DUALCASE VERSATILE ALUMINIUM SIGN SYSTEM
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1 VERSATILE ALUMINIUM SIGN SYSTEM Universal Components Ltd. May 2007
2 Introduction Nothing beats DualCase for speed of fabrication, aesthetic appearance and easy maintenance. With the minium of components and a range of time-saving integrally beaded sections, DualCase is the first choice of Britains signmakers for internally illuminated sign boxes. One of the most versatile aluminium sign systems ever introduced. DualCase allows single or double sided illuminated signs to be fabricated from the same basic system - with obvious benefits for sign makers and end users in speed of fabrication, ease of maintenance and aesthetic appearance. This versatility makes DualCase ideally suited for corporate identity programmes which require large runs of identical signs. DualCase is in use worldwide for applications as diverse as petrol station canopies, shopfronts, fascia signs, projecting, pole mounted or suspended signs - and many more. DualCase is available anodised or powdercoat painted to British Standards in a wide choice of colours and an attractive range of finishing beads is available.
3 Introduction The King of Sign boxes Speed of fabrication, ease of maintenance and aesthetic appearance are the hallmarks of the DualCase system. Only the minium of components are required to fabricate the DualCase box - an outer case, supports, reinforcing brackets and beads. DualCase is designed to accept any type of face panel from 3mm in thickness. A range of attractive bead profiles is available. The DualCase system is available in two widths: 6 and 9 ½. The 6 wide system features a range of integrally beaded extrusions - a MUST for the professional sign maker. These profiles are designed to replace the standard extrusion and bead on three sides of a sign leaving only the access side requiring a removable bead. For projecting sign installations a stand-off bracket is available. The 9 ½ version of DualCase is ideal for pole mounting. Finish DualCase profiles may be finished to the following specifications. - anodised to BS 1615 or BS 3987 in Silver, Black or Bronze. - stoved powder organic coating to BS 6496 in white and a range of RAL colours (to special order). - in mill finish. For further information please contact: Universal Aluminium Systems. Universal House. Pennywell Road, Bristol. BS5 0ER United Kingdom Tel: +44 (0) I Fax: +44 (0) mail to: signs@universal-aluminium.co.uk web:
4 The King of Sign boxes No Other System Gives You This Much Nothing beats DualCase for speed of fabrication, aesthetic appearance and easy maintenance. With the minimum of components and a range of time-saving integrally beaded sections, DualCase if the first choice of Britain s signmakers for internally illuminated sign boxes. Beads to ring the changes The DualCase system includes a comprehensive range of panel-retaining finishing beads to cater for all thicknesses of panel ans well as offering exciting options. UCL 121 The ultimate multi-purpose profile for single or double sided illuminated signs. Used with Removable beads on one side of the sign box, with integrally beaded sections on the remaining 3 sides UCL 128 Double sided integrally beaded profile which accepts 3mm face panels. Makes for quick and easy fabrication and minimises visible screws on the outside of the sign box. UCL 171 Double sided integrally beaded profile which accepts 5 or 6mm face panels. Quick to fabricate and easily accepts stand-off bracket for wall mounted signs. UCL 129 Standard square bead for panels up to 6mm UCL 189 Bevel bead - for a clinical finish UCL 199 Radius bead for a smooth look UCL 188 Half round bead for a softer look UCL 132 Single sided integrally beaded profile which accepts 5 or 6mm face panels. Quick and easy to fabricate. Minimises visible screws on the exterior of the sign box. UCL 194 Deep half round bead for boxes over 1.2m deep UCL 131 Deep square bead for boxes over 1.2m deep UCL 267 Wide bodied profile for larger signs. Ideal for suspending or pole mounting and extensively used on petrol station forecourts for vertical fuel pricing display signs. UCL 135 Stand-off bracket purpose-designed for use with integrally beaded sections UCL 128 and UCL 171. Suitable for neat and easy installation of double sided wall mounted DualCase signs. End caps available.
5 Box Assembly Instructions 1 2 Place side sections face down on the bench and drill a 5mm diameter hole Vertically through the centre of each screw port (see above). Turn side sections over and countersink the holes. Screw sides to base section using No.8 x 25mm self-tapping screws (see right). Clean all edges with a file. No.8 x 25mm (1 ) countersunk screw mm (6 ) 6 Rivet Rivet Stand partly assembled box on its base, beaded face away from you and measure 152mm (6 ) in from each end. Insert end supports at these positions and at approximately 750mm (29 ½ ) centres along the remaining length. When all supports are positioned, drill a hole at the bottom right hand corner of each support where the dye lines cross. Fix each support with a rivet. Clip reinforcing brackets (UCL 134) into each vertical support ensuring correct location of the bracket groove over the flange in base section. Fixing Horizontal Supports - 9 ½ DualCase Insert top and bottom horizontal supports into each vertical support, drill through vertical and horizontal supports and rivet. Also rivet front of bottom horizontal support to maincase extrusion. Place top section over supports and screw sides to it with No.8 x 25mm self-tapping screws. Lay box on bench, beaded edge downwards and check that all side sections and supports are square and that the top section is sitting correctly on the supports, Drill through supports and top and bottom sections where the dye lines cross and fix with rivets (two at each position). Finally drill and rivet top horizontal supports to front edge of main case extrusion. Drill through brackets and supports at their centre points and fix with rivets. Place top section over supports and screw sides to it with No.8 x 25mm (1 ) self-tapping screws. Lay box on bench, beaded edge downwards and check that all side sections and supports are square and that the top section is sitting correctly on the supports. Drill through supports and top and bottom sections where the dye lines cross and fix with rivets (two at each position). Finally install, drill and rivet top reinforcing brackets as previously described. Rivet here Bottom of sign box riveted here. Leave top free for any necessary adjustments on site
6 Basic Construction and Material Cutting Aluminium Single or Double Sided illuminated Sign Box System Backing Sheet Backing Sheet UCL 166 UCL 166 UCL 121 UCL 267 UCL 129 UCL 129 Basic Construction Corner Angle (for double sided signs) Basic Construction Length plus 52mm (2 ) Acrylic spacer blocks Material Cutting Main Case Extrusions and Beads Insert bead(s) into main case body and position acrylic spacer blocks (available from Universal) adjacent to saw cuts (and at the mid position for lengths of material over 1830mm (6 0 ) long). Secure bead(s) and spacers in position with adhesive tape. Lay material flat face down and mark off required lengths, adding 52mm (2 ) to each length as a cutting allowance. Set the saw blade to 45 from the vertical and cut through the material at the positions marked. Turn the section around and measuring from the mitred end, mark off the exact length required on the facing edge. *Cut both sections then repeat procedure for the other two sides. Stop Block Exact Length * Mark is aligned with cutting line on saw bed. Place a stop at the other end to ensure that the next piece is the same size. Saw Cut Support Extrusion - 6 Dualcase Vertical supports are square cut 14mm (9/16 ) less than overall box height. Support Extrusion - 9 ½ Dualcase Vertical supports are square cut 14mm (9/16 ) less than the overall box height. Horizontal supports are square cut at the back edge and mitre cut at 45 at the front edge to an overall length of 210mm (8 1/4 ). 45
7 Back Panel Assembly Instructions Back Panel Back panels can be either flat of folded. Flat panels must be cut 48mm (1 7/8 ) shorter than the finished box height. The panel is recessed into the body extrusion and fixed with rivets through both body and support sections. Space rivets at approximately 254mm (10 ) centres. Additional waterproofing can be provided by placing adhesive tape over the panel/box joints. Folded panels must be cut 24mm (1 ) longer than the finished box height which provides for a 12mm (½ ) location flange to be folded on both top and bottom edges. The panel is then slotted on to the back of the box and fixed with rivets as a flat panel. Before fitting panel mark the box body sections to enable support positions to be located. Rivet Height minus 48mm 12mm fold Beads. Lay the assembled box face upwards on the bench and remove adhesive tape securing bead in position. Discard acrylic spacers. Fit fascia panels into box, locating top hanging strip in groove on main case extrusion. Replace beads, hold lightly in position and drill a 3mm (1/8 ) diameter hole approximately 32mm (1 1/4 ) in from each corner on the upper dye line. Countersink holes and fix beads with No.6 bead screws. Repeat operation around the perimeter of the box, spacing holes at approximately 600mm (24 ) centres. Note: Acrylic panel should be 25mm (1 ) less in depth and width than the outside dimensions of the box. Acrylic hanging bar 12mm x 5mm should be cemented along the top back edge of the panel mm centres mm No6 Bead Screw UCL 402 for 6 UCL 403 for 9 ½ UCL 408 for 6 UCL 409 for 9 ½ Sleeving Plate For joining multiple lengths Corner Angle For alternative corner fixing with screw-free appearance Reinforcing Bracket For extra corner strengh where required
8 Double Sided DualCase Double Sided DualCase UCL 121/267 Dotted line indicates corner angle plates to UCL 171/128 give added strength to back corners of sign Off-cuts of bead section used as supports for tube clips or wires UCL 402/403 Radius Corners The wide Pre-formed 150mm (6 ) radius corners are available for use in conjunction with the standard maincase extrusions. The corners accommodate one or two beads for single or double sided applications and inc or por at e sleev ing pl at es whi ch si mpl y sl ot int o the channels on the straight lengths. The minium possible overall depth of a sign using individual corners is 610mm (24 ) 255mm (10 ) radius 152mm (6 ) 6 255mm (10 ) Stand-off Brackets A stand-off bracket (UCL 135) is available to suit signs with a projection of up to 1000mm (40 ). The sign should be fixed 6 Pole Mounting The wide DualCase extrusion is especially suitable for pole mounted signs where a 100mm (4 ) pole can be comfortably accommodated. Brackets should be fixed to both top and bottom main case extrusions and the pole. Lighting tubes should be installed vertically at either side of the pole to the stand-off bracket with nuts, bolts and washers. Washers should be a minimum 20mm (3/4 ) diameter and should also be used when bolting a sign directly to a wall. Lateral accuracy is ensured because the small raised ears on the bracket match the width if the maincas e extrusi on. Stand-off brackets should be cut 75mm (3 ) shorter than the overall height of the box and centred on height. Screw centers should not be more than 300mm (12 ) apart.
9 Shaped Signs Tri-Sign Divider The Tri-Sign divider (UCL 195) is designed for use in signs with two or three different illuminated panels, such as advertising units at passenger terminals and in the retail environment. The Tri-Sign divider must be used in conjunction with half round bead (UCL 188). Cut the required number of dividers to 80mm LESS than the overall height of the sign box. Insert a moulded casting (UCL 418) into each end of the divider sections, secure with clear adhesive. Insert beads and panels into box as described previously. Dividers are held in position by the panels which should be slid into the recesses in the divider sections Shaped Signs Using DualCase As an example of the versatility of the DualCase system all kinds of shaped signs can be easily manufactured using sleeving plates. UCL 188 Panel UCL 418
10 Integral A MUST for the professional signmaker Unique to the DualCase 6 sign box system, these integrally beaded extrusions are designed to save on fabrication time. They also provide the ideal solution for neat, attractive and secure double-sided signs Single Sided Signs Easier to cut No bead screws - neater finish Faster to fabricate UCL 132 Integral Bead Extrusion Use on THREE sides of the sign UCL 129 Bead UCL 121 Standard 6 Extrusion and UCL 129 Bead Use on ONE side of the sign (for access to the panels) Double Sided Signs UCL 129 Bead Easier to cut No bead screws - neater finish Faster to fabricate Easier to fit stand-off brackets UCL 171 Integral Bead Extrusion Use on THREE sides of the sign UCL 121 Standard 6 Extrusion and UCL 129 Bead Use on ONE side of the sign (for access to the panels) Remember INTEGRAL when you order 6 DualCase profiles
11 Basic Construction (6 system illustrated) Backing Sheet Support Reinforcing Bracket Bead Single Sided Standard system: 168mm Wide body system: 254mm Main Body Corner Angle (for double sided signs) Double Sided Standard system: 175mm Wide body system: 262mm Only the minium of components are required to fabricate the DualCase sign box - a main box section, supports, reinforcing brackets and beads. The system accepts any type of face material from 3mm in thickness. The standard 6 DualCase system features a range of integrally beaded extrusions which are A Must For The Professional Signmaker. These profiles are designed to replace the standard extrusion and bead on three sides of the sign box, leaving only one side requiring a removable bead for panel access, thus speeding manufacture. Systems and Service for the Sign Industry
12 Profiles and Accessories Bead Entry for single sided signs Screw location grooves for bead fixings Screw location grooves for mitred corner fixings Channels to take No. 8 self tapping screws Additional bead entry for double sided signs and access for folded backing sheet 6 DualCase Standard UCL 121 Opening to take 3mm angles for alternative corner fixings. Also sleeving plates for multiple length of extrusion mm Ballasts can be mounted on trays and riveted to this and opposite flat surface. Alternatively the ballast can be fitted to the vertical supports Vertical support extrusion entered into this channel Recess for aluminium or similar backing Accepts 5/6mm face panels Integral Double-Sided UCL mm Accepts 3mm face panels Integral Double-Sided UCL mm Integral Single-Sided UCL 132 Tri-Sign Divider Finishing Beads UCL 195 UCL 194 UCL 131 Profiles shown approximately full size
13 Profiles and Accessories Support Stand-Off Bracket UCL 135 Moulded Plastic End Caps are available UCL ½ DualCase UCL 267 Profiles shown approximately full size Corner Angle UCL 178 Available as a cut-to-size components for 6 DualCase (UCL 402) and 9 ½ DualCase (UCL 403)
14 Profiles and Accessories UCL 199 Reinforcing Bracket UCL 134 UCL 189 UCL 188 UCL 1129 (for face panels up to 6mm) Available as a cut-to-size component for use as horizontal supports in 6 DualCase (UCL 404) and for use as reinforcing corner brackets with 6 DualCase (UCL 408) or 9 ½ DualCase (UCL 409) For further information please contact: Universal Aluminium Systems. Universal House. Pennywell Road, Bristol. BS5 0ER United Kingdom Tel: +44 (0) I Fax: +44 (0) mail to: signs@universal-aluminium.co.uk web: Profiles shown approximately full size
15 VERSATILE ALUMINIUM SIGN SYSTEM For further information please contact: Universal Aluminium Systems. Universal House. Pennywell Road, Bristol. BS5 0ER United Kingdom Tel: +44 (0) I Fax: +44 (0) mail to: signs@universal-aluminium.co.uk web: Universal Components Ltd. May 2007
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