RELAZZO DECKING SYSTEMS Installation guide
RELAZZO decking systems - installation checklist The checklist is intended as an aid and does NOT replace the installation guide. Base: Gravel ballast Gradient min 10 mm/lfm Concrete blocks WPC fixing bracket possibly rubber spacers possibly WPC joining plate possibly adjustable foot possibly adjustable foot adapter possibly adjustable foot screw Alu-UK 21 x 30 fixing system Concrete slab Gradient min 10 mm/lfm possibly rubber spacers WPC fixing bracket possibly WPC joining plate possibly concrete blocks possibly adjustable foot possibly adjustable foot adapter possibly adjustable foot screw Alu-UK 21 x 30 fixing system Flat roof Gradient min 10 mm/lfm Substructure frame Rubber spacers WPC fixing bracket WPC joining plate possibly concrete blocks possibly adjustable foot possibly adjustable foot adapter possibly adjustable foot screw Alu-UK 21 x 30 fixing system Substructure: 90 installation Correct substructure clearance selected to the building min 10 mm For board joints 60 to 100 mm 45 installation Correct substructure clearance selected to the building min 10 mm For board joints 60 to 100 mm Boards: Brushing direction (print/identification groove) to a fixed building component min. 20 mm to a fixed building component min. 10 mm if board < 2 lfm for joint 3 mm/lfm Adhesive REHAU bracket system: End bracket Flush end bracket Centre bracket Quick installation clip Flex clip Finishing: End cap Adhesive Aluminium end trim Adhesive Fastening set Flexible end trim Adhesive Please note that any warranty claims are void if the installation guide is not complied with and components other than RELAZZO system components are used. Sketches and pictures are only provided for illustration purposes. 2
CONTENTS 1 Product Range 4 2 Important Information 8 3 General RELAZZO installation and assembly 11 3.1 Foundation 11 3.2 Level compensation 13 3.3 Substructure 15 3.4 Board 19 4 RELAZZO puro 22 4.1 WPC substructure 22 4.2 Custom installations 27 4.3 Accessories 31 5 RELAZZO finello, naturo, coro, calmo 35 5.1 WPC substructure 35 5.2 Aluminium substructure 38 5.3 Custom installations 43 5.4 Accessories 48 3
1 PRODUCT RANGE General base Adjusting foot 50-90 mm Adapter for adjusting foot 50-90 mm: Rubber spacer 3, 5, 10 mm 60 mm 40 mm 50 mm 30 mm 40 mm 60 mm 30 mm 50 mm 1.7 kg / lfm 1.7 kg / lfm 1.3 kg / lfm 1.3 kg / lfm WPC substructure 60 x 40 WPC substructure 60 x 40 WPC substructure 50 x 30 WPC substructure 50 x 30 WPC fixing bracket (V4A stainless steel) WPC joining plate (V4A stainless steel) Aluminium adjustable foot screw WPC adjustable foot screw 4
General accessories 60 mm 40 mm Adhesive Aluminium trim 60 x 40 LED spot set RELAZZO puro solid, coro Edge fixing strip Fixing bracket RELAZZO puro (30 mm) 1.9 kg/lfm 2.6 kg/lfm 4.4 kg/lfm RELAZZO puro 30 x 140 board RELAZZO puro 30 x 194 board RELAZZO puro solid 30 x 140 board End cap 30 x 140 End cap 30 x 194 Joint cover Flush end bracket 30 WPC End bracket 30 WPC Centre bracket 30 WPC 5
Aluminium step profile 30 WPC Joint filler profile 30 RELAZZO flex trim 30 RELAZZO naturo, finello, coro, calmo (23 mm) 2.3 kg/lfm 3.6 kg/lfm 0.62 kg/lfm RELAZZO naturo/finello 23 x 169 board RELAZZO coro, calmo 23 x 140 board Aluminium substructure 21 x 30 RELAZZO fixing set 21 x 30 Quick installation clip 23 aluminium Flex clip 23 aluminium End bracket 23 WPC End bracket 23 aluminium Flush end bracket 23 WPC Centre bracket 23 WPC Centre bracket 23 aluminium End cap 23 x 169 6
Aluminium step profile 23 aluminium Aluminium step profile 23 WPC Flex trim 23 Tool list Protective goggles Spirit level Measuring tape Chop saw Side cutter Drill Wood drill bit 2.0 mm Metal drill bit 3.5 mm, 4 mm Surface grinder Hole saw Rubber mallet 7
2 IMPORTANT INFORMATION Explanation of the icons: permitted, correct application NOT permitted, incorrect application Attension: Do not screw together directly RELAZZO boards must not be directly screwed together. Bear the installation direction in mind Ensure an even installation of the boards in brushing direction (arrow printed on board). In addition to this, pips can be seen inside cavities on hollow profiles and on the side of solid profiles to indicate the profile orientation. 8
min. 10 mm/lfm Gradient A gradient of min. 1 % (10 mm/lfm) is to be adhered to in order to prevent water spots and waterlogging. In addition to this, the gradient also helps remove dirt naturally with rain and is very slip-resistant thanks to this. ~ 1.1 Nm Pilot drilling and screwing together Use a low torque setting so as not to over-tighten screws when screwing them in. Cut A 90 cut on the board ends is recommended for an optimum joint pattern. Boards recommended. 9
Bear expansion joints in mind WPC decking boards are subject to natural expansion. A sufficient expansion joint therefore has to be planned in between each board as well as the substructure. Air flow and ventilation In order to ensure quick drying of the materials underneath the boards as well as the board underside, it is mandatory to observe specified minimum clearances. Waterlogging is to be prevented. When using jointing profiles, the clearance between the subsoil and the board underside is to be increased to a minimum of 10 cm. In particular in this case, it is essential that the minimum clearances to fixed building components are maintained or increased in order to ensure sufficient air flow and ventilation. The clearance between the subsoil and the board must not be backfilled. Documentation of the installation It is recommended to photograph the decking during installation of the substructure and immediately following its completion. Document the pictures as part of the acceptance record for subsequent modifications for documentation of the ground design and the installation clearances as well as in general as evidence that this installation guide has been adhered to. Not suitable for self-supporting, structural purposes The WPC profile RELAZZO and the substructure have been specially developed for use as decking surfaces. The products do not have building authority approval and for this reason are not to be used for self-supporting or structural purposes. The local building regulations are to be observed accordingly. Colour development The raw material wood also means possible colour variations and tinges that enhance the natural wood appearance. When using different batches, it is recommended that they be mixed up so that this natural effect is used to its full potential. Safety warnings The information and recommendations given here do not release the fabricator from strict adherence to all applicable safety and environmental regulations as well as the regulations of the Labour Inspectorate and employer's liability insurance association, as these always take precedence. The safety regulations of the adhesives used must be noted and strictly observed. Auxiliary materials such as alcohol-based cleaning products and other easily flammable materials should only be stored in safe and well-ventilated places. Safety equipment such as gloves, safety goggles, ear protection and dust masks are always to be used. 10
3 RELAZZO INSTALLATION AND ASSEMBLY General installation 3.1 Foundation 3.2 At the same level 3.3 Substructure 3.4 Board 3.1 Underground Floor construction NOT allowed Load-bearing building components floor construction RELAZZO has no approval for self-supporting, structural purposes. Construction on balconies or bridges is only permitted following the approval of a structural engineer in the case of a sufficiently static subsurface (e.g. steel mesh) taking into account the local building regulations. Lawn/soil floor construction An installation on the soil or lawn is not permissible without a frost-resistant or water and erosion-resistant design of the subsoil and installation by a specialist company due to ground settlements. 11
Sand floor construction An installation on sand is not permissible without a frost-resistant or water and erosion-resistant design of the subsoil and installation by a specialist company due to ground settlements. Floor construction allowed Frost-resistant stone filling floor construction The local building regulations for a design of the frost-resistant stone filling in accordance with standards are to be complied with. The specialist department of your choice is responsible for the design. REHAU cannot provide a warranty for the design of the stone filling. Concrete floor construction The local building regulations for the design of the frost-resistant concrete slab in accordance with standards are to be complied with. The specialist department of your choice is responsible for the design. REHAU cannot provide a warranty for the design of the concrete slab. 12
Flat roof floor construction The local building regulations for the design of a flat roof in accordance with standards are to be complied with. The specialist department of your choice is responsible for the design. REHAU cannot provide a warranty for the design of the flat roof. Please ensure that the foundation (e.g. damping) does not buckle due to potential loads. 3.2 Level compensation a. Rubber spacer Rubber spacers 50 x 50 x 3, 5, 10 mm Rubber pads may be used for levelling and raising the substructure (to prevent water logging). The rubber spacers also serve the purpose of reducing noises (impact sound). Rubber spacers must not be stacked. b. Concrete spacers Concrete blocks may be used for levelling and raising the substructure (to prevent water logging). 13
c. Adjustable foot - The height is adjusted with millimetre precision by rotating the eight revolving fingers of the height-adjustment wheel. Note: the maximum bore height has been reached once the hole in the thread and the notch of the foot meet - The installation is carried out by placing the substructure onto the adjusting foot and fusing the fixing clips together - Pedestal: 50-90 mm height adjustable - Pedestal extender: 35 mm - Floor space: Ø 200 mm - Max. allowable load per pedestal: 4 kn Adjusting foot 50-90 mm 13171111001 Adjustable foot adapter Adjusting range (mm) from up to 1 + 1 90 125 1 + 2 125 160 1 + 3 160 195 1 + 4 195 230 1 + 5 230 265 1 + 6 265 300 1 + 7 300 335 1 + 8 335 370 1 + 9 370 405 1 + 10 405 440 1 + 11 440 475 1 + 12 475 510 max. permissible total height: 510 mm WPC substructure Aluminium substructure <300 mm* <300 mm* <400 mm <400 mm <370 mm <370 mm <470 mm <470 mm *Note: if the upright WPC substructure 60 x 40 is used, the support width can be increased to 400 mm. Adjustable foot with screw for WPC substructure Adjustable foot with screw for aluminium substructure The option of fixing the foot to the notching supplied with concrete slabs exists as an alternative to screwing the adjustable foot with the foundation. 14
3.3 Substructure a. Installation on various bases Installation on frost-resistant stone filling The substructure profiles must not be installed directly onto the subsoil. The substructures are to be fixed onto concrete spacers with fixing bracket, fastening system aluminium substructure or onto the adjusting feet with screws. Installation on concrete The substructures located at the edge of the surface are to be fixed onto concrete base with a fixing bracket, fastening system aluminium substructure or onto the adjusting feet with screws. Uneven ground is to be levelled using rubber pads. If the substructure profiles are installed across the gradient, rubber pads, slabs (blocks, paving stones) or adjustable feet are to be used to prevent water logging. Installation on a flat roof A frame is to be built using the substructure. This frame is to be raised off the drainage membrane using rubber spacers or adjustable feet. It is forbidden to screw the substructure down. Weights/fastenings to prevent movement under wind loads must be confirmed by a specialist. Any damage to the flat roof membrane is to be ruled out! The compatibility of the rubber spacers and adjustable feet with roofing felt is to be checked. 15
b. Requirement table subsoil - substructure = required = optional = impermissible Gravel ballast Concrete slab Flat roof Concrete spacers Rubber base for water drainage Rubber base for levelling Assembly system for fixing to the subsoil Mounting angle for the framework construction Joining plate for substructure extension Adjustable foot 16
c. General installation dimensions of the RELAZZO substructures 10 mm min. 10 mm min. max. 300 mm* max. 400 mm *Note: if the upright WPC substructure 60 x 40 is used, the support width can be increased to 400 mm. 10 mm min. 10 mm min. 10 mm min. 10 mm min. Expansion joint Expansion joint Expansion joint A Width max. 14 m A Width max. 14 m Expansion joint (mm) = width (m) x 1.5 = min. 10 mm If the width (substructure length) exceeds 14 m, an expansion joint is to be created between the substructures and the boards (joint width (mm) = min. 2 x ). 17
d. Fastening points on the subsoil/frame construction Fastening to the subsoil Frame construction Fastening the substructure to the edge of the surface and in the surface for continuous board joints. Fastening the substructure to the edge of the surface and in the surface for continuous board joints. 18
3.4 Boards The expansion joints are to be calculated according to the longest used profile length: 3 mm / lfm (in tropical or sub-tropical / humid-warm climate 4 mm / lfm) Tip: Choose profile lengths of 3 m for two or more joints in a row. Dielenlänge Dehnfuge 4 lfm 12 mm 5 lfm 15 mm 6 lfm 18 mm 10 mm min. 30 50 mm (5 mm for aluminium end trim ) min. 20 mm (min. 10 mm if the board 2 lfm) 20 mm min. 3 mm / lfm 3 mm / lfm 1.5 mm / lfm Towards fixed building components: min. 20 mm (min. 10 mm if board 2 lfm) Special case (longitudinal/diagonal boards): 1.5 mm/lfm) 19
Installation types - substructure layout (WPC and aluminium) Brick pattern 45 The load-bearing distance for the board must be reduced by 25% if installed diagonally. Joint 20
Mitre 21
4 RELAZZO PURO 4.1 WPC substructure 10 mm min. max. 500 mm max. 300 mm* *Note: if the upright WPC substructure 60 x 40 is used, the support width can be increased to 400 mm. a. Fixing the substructure (to the edge of the surface) max. 100 mm max. 1000 mm max. 100 mm 22
b. Use of brackets End bracket 10 mm min. 4.2 x 25 Centre bracket ~ 1.1 Nm 4.2 x 25 Flush end brackets 0 mm 4.2 x 25 max. 500 mm max. 50 mm 10 mm min. c. Board assembly 23
5 mm It is to be ensured during the installation that the screws are only screwed in halfway so that the bracket remains loose in order to also insert the subsequent boards in the same way. The screws are subsequently fully screwed in. d. Dismantling and reassembling 24
5 mm 25
26 RELAZZO DECKING SYSTEMS INSTALLATION INSTRUCTIONS
4.2 Custom installations The local building regulations for the design of a step geometry in accordance with standards are to be complied with. a. Step installation with WPC substructure max. 500 mm 150 mm min. 33-35 mm 1. Substructure design 2. Fastening the first bracket 3. Install the step riser 4. Step profile fastening It is permitted to cut the hollow section board in longitudinal direction (max. board length 80 cm) if a step profile is used. Length Cutting 5. Calculating the step Length = first bracket to the spacer block of the aluminium step profile 6. RELAZZO board pre-cuts Pre-cut part = length - 147 mm per board 7. Calculating the step 8. View of the step construction 27
b. Step installation with edge fixing angle and RELAZZO puro solid The provided countersunk head screws must be used for installing the edge fixing angle. Cut to size min. 40 mm max. 500 mm Cutting Height min. 3 screws 1. Pre-cut part calculation: Pre-cut part = (height / 2) - 4 mm 2. Fastening RELAZZO puro solid with edge fixing angle Width Cut to size min. 40 mm Cutting min. 2 screws 3. Attaching the edge fixing angle to the substructure 4. Calculation cut size: Cut size = (Width / 2) 4 mm Height for pre-cut part min. 3 screws per board min. 2 screws 5. Fastening RELAZZO puro solid with edge fixing angle 6. Fasten the fixing angle with substructure and fasten the centre bracket min. 2 screws min. 3 screws per board 7. Fastening RELAZZO puro solid with edge fixing angle 8. Fasten the fixing angle with substructure and fasten the centre bracket 28
c. Edging with edge fixing strip The provided countersunk head screws must be used for installing the edge fixing strip. 40 mm min. min. 2 screws min. 3 screws 1. Fastening with RELAZZO edge fixing strip 2. Attaching the edge fixing strip to the substructure max. 500 mm 3. Screwing the centre bracket onto the next RELAZZO board d. Edging with edge fixing angle The provided countersunk head screws must be used for installing the edge fixing angle. min. 70 mm Cutting min. 2 screws min. 3 screws per board 40 mm min. 1. Fasten RELAZZO edge with fixing angle 2. Attaching the edge fixing angle to the substructure 3. Screwing the centre bracket onto the next RELAZZO board max. 500 mm 29
e. Pool border 20 mm Board length max. 2 m 10 mm 20 mm 30
4.3 Accessories a. Aluminium finisher A fixing set is sufficient for approx. 8 m aluminium end trim (15 mm spacers) 5 mm ø 4 mm ø 2 mm 15 mm min. 4.0 x 30 15 mm min. max. 500 mm min. 5 mm min. 5 mm 31
b. Installation of joint profiles Joint filler profile Joint cover The joint cover should be cut to length free from tension prior to installation. When using jointing profiles, the clearance between the subsoil and the lower board edge is to be increased to a minimum of 100 mm. In particular in this case, it is essential that the minimum clearances to fixed building components are maintained or increased in order to ensure sufficient air flow and ventilation. The clearance between the subsoil and the board must not be backfilled. c. End cap It is to be ensured that the ventilation/drainage slits of the end caps maintain their function and are not sealed by adhesive. 32
d. Flexible end trim 2 mm 2 mm 10-12 mm min. 17 mm min. 16 mm 33
e. LED spotlight installation ø 68 mm approx. 2000 mm 3 mm 40 mm approx. 6000 mm approx. 3000 mm approx. 200 mm 20 mm ø 44-46 mm ½ ½ max. 60 mm LED spot set - Do not screw the transformer onto the board - Install cable loosely (not under tension). 220-240 V 47-63 Hz This connection must be established by an electrical specialist. 34
5 RELAZZO FINELLO, NATURO, CORO, CALMO 5.1 WPC substructure 10 mm min. max. 420 mm max. 300 mm* *Note: if the upright WPC substructure 60 x 40 is used, the support width can be increased to 400 mm. a. Fixing the substructure (to the edge of the surface) max. 100 mm max. 1000 mm max. 100 mm 35
b. Use of brackets WPC substructure End bracket 10 mm min. 4.2 x 25 Flush end bracket 4.2 x 25 max. 500 mm max. 50 mm 10 mm min. Centre bracket ~1.1 Nm 4.2 x 25 36
c. Board installation with WPC substructure and V4A bracket system It is to be ensured during the installation that the screws are only screwed in halfway remains loose in order to also insert the subsequent boards in the same way. The screws are subsequently fully screwed in. so that the bracket 37
5.2 Aluminium substructure 10 mm min. max. 420 mm max. 400 mm a. Fixing the substructure (to the edge of the surface) and construction of a frame max. 100 mm max. 1000 mm 38
b. Use of brackets End bracket 10 mm min. 3 mm 3 mm 4.0 x 22 3 mm 3 mm Drill hole area Quick installation clip The quick installation clip has to be installed alternately into each side of the aluminium substructure. A fixing pin must be pressed into the quick installation clip for a quick installation clip per board. A fixing pin is cast onto each fourth quick installation clip and must be broken off in order to be able to use it. 39
Centre bracket max. 6 m max. 6 m 4.0 x 22 A steel centre bracket must be screwed on every max. 6 m board width in every aluminium substructure. Flex clip 4.0 x 22 If the board is not installed at a right angle to the aluminium substructure (e.g. mitre) a flex clip must be used. 40
c. Board installation with aluminium substructure and quick installation bracket 41
d. Dismantling and reassembling 42
5.3 Custom installations a. Step installation with aluminium substructure The local building regulations for the design of a step geometry in accordance with standards are to be complied with. 1. Installation of the substructure and end bracket 2. Fastening the aluminium step profile 3. Installation of the substructure and steps 4. Offset installation substructure min. 15 mm 5. Steps installation 6. Install the step riser 43
b. Step installation with WPC substructure The local building regulations for the design of a step geometry in accordance with standards are to be complied with max. 420 mm 1. Substructure design 2. Fastening the first bracket 3. Install the step riser 4. Step profile fastening Cutting 5. Steps 6. RELAZZO board pre-cuts 7. Steps 8. View of the step construction 44
c. Step installation with a edge fixing angle The provided countersunk head screws must be used for installing the edge fixing angle. Cut to size min. 40 mm max. 420 mm Cutting Height min. 3 screws 1. Pre-cut part calculation: pre-cut part = (height/ 2) - 4 mm 2. Fastening RELAZZO coro with edge fixing angle Width Cut to size min. 40 mm Cutting min. 2 screws 3. Attaching the edge fixing angle to the substructure 4. Calculation cut size: cut size = (width / 2) 4 mm Height for pre-cut part min. 3 screws per board min. 2 screws 5. Fastening RELAZZO coro with edge fixing angle 6. Fasten the fixing angle with substructure and fasten the centre bracket min. 2 screws min. 3 screws per board 7. Fastening RELAZZO coro with edge fixing angle 8. Fasten the fixing angle with substructure and fasten the centre bracket 45
d. Edge fixing strip The provided countersunk head screws must be used for installing the edge fixing angle. min. 40 mm min. 2 screws min. 3 screws 1. Fastening with RELAZZO edge fixing strip 2. Attaching the edge fixing strip to the substructure 3. Screwing the centre bracket onto the next RELAZZO board max. 420 mm e. Fixing bracket The provided countersunk head screws must be used for installing the edge fixing angle. min. 70 mm Cutting min. 2 screws min. 3 screws per board min. 40 mm 1. Fasten RELAZZO edge with fixing angle 2. Attaching the edge fixing angle to the substructure 3. Screwing the centre bracket onto the next RELAZZO board max. 420 mm 46
f. Pool border 20 mm Board length max. 2 m 10 mm 20 mm 47
5.4 Accessories a. Aluminium finisher A fixing set is sufficient for approx. 8 m aluminium end trim (15 mm spacers) 5 mm min. 15 mm ø 4 mm ø 3.5 mm 4.0 x 30 max. 500 mm min. 15 mm b. End cap It is to be ensured that the ventilation/drainage slits of the end caps maintain their function and are not sealed by adhesive. 48
c. Flexible end trim 2 mm 2 mm 10-12 mm min. 12 mm min. 12 mm d. Installation of the joint cover Joint cover (only possible in combination with stainless steel brackets) The joint cover should be cut to length free from tension prior to installation. When using the joint cover, the clearance between the subsoil and the bottom edge of the board is to be increased by min. 100 mm. In particular in this case, it is essential that the minimum clearances to fixed building components are maintained or increased in order to ensure sufficient ventilation and ventilation at rear. The clearance between the subsoil and the board must not be backfilled. 49
e. LED spotlight installation ø 68 mm approx. 2000 mm 3 mm 40 mm approx. 6000 mm approx. 200 mm approx. 3000 mm 20 mm ½ ø 44-46 mm ½ max. 60 mm LED spot set - Do not screw the transformer onto the board - Install cable loosely (not under tension). 220-240 V 47-63 Hz This connection must be established by an electrical specialist. 50
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Do you require more information, samples or advice? Please contact your local retailer. You can find a local distributor and further information about the RELAZZO product range as well as the up-to-date installation guide and technical information on our homepage www.rehau.com/relazzo. You can of course also contact us by e-mail at relazzo@rehau.com. Legal information: The WPC profile RELAZZO and the substructure do not have general technical approval and for this reason are not to be used for self-supporting, structural purposes. The local building regulations are to be observed accordingly. Please observe the current technical information. Subject to technical changes. This document is protected by copyright The rights conferred therein, particularly the translation, reprinting, extraction of pictures, electronic transmission, reproduction in any form or by similar means and the storage on data processing systems, remain reserved. Our verbal and written advice with regard to usage is based on years of experience and standardised assumptions and is provided to the best of our knowledge. The intended use of REHAU products is described comprehensively in the technical product information. The latest version can be viewed at www.rehau.com/ti. We have no control over the application, use or processing of the products. Responsibility for these activities therefore remains entirely with the respective user/processor. Where claims for liability nonetheless arise, they shall be governed exclusively according to our terms and conditions, available at www.rehau.com/conditions, insofar as nothing else has been agreed upon with REHAU in writing. This applies also for any claims on warranty, where the warranty applies to the consistent quality of our products as per our specification. Subject to technical changes. REHAU AG + Co Rheniumhaus D-95111 Rehau (Germany) R20604 EN 03.2017