In-line Patio Fabrication & Installation Instructions 2 Pane Patio p2 Cutting and Preparation p2 Welding and Cleaning p2 Assembly p2 Fabrication Instructions for 3/4 Pane Lock Style p3 Installation (removable section) p4 Product Identification p5 Fitting Thresholds Fixing Furniture Cutting and Glass Deductions Available Kit Sizes Tel: +44 (0)1623 443200 Fax: +44 (0)1623 550243 Web: www.synseal.com Synseal Extrusions Ltd, Common Road, Huthwaite, Nottinghamshire, NG17 6AD
p2 2 Pane Patio The patio comes in the form of a height kit and a width kit. Ensure that you have the correct size kits before cutting components. Inside the kits you will find a component checklist. Please identify the components from the sectional drawings and ensure that all components are in the boxes. Before cutting any PVCu sections, ensure that all reinforcements are removed from profiles. Use the cutting tables to establish the cutting sizes of the outer frame and sashes, and determine glass sizes. Unit thickness is 28mm. Ensure that 30mm sill has been deducted from height before calculating deductions. When using head vent HV71, deduct a further 44mm from height before calculating deductions. Assembly 1. Cut the aluminium packer into sections of no less than 200mm long. 2. The sections are then fitted to the outer frame on the fixed side of the patio. These are used to locate the correct position of the fixed sash. See Drawing C for position of packers. 26mm Cutting and Preparation Drawing C Drawing D Synseal Extrusions strongly recommend the sliding door is installed on the external track. 1. Cut the outer frame and sashes at required lengths, centralising profile to cut even amounts off each end at 45 degrees. 2. Fit hardware fixing strip in the sliding side of the outer frame. This is to ensure that the keep fixings are secured into steel. 3. Before welding any profiles, replace all relevant reinforcements and secure into position ensuring that the reinforcement is kept at least 6mm short of each end of the cut length. 4. Fit the woolpile to the sashes (both sides of the eurogroove) See Drawing A. 3. Square cut the aluminium and PVCu Interlocks to the overall height of the welded sashes. 4. Fix the aluminium interlocks to the sashes 26mm from back of sash as shown, using 3.9 x 25cm screws. See Drawing D. 5. The PVCu interlocks require cut outs at both ends 8mm from the end. See Drawing E. 6. In addition, file or cut an arc in the sliding sash PVCu interlock at the bottom end to provide clearance for the radius of the steel track. See Drawing F. Allow extra 1mm clearance at both ends for sliding sash. The two interlock stiles do not require any woolpile. 26mm 8mm 8mm Drawing A Drawing B Drawing E Drawing F Drawing G Welding and Cleaning There are four timber blocks in the kit, these are inserted into the inside of the outer frame and the outside of the sash. These must be used during the welding process to support the profile to prevent any crushing of the sections. See Drawing B. 1. Weld frame and sash. 2. Groove or knife surfaces as required. 3. Ensure that all weld sprues are removed. 7. Fit the woolpile along the entire length of both PVCu interlocks. 8. Gasket and bead both sashes (you may find it easier to complete this operation before the sashes have been put into the frame). 9. Fit the fixed sash into the frame by lifting the top of the sash into the frame upstand and then pushing the bottom of the sash over the frame upstand. Slide the sash over the aluminium packers until the sash butts up firmly against the outer frame and secure to the outer frame (through the aluminium blocks) using 4.8 x 80mm screws. 10. Clip the PVCu interlock onto the fixed sash. See Drawing G.
p3 Fabrication Instructions for 3/4 Pane Lock Style 3 Pane 3 Pane 4 Pane 1. Fit dust covers into the central rebate of outer frame (see Drawings H and I). 2. When the fixed panel adjacent to the slider has been secured, the 3/4 pane aluminium lock style is cut equal to the measurement of the internal rebate of the outer frame. The aluminium lock style is then screwed in position using 4.8 x 65mm screws at approximately 400mm centres. 3. The lock keeps are fitted into position onto the lock style, and the euro cover is fitted between the keeps. 4. Measure the rebate from fixed sash to frame, cut and fit steel track. The 3 Pane patio kit is intended for 0-X-0 configuration. Drawing H Drawing I 4 Pane 1. As 3 Pane instructions with the exception of cutting an extra 4mm off the aluminium lock style, this enables the sliding slave sash to glide over the track. The track is to be cut at overall length of frame - 105mm. 2. Where the style meets the track, a 10mm hole is drilled 10mm up from the bottom of the style and filed square (see Drawing J). 2mm Drawing J The 4 Pane patio kit is intended for 0-X-X-0 configuration. O X O O X X O Please note: If the patio is to be installed into an exposed location, please contact the Technical Department for advice.
p4 Installation 1 2 3 Check that the patio door frame has been made to the correct sizes before removing the existing frame. Check also that the sealed units are the correct sizes. Temporarily secure the new frame into the opening. The patio door must then be packed under the sill, over the head, and along the sides to ensure the door is level and square. NOTE - THE DOOR WILL NOT FUNCTION CORRECTLY UNLESS THIS IS ACHIEVED. 4 Once satisfied that the frame is level and square, the fixed pane should be slid away from the frame. The frame should then be drilled through the centre and fixed into the brickwork with appropriate frame fixings. 5 6 7 Once the frame is securely fixed to the brickwork, slide the fixed sash over the aluminium blocks until the sash butts up firmly against the outer frame. Then secure the fixed sash to the outer frame using 4.8 x 80mm screws. The sealed units are now ready to be fitted. Glaze the OUTER PANE first ensuring that the units are packed using suitable glazing packers. When glazed, ensure that the patio sash slides evenly and that equal coverage is being achieved over the outer frame. The tandem rollers can be adjusted up or down as required. 8 9 10 Clip in the top and bottom pre-cut thresholds (marked A and B) ensuring that the prescribed end fits around the fixed sash. Clip in the vertical threshold (marked C) and the vertical threshold on the side of the fixed (marked D). Fit bump stop at the top of the fixed sash (if not already factory fitted). Seal around both the outside and inside using an appropriate sealant.
p5 Product Identification Main Profiles Patio Outer Frame Patio Sash Midrail Reinforcements Track Bead Patio Outer Frame Reinforcement Patio Sash Prep Steel Patio Sash Reinforcement Patio Track 28mm Low Line Bead Aluminium Sections Ancillaries Lock 1 Piece keep Spindle & screw set Cylinder Mechanical Joint For Midrail Packer Lock Keep/Hardware Fixing Strip Interlock Handle set Rollers Anti-lift blocks Trims Woolpile Bump stop Dust cover Threshold Interlock Cover Euro Cover Plastic Aluminium Rubber Steel Please note: The drawings shown are a visual representation only, these are not to scale.
Fitting Thresholds Cutting and Glass Deductions 1. Measure the internal height of the outer frame. Cut the threshold to suit (sliding sash side). Make a square cut each end and fit woolpile along the entire length of the threshold. Clip into position. 2. The top and bottom thresholds are pre-scribed at one end to fit around the fixed sash interlock. See Drawing K. 3. Square cut the other ends to butt up to the vertical threshold already fitted. Fit the woolpile and clip into position. On the fixed sash side, the vertical threshold is square cut to the internal height of the frame. Fit the woolpile along the entire length, then clip the square cut thresholds (or 45 degree optional) into position. 4. Cut the stainless steel track (overall width 105mm) and clip into position. Fixing Furniture 1. Fit the anti-lift blocks into the top of the outer frame. See Drawing L. Fit the euro cover strip either side and in-between the anti-lift blocks. 2. Fit the tandem rollers into the eurogroove on the bottom of the sliding sash, approximately 90mm in from each side, ensuring they can easily be adjusted. 3. Fit the lock, cylinder and handles into position. 4. Fit the sliding sash into position, adjusting the rollers as necessary. Clip the previously prepared interlock into position. 5. There is a one piece lock keep which should be fitted into the outer frame to align with the lock positions in the sash. 90mm Anti-lift blocks are placed in the outer frame, directly above the bogey wheels for maximum efficiency Drawing K Outer Frame (PF01) 2 pane Sash (PZ01) Glass Midrail (Mech.) (PMO1) Midrail Glass 3 pane Sash (PZ01) Glass Midrail (Mech.) (PM01) Midrail Glass 4 pane Sash (PZ01) Glass Midrail (Mech.) (PM01) Midrail Glass Available Kit Sizes O/A Width + Weld O/A Height + Weld O/A Height - 84mm + Weld O/A Width / 2+3mm + Weld O/A Height -235mm O/A Width / 2-149mm O/A Width / 2-131.5mm Frame Top/Bottom to Rail Centre -172mm O/A Height -84mm + Weld O/A Width / 3 +1 mm + Weld O/A Height -235mm O/A Width /3-150mm O/A Width /3-133mm Frame Top / Bottom to Rail Centre -172mm O/A Height - 84mm + Weld O/A Width / 4 +22mm + Weld O/A Height -235mm O/A Width / 4-129mm O/A Width / 4-112mm Frame Top/Bottom to Rail Centre -172mm 2 pane patio height kit Welded outer frame PKH-221 Maximum height 2150mm PKH-224 Maximum height 2450mm 2 pane patio width Kit Welded outer frame PKW-221 Maximum width 2100mm PKW-225 Maximum width 2500mm PKW-230 Maximum width 3000mm 3 pane patio height kit Welded outer frame PKH-321 Maximum height 2150mm PKH-324 Maximum height 2450mm 6. Slide the sash until nearly closed. 90mm With a pencil, mark the lock keep position on the outer frame. Open the door and fit the lock keep using 3.9 x 30mm screws. These will penetrate the previously fitted hardware fixing strip for added security. Slide the door closed and check the operation of the lock. 7. With the sliding sash in the closed position, fit the bump stop approximately 140mm from the outside edge of the outer frame, to the centreline of the door sash. Drawing L 3 pane patio width kit Welded outer frame PKW-332 Width 2500mm - 3200mm PKW-338 Width 3201mm - 3800mm PKW-345 Width 3801mm - 4500mm 4 pane patio height kit Welded outer frame PKH-421 Maximum height 2150mm PKH-424 Maximum height 2450mm 4 pane patio width kit Welded outer frame PKW-441 Width 3200mm - 4100mm PKW-450 Width 4101mm - 5000mm PKW-459 Width 5001mm - 5900mm We reserve the right to alter specifications and descriptions without prior notice as part of our policy of continuous development. E&OE. 226JUN13/v2