assembly guide - gratnells · 2020-02-04 · assembly guide the bored out ‘node’ is to be used...
TRANSCRIPT
A guide to building flat stages, tiered blocks,
fitting deck bars and steps.
Assembly Guide
The bored out ‘Node’ is tobe used to secure thebase of the handrail post.
Handrail assembly for a flat stage...
Please note that the nodehas been cut down toprovide a more stablebase.
Insert the leg through theNode so that the legprotrudes slightly, almostflush.
The leg should nowresemble the above.
Add the Handrail Adaptermouldings to both top andbottom. Then build thestage as normal.
When inserting handrailsand posts, ensure the postseats in the bottommoulding.
First create a 150mm highunit by combining thegreen and black rails tothe legs.
Assembling step flights for a 600mm high stage...
Complete the unit with adeck panel and place tierriser cups in the back legsas if for a tiering block.
Insert 450mm legs intothe riser cups and connectthese with a black railbefore continuing to buildthe higher units as per anormal stage.
If the Steps are to berecessed into the stagethere should be a furtherriser cup used on the sideof the unit.
Once the 2 step unit hasbeen added there is acontinuous 150mm rise inthe step flight. The treaddepth is a constant300mm deep.
More commonly the stepflight projects from thefront of the stage.
First create a 300mmhigh unit by combiningthe green and blackrails to the legs.
Assembling step flights for a 750mm and 900mm high stage...
Complete the unit witha single step unit, deckpanel and place tier risercups in the back legsas if for a tiering block.
Continue to build in thisway to create the lowerlevel.
Continue to build theupper level of the stageusing the standardbuilding technique.
Once the upper level iscomplete add the doubletread step unit to thefront before addingpanels
This creates an evenstep rise with a consistentdepth of 300mm.
For 900mm Stagesbuild the first 450mmunit complete withdouble step thencontinue to build untilboth levels are completewith frame work.
Add a double step to thefront and finish the stageas normal. Please notethat this step flight canalso be recessed.
The Trolley is designedto utilise the equipmentfor your stage to buildadjustable racking.The trolley base itself issupplied as one piece andshould not be dismantled.
Trolley assembly...
Begin by adding tier risercups to the corners of thetrolley base, ensuring thatthe cups sit securely.
Using 450mm legs, blackand green rails create aunit frame on top of thetrolley itself. This shouldthen be topped with adeck panel.
Repeat this process usingmore 450mm legs andtier riser cups, until thetrolley resembles theabove, in all cases ensurethat the components seatsecurely into each other.
Use 300mm legs on thetop of the trolley to providea safety rail and ensurethat the equipment storedon top will not fall offduring transit.
When loading the trolleythe deck panels mustalways go on the bottomof the trolley to aidstability. Enclosing panelscan then be used on thesides.
t: 01509 264112m: 07768 931016
The bored out ‘Node’ is tobe used to secure thebase of the handrail post.
Handrail assembly for a flat stage...
Please note that the nodehas been cut down toprovide a more stablebase.
Insert the leg through theNode so that the legprotrudes slightly, almostflush.
The leg should nowresemble the above.
Add the Handrail Adaptermouldings to both top andbottom. Then build thestage as normal.
When inserting handrailsand posts, ensure the postseats in the bottommoulding.
First create a 150mm highunit by combining thegreen and black rails tothe legs.
Assembling step flights for a 600mm high stage...
Complete the unit with adeck panel and place tierriser cups in the back legsas if for a tiering block.
Insert 450mm legs intothe riser cups and connectthese with a black railbefore continuing to buildthe higher units as per anormal stage.
If the Steps are to berecessed into the stagethere should be a furtherriser cup used on the sideof the unit.
Once the 2 step unit hasbeen added there is acontinuous 150mm rise inthe step flight. The treaddepth is a constant300mm deep.
More commonly the stepflight projects from thefront of the stage.
First create a 300mmhigh unit by combiningthe green and blackrails to the legs.
Assembling step flights for a 750mm and 900mm high stage...
Complete the unit witha single step unit, deckpanel and place tier risercups in the back legsas if for a tiering block.
Continue to build in thisway to create the lowerlevel.
Continue to build theupper level of the stageusing the standardbuilding technique.
Once the upper level iscomplete add the doubletread step unit to thefront before addingpanels
This creates an evenstep rise with a consistentdepth of 300mm.
For 900mm Stagesbuild the first 450mmunit complete withdouble step thencontinue to build untilboth levels are completewith frame work.
Add a double step to thefront and finish the stageas normal. Please notethat this step flight canalso be recessed.
The Trolley is designedto utilise the equipmentfor your stage to buildadjustable racking.The trolley base itself issupplied as one piece andshould not be dismantled.
Trolley assembly...
Begin by adding tier risercups to the corners of thetrolley base, ensuring thatthe cups sit securely.
Using 450mm legs, blackand green rails create aunit frame on top of thetrolley itself. This shouldthen be topped with adeck panel.
Repeat this process usingmore 450mm legs andtier riser cups, until thetrolley resembles theabove, in all cases ensurethat the components seatsecurely into each other.
Use 300mm legs on thetop of the trolley to providea safety rail and ensurethat the equipment storedon top will not fall offduring transit.
When loading the trolleythe deck panels mustalways go on the bottomof the trolley to aidstability. Enclosing panelscan then be used on thesides.
t: 01509 264112m: 07768 931016
The bored out ‘Node’ is tobe used to secure thebase of the handrail post.
Handrail assembly for a flat stage...
Please note that the nodehas been cut down toprovide a more stablebase.
Insert the leg through theNode so that the legprotrudes slightly, almostflush.
The leg should nowresemble the above.
Add the Handrail Adaptermouldings to both top andbottom. Then build thestage as normal.
When inserting handrailsand posts, ensure the postseats in the bottommoulding.
First create a 150mm highunit by combining thegreen and black rails tothe legs.
Assembling step flights for a 600mm high stage...
Complete the unit with adeck panel and place tierriser cups in the back legsas if for a tiering block.
Insert 450mm legs intothe riser cups and connectthese with a black railbefore continuing to buildthe higher units as per anormal stage.
If the Steps are to berecessed into the stagethere should be a furtherriser cup used on the sideof the unit.
Once the 2 step unit hasbeen added there is acontinuous 150mm rise inthe step flight. The treaddepth is a constant300mm deep.
More commonly the stepflight projects from thefront of the stage.
First create a 300mmhigh unit by combiningthe green and blackrails to the legs.
Assembling step flights for a 750mm and 900mm high stage...
Complete the unit witha single step unit, deckpanel and place tier risercups in the back legsas if for a tiering block.
Continue to build in thisway to create the lowerlevel.
Continue to build theupper level of the stageusing the standardbuilding technique.
Once the upper level iscomplete add the doubletread step unit to thefront before addingpanels
This creates an evenstep rise with a consistentdepth of 300mm.
For 900mm Stagesbuild the first 450mmunit complete withdouble step thencontinue to build untilboth levels are completewith frame work.
Add a double step to thefront and finish the stageas normal. Please notethat this step flight canalso be recessed.
The Trolley is designedto utilise the equipmentfor your stage to buildadjustable racking.The trolley base itself issupplied as one piece andshould not be dismantled.
Trolley assembly...
Begin by adding tier risercups to the corners of thetrolley base, ensuring thatthe cups sit securely.
Using 450mm legs, blackand green rails create aunit frame on top of thetrolley itself. This shouldthen be topped with adeck panel.
Repeat this process usingmore 450mm legs andtier riser cups, until thetrolley resembles theabove, in all cases ensurethat the components seatsecurely into each other.
Use 300mm legs on thetop of the trolley to providea safety rail and ensurethat the equipment storedon top will not fall offduring transit.
When loading the trolleythe deck panels mustalways go on the bottomof the trolley to aidstability. Enclosing panelscan then be used on thesides.
t: 01509 264112m: 07768 931016
Deck bar assembly for a flat stage...
Assembling step flights for a 600mm high stage...
Assembling step flights for a 750mm and 900mm high stage...
First create a 150mm high unit by combining the green and black rails to the legs.
Complete the unit with a deck panel and place tier riser cups in the back legs as if for a tiering block.
Insert 450mm legs into the riser cups and connect these with a black rail before continuing to build the higher units as per a normal stage.
If the Steps are to be recessed into the stage there should be a further riser cup used on the side of the unit.
More commonly the step flight projects from the front of the stage.
Once the 2 step unit has been added there is a continuous 150mm rise in the step flight. The tread depth is a constant 300mm deep.
First create a 300mm high unit by combining the green and black rails to the legs.
Complete the unit with a single step unit, deck panel and place tier riser cups in the back legs as if for a tiering block. Continue to build in this way to create the lower level.
Continue to build the upper level of the stage using the standard building technique.
Once the upper level is complete add the double tread step unit to the front before adding panels
This creates an even step rise with a consistent depth of 300mm.
Add a double step to the front and finish the stage as normal. Please note that this step flight can also be recessed.
For 900mm Stages build the first 450mm unit complete with double step then continue to build until both levels are complete with frame work.
Gratnells Ltd, 8 Howard Way, Harlow, Essex CM20 2SU United KingdomT, 01279 401550 F, 01279 419127 E, [email protected] W, www.gratnellsstage.com
The bored out ‘Node’ is to be used to secure the base of the deck bar post.
Please note that the node has been cut down to provide a more stable base.
Insert the leg through the Node so that the leg protrudes slightly, almost flush.
The leg should now resemble the above.
Add the deck bar Adapter mouldings to both top and bottom. Then build thestage as normal.
When inserting deck bars and posts, ensure the post seats in the bottom moulding.
Stage 1 contents
COMPONENT NUMBER
450mm legs 20
750mm deck bars 31
750mm x 750mm deck panels
12
Birch trims 4
Gap mouldings 7
Corner mouldings 4
2 step unit 1
Stage 2 contents
COMPONENT NUMBER
450mm legs 28
750mm deck bars 45
750mm x 750mm deck panels
18
Birch trims 6
Gap mouldings 9
Corner mouldings 4
2 step unit 2
Stage 3 contents
COMPONENT NUMBER
450mm legs 35
750mm deck bars 58
750mm x 750mm deck panels
24
Birch trims 6
Gap mouldings 11
Corner mouldings 4
2 step unit 2
Stage 4 contents
COMPONENT NUMBER
450mm legs 35
750mm deck bars 58
750mm x 750mm deck panels
24
Birch trims 6
Gap mouldings 11
Corner mouldings 4
2 step unit 2
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Building a tiered block...
Ensure all rails are securely seated atboth ends, at this point you can addtrims or steps to a unit which will beon the outside edge of your stagelayout.
Complete the first unit by adding adeck panel, then continue to build bycompleting the frame using blackand green rails. Repeat these steps until the entire
stage is built.
If using handrails on a flat level stageplease see the Handrail Assemblyinstructions (overleaf) for additionalinstructions for building the outsideunits of your stage.
Fitting Steps and Trims...
Steps and trims attach to the frame before the deck panel is located. It is advisablethat they be situated before the panel is placed in any stage build to avoid trappingfingers.
Corner mouldings are supplied to fitflush with the top of the trim andstep. These simply locate in the freepegs on the node.
A gap trim fits between trims in orderto provide a level edge to the stage.
Using 150mm legs create the firstrow by assembling rails as per for astandard stage. Once the frame iscomplete add a single deck panel to‘Square’ the unit. Then continue tobuild until the first row is completed.
Add Tier Riser Mouldings to the rearof the row, ensuring that each sitssecurely in the Node.
Once completed insert 300mm legsinto the Riser and connect withBlack rails.
The bottom clasp of the handrailshould rest on the bottom handrailadapter. By eye this should leave aclear path through for the nexthandrail.
Insert the leg of the handrail throughboth adapters. Note; It is easier tohold the handrail at 45o to the tieringin order to swing the clasps onto theadapters on the next level.
Handrail adapters should always belocated in the first and second nodesfrom the top of the row. This shouldbe done for all rows after the first.
In every case ensure eachcomponent is securely fastened intoit’s companion piece beforecontinuing.
Any further rows from this will bebased upon this structural format.For example: a fifth row would be450mm legs, 600mm legs and300mm legs down the rear whilst asixth would be 450mm, 600mm and600mm legs.
Repeat the build sequence with risercups, 300mm legs and black rails onthe front of the forth row.
Connect this frame using green railsinto 600mm legs into the back of thetiering block.
Again use a deck on the first unit toensure that the frame is squared andto avoid any deviation in the rowitself.
Add all necessary Trims and a singlestep to ensure the row rise continuesevenly.
Once the second row is completecontinue to build the base of thetiering block by using 450mm legs.
Insert Tier Risers into each nodealong the base of the tiering block.Connect the riser cups of the thirdrow (front and back) using 300mmlegs, black and green rails.
Once any necessary steps and trimsare in place fit the deck to thesecond row unit and continuebuilding the second row in thisway until complete.
Steps should be added to the tieringfrom the second row onwards toprovide an even row rise throughoutthe tiering block.
Then continue to build the secondrow using green Rails connectedto 450mm Legs.
Insert the next handrail through bothadapters making sure that the claspof the previous handrail locateseither side of the handrails leg.
Repeat this process for both sidesand back completing all handrailruns with a locking handrail post toensure they are secure.
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Aalborg Assembly v2.pdf 1 10/09/2015 14:03
Ensure all rails are securely seated at both ends, at this point you can add trims or steps to a unit which will be on the outside edge of your stage layout.
Connect a rail securely into the ‘Node’ at the top of the leg ensuring it is fully located.
Repeat this until the rail is fitted with the same sized legs at each end.
Insert a green rail at 90o to the black Rail. Repeat the above until you have created a rectangular frame.
If using handrails on a flat level stage please see the Handrail Assembly instructions (overleaf) for additional instructions for building the outside units of your stage.
Fitting Steps and Trims...
Complete the first unit by adding a deck panel, then continue to build by completing the frame using black and green rails. Repeat these steps until the entire stage
is built.
Corner mouldings are supplied to fit flush with the top of the trim and step. These simply locate in the free pegs on the node.
A gap trim fits between trims in order to provide a level edge to the stage.
Steps and trims attach to the frame before the deck panel is located. It is advisable that they be situated before the panel is placed in any stage build to avoid trapping fingers.
Building a stage...
Using 150mm legs create the first row by assembling rails as per for a standard stage. Once the frame is complete add a single deck panel to ‘Square’ the unit. Then continue to build until the first row is completed.
Again use a deck on the first unit to ensure that the frame is squared and to avoid any deviation in the row itself.
Repeat the build sequence with riser cups, 300mm legs and black rails on the front of the forth row.
Connect this frame using green rails into 600mm legs into the back of the tiering block.
In every case ensure each component is securely fastened into it’s companion piece before continuing.
Add Tier Riser Mouldings to the rear of the row, ensuring that each sits securely in the Node.
Once completed insert 300mm legs into the Riser and connect with Black rails.
Then continue to build the second row using green Rails connected to 450mm Legs.
Steps should be added to the tiering from the second row onwards to provide an even row rise throughout the tiering block.
Deck bar adapters should always be located in the first and second nodes from the top of the row. This should be done for all rows after the first.
Once any necessary steps and trims are in place fit the deck to the second row unit and continue building the second row in this way until complete.
Insert the leg of the handrail through both adapters. Note; It is easier to hold the deck bar at 45o to the tiering in order to swing the clasps onto the adapters on the next level.
Once the second row is complete continue to build the base of the tiering block by using 450mm legs.
Insert Tier Risers into each node along the base of the tiering block. Connect the riser cups of the third row (front and back) using 300mm legs, black and green rails.
The bottom clasp of the deck bar should rest on the bottom handrail adapter. By eye this should leave a clear path through for the next handrail.
Add all necessary Trims and a single step to ensure the row rise continues evenly.
Insert the next handrail through both adapters making sure that the clasp of the previous deck bar locates either side of the handrails leg.
Repeat this process for both sides and back completing all deck bar runs with a locking handrail post to ensure they are secure.
Any further rows from this will be based upon this structural format. For example: a fifth row would be 450mm legs, 600mm legs and 300mm legs down the rear whilst a sixth would be 450mm, 600mm and 600mm legs.
Building a tiered block...
W, www.gratnellsstage.com E, [email protected] T, 01279 401550
6656 Gratnells Stage Instructions.indd 2-3 13/10/2015 07:17