise noted on the order. Ivory White Stainless Steel Brass Black Antique Brass Chrome REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 7 OF 31
8 TILT RODS CLEARVIEW The Clearview tilt rod is placed at the rear of the shutter and screwed to the end of blades on the hinged side of the shutter. The Clearview tilt rod protrudes the rear of the blade by approx 7mm. OFFSET An alternative take on the tradtional center rotation. Minimises view interruption. TRADITIONAL CENTER The Timber tilt rod is placed on the front of the panel and is attached by stainless steel staple to staple method. SPLIT ROTATION The below table describes where the tilt rod rotation will automatically split into 2 parts. The number of louvers indicates the amount between either: 1) The top and bottom rail 2) The divider rail and top/ bottom rail Louvre Size 64mm <21 89mm** <15 114mm >10 Number of Louvers **89mm includes flat and light block blades STANDARD TILT ROD DIMENSIONS Applies to all front facing tilt rods. Clearview & Offset 40 tilt rods are placed on the hinged side of the shutter by default, with the exception of fixed panels where the tilt rod is placed on the left side of the shutter by default. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 8 OF 31
9 If you require a specific mid-rail position to work CRITICAL MID-RAIL with a particular point in a window, such as a storm bar, the option critical mid-rail must be selected on the order form. We will align the center point of the mid-rail to the dimension If you require a specific mid-rail position to specified on you order. work with a particular point in a window, such as a storm bar, the option critical mid-rail We will communicate with you if adjustments must be selected on the order form. We will are required for the panel to achieve this midrail position, as modification may alter the struc- align the center point of the mid-rail to the dimension specified on your order. tural stability or the panels aesthetics. We will communicate with you if adjustments are required for the panel to achieve this MEASURING : midrail position, as modification may alter the We require you to measure from the floor level structural stability or the panels aesthetics. to the center position of the storm-bar / window mullion and provide us with that measurement. If you do not specify your mid-rail as critical, the MEASURING : panel aesthetics may alter the exact position by We require you to measure from the floor level a minimal amount. For example, if you order an to the center position of the storm-bar / window 89 mm blade, the variation in the center point mullion and provide us with that measurement. of the mid-rail can vary plus or minus 44 mm. If you do not specify your mid-rail as critical, In this case, if you requested 800 mm it may be the panel aesthetics may alter the exact 840 mm. position by a minimal amount. For example, if you order an 89 mm blade, the variation in the center point of the mid-rail can vary plus or minus 44 mm. In this case, if you requested 800 mm it may be 840 mm. STANDARD PANEL WITH NON-MORTISE HINGE FIXED PANEL Inside Mount Deduction between Panel and Inside Mount Deductions Reveal is 2.5mm. between Panel and Reveal is 2.5mm. No 19x19mm Light Block is supplied when Y deductions are made is selected for Left, Right, Top or Bottom on Inside Mount Deduction between between panels. Panel order form. and Reveal is 2.5mm. Panels are fixed in place The window opening dimension is required 19x19mm Light Block with is 19x19mm supplied timber when when ordering. Y is selected for beading Left, Right, 4 sides, Top on or Bottom on order form. sides of the panel (as per both drawing below). The window opening dimension is required when ordering. The window opening dimension is required when ordering. Inside M and Rev made be Panels a timber b the pane The win quired w REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 9 OF 31
10 L-FRAME OPTIONS Small Frames are designed to clear the 64mm centre tilt rod blade, Medium will clear the 89mm centre tilt rod blade & the Large 74mm will clear the 115mm Centre tilt rod blade, with the exception of the Clearview Tilt Rods which protrude 7mm Flat L 47 Custom 35Wood Shutter Specification40 Beaded L 47 Insert L Flat L Custom 57 Wood Shutter Specification Beaded L Insert L Flat L Beaded L Insert L 74 ***Frames are joined together using Butterfly Clamps (hoffman keys). 3 sided frames, by default, are supplied with Light Block for the 4th side. Max Length of frame/timber is 3000mm (longer will be cut in centre)*** REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 10 OF 31
11 2 FRAME OPTIONS SILL PLATE A Sill Plate is simply an L Frame used for one or more sides of the frame, where a Z frame will not fit. For example: a window with a Sill, cannot use a Z frame on the sill side, so a Sill Plate is used. To order, place a Y for the Frame side and in the notes write Sill Plate Required for Bottom/Top side etc. BAY/ CORNER/ T-POSTS REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 11 OF 31
12 D-MOULD Mould is a cover strip used to block the light from between meeting panels. Panel Configuration example: L-DR, indicating the D-Mould will be attached to the Right hand panel. standard deductions Standard Deductions Standard Panel and Reveal Fixed Panel and Reveal Between Meeting Panels Between Meeting Panels w/d-mould Between Panel and Frame Between Frame and Reveal Non-Mortise Hinge Bi-Fold Hinge Pivot Hinge Width Pivot Hinge Height (per hinge) Top Track Bottom Track (bi-fold and sliding) Bottom Sliding w/ Floor Guide Bottom Track Recessed (bi-fold & sliding) Bottom Bi-Fold Pivot Height Bottom Bi-Fold Pivot Width 2.5mm 2.5mm 2.5mm 5mm 2.5mm 2mm 2.5mm 2.5mm 2.5mm 7mm 52mm 20mm 10mm 28mm 20mm 5mm Standard Timbers 19 x 19mm 33 x 20mm 26 x 33mm 26 x 40mm 26 x 65mm 33 x 33mm **Max length of Frame and Timbers is 3000mm (over this length will be cut in centre) Bottom Bi-Fold No Track 20mm NOTE: If you require the ends of the Timbers to be sanded & painted, please select from the Special Instruction box on the order form REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 12 OF 31
13 COMPONENT LIST - STILES RAILS - STANDARD REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 13 OF 31
14 BULLET MAGNETS Bullet magnets come standard rebated into the top and bottom of panel. No bullet magnets are supplied for Sliding with track, Bi-fold with track, or Fixed panel. Please see below for striker plate placement with respective panel configurations. Framing Hinge Mounting Light Block Striker Plates Notes Framed Panels N/A N/A No 3 Sided Frame N/A N/A No Panel Only Non-Mortise Inside Yes Panel Only Non-Mortise Inside No Panel Only Pivot Inside Yes Panel Only Pivot Inside No Panel Only Pivot Outside No Round, attached to frame Round, attached to frame at top and light block at bottom 2 Round, attached to beading 2 L striker, supplied loose 2 Round, attached to beading 2 L striker, supplied loose 2 Round, supplied loose If 10mm door clearance is selected, no light block or bottom magnet is supplied NOTE: Magnets also supplied loose. NOTE: If frame or panel is supplied with a top section and no bottom section, a round striker plate is supplied for the top and a L supplied for the bottom. If panels are reverse hinged, the magnets will be inserted into the front of the panel by default REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 14 OF 31
15 MEASURING AND INSTALLING REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 15 OF 31
16 STANDARD PANEL WITH PIVOT HINGE INSIDE MOUNT The Window Opening dimension is required when ordering. To order rebates for Pivot Hinges, note Pivot Hinge Rebate in the Special Instruction field on the order form. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 16 OF 31
17 STANDARD PANEL WITH PIVOT HINGE OUTSIDE MOUNT The outside dimension of panels is required when ordering. To order rebates for pivot hinges, note Pivot Hinge Rebate 7mm in the Special Instruction field on the order form. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 17 OF 31
18 PELMETS - 3 TYPES AVAILABLE INSIDE MOUNT Pelmet is fixed into the opening and the headboard is screwed up into the opening, the Fascia will sit flush with the front of the opening and will not have returns. OUTSIDE MOUNT Pelmet is fixed on to the outside of the opening, normally above the architrave. The Headboard is attached using a 30x30mm cleat. Fascia and full length Returns are supplied. SEMI REVEAL MOUNT Pelmet is fixed half in the opening and half out of the opening and the Headboard is screwed up into the opening. An Outside Mount Fascia and Returns are supplied, the Returns will stop short of the width of the Pelmet and hit the face of the opening. To Order: note Semi Reveal Mounted Pelmet in the Special Instruction field on your order form. BI-FOLD PELMET WITH TRACK INSIDE MOUNT & REVEAL MOUNT When measuring, please provide the reveal opening dimensions. OUTSIDE MOUNT When measuring, provide the Bottom of Head to Floor Dimension for Height and Outside of Panel to Panel Dimension for the Width, excluding Sideboards (normally arch to arch measurement) Component Head Board Head Mounting Cleat Outside Mount Fascia & Returns Inside Mount Fascia & Returns Sideboards Side Mounting Cleat Bottom Board Measurements 100 x 18mm 30 x 30mm 95 x 12mm 65 x 12mm 100 x 18mm 33 x 33mm 100 x 18mm NOTE: All above are inside measurements -Pelmets are supplied pre-assembled and maximum single length is 3600mm. -Centre Tilt Rods are offset 7mm for better stacking in the open position. -Standard factory deductions are Top 52mm, Bottom 20mm. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 18 OF 31
19 BI-FOLD TRACK AND HARDWARE Top Track Top Track Drawing Carrier (inc saddle) Top Pivot Bottom Wall Pivot Bottom Floor Pivot SLG Bottom Track* Bottom Track Drawing *Must be included for item to be under warranty. Optional Extra: The Bottom Track can be recessed into the bottom board. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 19 OF 31
20 BI-FOLD PELMET **with recessed bottom track REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 20 OF 31
21 SLIDING PELMET WITH 2 TRACKS Component Headboard 64mm Blade Headboard 89 mm Blade Head Mounting Cleat Outside Mount Fascia & Returns Inside Mount Fascia & Returns Sideboards 64mm Blade Sideboards 89mm Blade Side Mounting Cleat Bottom Board 64mm Blade Bottom Board 98mm Blade NOTE: All above are inside measurements Measurements 180 x 18mm 220 x 18mm 30 x 30mm 140 x 12mm 95 x 12mm 180 x 18mm 220 x 18mm 33 x 33mm 180 x 18mm 220 x 18mm - Pelmets are supplied pre-assembled and maximum single lengthis 3600mm. - Sliding Panels over 1050mm wide are made as a joined panel by default -Standard factory deductions are Top 52mm, Bottom 10mm (with bottom guide), or Bottom 20mm (with bottom track). SLIDING TRACK & HARDWARE Inside Mount & Reveal Mount When measuring, please provide the window opening dimensions. Outside Mount When measuring, provide the Bottom of head to Floor Dimension for height and outside of Panel to Panel Dimension for the Width, excluding Sideboards (normally arch to arch measurement). Top Track Top Track Drawing Carrier (inc. saddle) Floor Guide SLG Bottom Track Bottom Optional Track Extra: Drawing The Bottom Track can be recessed into the bottom board. Floor Guide SLG Bottom Track Bottom Track Drawing REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 21 OF 31
22 PRODUCT INFORMATION MANUAL " $ "# ) SLIDING PELMET +)bb 7aVYZ >ch^yz Bdjci Ha^Y^c\ DeZc Ha^Y^c\ H]jiiZgh -.bb 7aVYZ Djih^YZ Bdjci Ha^Y^c\ DeZc **Light Beads = 25mm wide x depth to clear blades 8" '%&& BVYZ ' IgVYZ Ein AiY# 6aa G^\]ih GZhZgkZY# '%%. BVYZ ' IgVYZ Ein AiY# 6aa G^\]ih GZhZgkZY# REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 22 OF 31
23 SLIDING PELMET - ALL BLADES SLIDING **180mm Headboard Supplied OVERLAP = STILE WIDTH - 10MM JOINED PANELS Sliding Panels over 1050mm wide are joined by default. Joining Stiles are 35mm. Panels are supplied separately with dowels and joined on site with screws. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 23 OF 31
24 SHAPED SHUTTERS Shapes are charged at the Max Height and Width plus a surcharge per opening Straight rails/horizontal blades are supplied by default, advise if you require stepped rails/fan blades Height on the order form is the maximum height, please advise the second height in Height2 Shapes not listed below require a drawing/template and attract an additional surcharge. Arches are not available with the Face Mount L or the Face Mount Deco Raked panels require changes to the blades/rails which limits closure to an approx. 45º pitch. Panels using stepped rail design allow standard closure in Clearview and Centre control bar. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 24 OF 31
25 FRENCH DOOR CUT-OUTS BACKING BOARD Please note that all French Doors come with a backing board as a default. If you do not wish for one to be provided, please state in notes. ORDERING Please supply measurements x2, y2, y3 as outlined on drawings below. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 25 OF 31
26 MEASURING **Inside Mount Deduction between Frame and Reveal is 2mm. Shown deductions are standard factory clearances. WINDOW OPENING REQUIRED WINDOW OPENING REQUIRED OUTSIDE DIMENSION REQUIRED How to Measure a Mid Rail Measurement required from the bottom of the panel or frame to the centre of the Mid Rail How to Measure a T-Post Measurement required from the Left of panel or frame to the centre of the T-Post REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 26 OF 31
27 MEASURING A BAY WINDOW (135 DEGREE ANGLE) Specify opening size for all Bay Wiindows. Z FRAME INSIDE MOUNT L FRAME INSIDE MOUNT L FRAME OUTSIDE MOUNT REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 27 OF 31
28 MEASURING A CORNER WINDOW (90 DEGREE ANGLE) Specify opening size for all Corner Wiindows. L FRAME INSIDE MOUNT L FRAME OUTSIDE MOUNT MEASURING A BOX BAY WINDOW L FRAME OUTSIDE MOUNT Z FRAME INSIDE MOUNT REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 28 OF 31
29 HANG STRIPS Window size: measure both width and height from inside of window to inside of window (see diagram below). Window size: measure both width and height from inside of window to inside of window (see diagram below). Note: There are only two vertical hang strips behind panels Note: on each There side are as only standard two and vertical we will hang provide light block strips bead behind for panels the top on and each the bottom side as of the opening. standard and we will provide light block bead for the top and the bottom of the opening. SIDE VIEW TOP VIEW REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 29 OF 31
30 TIMBER SHUTTERS LEAD TIME AND DELIVERY Lead times will vary throughout the year however as a general guide, to custom make your order, we expect approximately 8 weeks lead time. Lead times commence from order entry. REMAKES Remakes will be prioritised and scheduled for immediate production; however they will still be shipped by sea-freight and therefore subject to the timing of our next container. Remakes for replacement louvres and panels must be provided on the Louvre Replacement/Panel Replacement Form contained within the Technical manual. This information is critical in ensuring we are able to correctly manufacture your requirements to avoid further delay. PRODUCT CARE Dust can be easily brushed off at regular intervals using a clean soft cloth, a feather duster or a vacuum cleaner with brush attachment. To dust or vacuum, tilt the louvre up and then down (but not entirely closed) to reach the entire top and bottom surface of the louvre. Do not use chemical based cleaning products to clean the shutters. Your timber shutter is a natural product and over time will age from the effects of the sun. Do not allow water to come into contact with the timber. Although the timber is coated, if water comes into contact with the timber, it can cause the louvres to warp, bow or twist, water stains to occur or paint to peel. Do not use a damp cloth when cleaning. Damage to shutters caused by water is not covered under warranty. WARRANTY INFORMATION LUXAFLEX NEWSTYLE Timber Shutters are covered by a five (5) year Warranty*. Copies of the warranty are available on request and will be packed with each Shutter order. The installer should pass this important document on to the customer and explain who to contact in the case of a problem in the future. For proof of repair under warranty, photographic evidence is required. It is important to remember that timber is a natural product, and therefore variations and changes in the timber are normal characteristics of this product. As such, the following is not covered under warranty: Any conditions caused by normal wear and tear. Abuse to the product, such as alterations, accidents and misuse. Exposure to the elements (i.e. Sun damage), discolouration over time. Failure to follow instructions with respect to measurement, proper installation, cleaning or maintenance. Warpage through exposure to high humidity e.g. kitchens / bathrooms and natural variations in grain, colour and texture of the timber. Varying levels of light penetration will occur between the louvres. Timber Shutters are neither intended, nor guaranteed to provide blockout conditions when closed. As with timber flooring and furniture, your shutters will require some care in the future. Re-finishing and repairs to the surface are not covered under the original warranty. Louvres can be simply operated by the vertical tilt rod or by adjusting the louvres themselves. If the louvre tension becomes loose or tight, adjust the tensioning screws located on the side of the shutter to the desired tension with a Phillips head screwdriver. *Refer to website for warranty details. If the shutters are bi-folded, please ensure the louvres are closed prior to stacking in order to prevent damage. REPLACES ISSUE DATE: JANUARY 2014 APPROVED BY: N.CROFT PAGE 30 OF 31
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