Download - Alufusion Eng Trocal

System description

System attributes

TROCAL AluFusion AD

System

AluFusion AD

Register

1.1

Page

1

Scale

1:1 / 1:2June 2008

Subject to modifications without prior notice.

1.1 System attributes TROCAL AluFusion AD

Five-chamber profile system with 70 mm

installation depth. Lean look owing to

gentle curves and bevelled edges.

No visible glazing beads inside. So greater

tightness, no dirt trap and no displacement in

the mitres, smooth clear design.

Weldable or conventional EPDM gaskets in

black or grey.

High inherent rigidity of the aluminium cover,

window sashes need no steel reinforcement

The aluminium cover bears all the loads,

and steel is used only on special designs,

e.g. for greater sound insulation require-

ments or pressure loads.

Controlled drainage and ventilation through

the antechambers in the outer and sash

frames.

16 mm hardware groove with undercut for

clip-on hardware.

Glazing or panelling up to 40 mm possible

without additional profiles. No sash deflec-

tion even with heavy glazing.

Variable outer frame clip designs for simple

and professional installation. The TROCAL

range of additional and ancillary profiles pro-

vides an extensive line of alternative choic-

es. Dowel holes are possible through sepa-

rate installation chambers.

Classical joint design, straight-edged and

therefore stress-free connection, customis-

able colour scheme for the aluminium cover

profile.

System description

Opening modes

TROCAL AluFusion AD

System

AluFusion AD

Register

1.2

Page

1Scale

not to scale

June 2008


fixed frame fixed frame fixed frame fixed tilt/turn

tilt/turn tilt/turn tilt/turn bottom-hung

tilt/turn

balcony door 2-part balcony door

fixed tilt/turn

2-part balcony door with floating mullion

bottom-hung tilt/turn

parallel sliding-tilting door

1.2 Opening modes

residential door

System description

Specifications

TROCAL AluFusion AD

System

AluFusion AD

Register

1.3

Page

1

ScaleJune 2008


The profiles are manufactured in an extrusion process.

Constant production control safeguards the quality and geometrical precision of the pro-

files. The profiles fulfil the requirements under RAL-GZ 716/1, Part 1.

profile material moulding compound, white as per

DIN 7748 PVC-u, EDLP, 080-35-28

density DIN EN ISO 1183 1.44 g/cm3

impact toughness up to -40 C DIN 53453 (small standard test piece)

w/o fracture

notch toughness DIN EN ISO 179

(in standard atmosphere 23 C (1fc test piece) 40 kJ/m2

under DIN EN ISO 179)

ball hardness DIN ISO 239 T1 100 N/mm2

(impression time 30 s)

tensile strength DIN EN ISO 527 40 N/mm2

modulus of elasticity DIN EN ISO 527 2500 N/mm2

heat distortion temperature:

Vicat VST/B (measured in oil) DIN ISO 306 80 CISO R 75/A (measured in oil) DIN 53461 69 C

linear thermal expansion

coefficient -30 C to +50 C 0.8 x 10-4

K-1

thermal conductivity DIN 52612 0.16 W/mK

volume resistivity DIN VBE 0303 T3 1016

W cm

relative permittivity DIN 53483 3.3 at 50 Hz;

2.9 at 106

Hz

fire behaviour DIN 4102 flame

resistant,

self-extinguishing

weather resistance

RAL GZ 716/1 after 8.0 GJ/m2

insolation energy better than resistance grade

4 of the grey scale

according to DIN ISO 105-A03

weathering resistance

RAL GZ 716/1 after 8.0 GJ/m2

insolation energy drop in notch

toughness < 30%

or > 28 KJ/m2

particular resistances termite-proof, rot-proof, chemical-resistant as

per DIN 8061 Bbl. 1, e.g. to: lyes, acids,

salts, salt solutions, alkalis, seawater, petrol,

oil, lime, cement, exhaust gases of all kinds

1.3 Specifications

System description

Specifications

TROCAL AluFusion AD

System

AluFusion AD

Register

1.3

Page

2

ScaleJune 2008


physiological properties

and environmental behaviour inert, neutral

Its weather, chemical, and rot resistance ensure that

they pose no risk to health or the environment when

handled.

profile wall thickness as per RAL GZ 716/1

machining operations drilling, milling, sawing, filing, welding,grinding

corner connections welded

opening modes side-hung, tilt/turn, bottom-hung, sliding/tilting door

glazing types dry glazing with roll-in peripheral EPDM gaskets or

coextruded weldable TPE gaskets (sashes only)

pane types insulating glass,

glass thicknesses from 20 to 40 mm possible

glazing beads for fixed glazing only,

engaged over the whole length

gaskets a) frame sash

b) fixed glazing

material EPDM

gasket colour black and light grey (RAL 7035)

(other colours on request)

hardware commercially available, according to TROCAL hard-

ware list

chamber size according to installation instructions for 12+1 mm hard-

ware

hardware fasteners screws

sash stop simple

drainage drilled or elongated holes near the rebate;

slots in drainage antechamber

(as per instructions)

sealing flexible between wall and outer frame

flush-mounted basic frame not necessary

installation in building facade all usual installation types possible

profile shapes as per workbook

surfaces colour white

aluminium surfaces anodised and any RAL chart colour scheme

paint finish possible

cleaning and care Kraclean extra (colour white), water and suitable

household cleaner (non-abrasive, non-dissolving). We

cannot accept liability for all household cleaners. Do

not use any cleaning or polishing agents that dissolve

PVC.

System description

Specifications

TROCAL AluFusion AD

System

AluFusion AD

Register

1.3

Page

3

ScaleJune 2008


heat transfer coefficients window insulation value (Uw) depends on the glazing

used and the profiles insulation value

glazing insulation value (Ug) approx 2.6 to 0.5 W/m2 K

frame insulation value (Uf) depending on the system

and profile combination approx 1.01.3 W/m2 K

aluminium cover material Al Mg Si 0, 5, F22

Reinforcements DIN EN 10.142/10.147/DX 51D+Z,

cold-rolled as per DIN 59413/17118 or

DIN EN 10.142/10.147, galvanised as per DVV 7

Table 4a + 4b

Important note The observed changes in length experienced by the

heated profiles are minimal as demonstrated by

numerous example installations. Owing to the extre-

mely low thermal conductivity of PVC the profiles are

not thoroughly heated, i.e. potential changes in length

based on the coefficient of linear thermal expansion

do not occur in practice.

Profile overviewMain profiles

TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

Page

1

Scale

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June 2008


2.1 Main profiles

61 01 00

67 70 0752 06 08, 52 07 08,

51 03 08

61 02 00

67 71 0752 06 08, 52 07 08,

51 03 08

62 05 00

67 80 07 / 67 81 0752 05 08

62 22 00

67 85 07 / 67 86 0751 04 08, 52 23 08

62 25 00

67 83 07 / 67 82 07 / 67 84 0792 65 08

53 11 00

67 91 07 / 67 90 0753 11 08

53 16 00

67 91 07 / 67 90 0753 15 08

63 01 00

67 75 0753 03 08, 57 03 08

63 22 00

67 76 07

63 22 00

67 69 07

63 24 00

67 77 0752 06 08


TROCAL AluFusion AD

System

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Register

2.1

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Scale:

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67 70 07 aluminium coverE = 229 mm

S = 112 mm

61 01 00 outer frame


Scale 1:1

52 06 08

50 03 00 black50 03 30 greyEPDM weatherseal

59 44 88mounting sleeve forT connector 36.3 mm

69 70 10drainage tube 10 x 14 mm

S (mm) Ix (cm4) Iy (cm

4)

1.251.50

1.31.6

0.2

0.3

52 07 08


4)

1.502.00

2.12.6

0.7

0.9

50 60 20 whitegroove panellingprofile

51 03 08


4)

1.50 2.6 2.1

59 28 10dowel sup-port

59 62 10glazing rebateblock

59 66 10glazing rebateinsert withbearing packer

Legends

E = anodised surface

S = visible surface


90 31 00 black90 31 30 greyEPDM glazing gasket5 mm

19 85 10transportlock


TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

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Scale:

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Legends


S = visible surface


S = 127 mm



Scale 1:1

52 06 08



59 45 88mounting sleeve forT connector 51 mm


4)

1.251.50

1.31.6

0.2

0.3


57 04 08


4)

2.00 4.5 7.9

59 28 10dowel sup-port


59 66 10glazing rebate insertwith bearing packer





TROCAL AluFusion AD

System

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Register

2.1

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Scale:

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Legends


S = visible surface

62 05 00 sash profile


S = 96 mm


62 05 40 with two coextruded gaskets

10 08 00 black10 08 30 greyEPDM glazinggasket 4.5 mm


52 05 08


4)

2.00 2.9 0.9



10 11 30 greyEPDM glazinggasket 0.8 mm


S = 98 mm



59 66 10glazing rebate insertwith bearing packer

69 80 10end cap for 67 80 07

69 81 10end cap for 67 81 07

Scale 1:1


TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

Page

6

Scale:

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Legends


S = visible surface



S = 133 mm





52 23 08


4)

2.00 5.5 6.2







69 85 10end cap for 67 85 07

51 04 08


4)

1.502.00

4.25.5

3.7

4.8

59 37 10welded corner con-nector for 51 04 08


9679 clamping leverSteel also available in

prepunched designs for

the lock side!

Scale 1:1


TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

Page

7

Scale:

1:1June 2008


Legends


S = visible surface



S = 125 mm





52 23 08


4)

2.00 5.5 6.2







69 86 10end cap for 67 86 07

51 04 08


4)

1.502.00

4.25.5

3.7

4.8



9679 clamping leverSteel also available in

prepunched designs for

the lock side!

Scale 1:1


TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

Page

8

Scale:

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Legends


S = visible surface

62 25 00 residential door sash profile


S = 158 mm










69 83 10end cap for 67 83 07

92 65 08

S

(mm)

Ix

(cm4)

Iy

(cm4)2.50 12.8 25.8


9679 clamping lever

Steel also

available in

prepunched

designs for

the lock side!

50 22 00 black50 22 30 greyEPDM weatherseal for residen-tial door

50 23 30 greyEPDM weatherseal for residen-tial door

Scale 1:1


TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

Page

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Scale:

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Legends


S = visible surface


67 82 07aluminium cover (planned)E = 310 mm

S = 154 mm










69 82 10(planned)end cap for 6782 07

92 65 08

S

(mm)

Ix

(cm4)

Iy

(cm4)2.50 12.8 25.8


9679 clamping lever

Steel also

available in

prepunched

designs for

the lock side!



Scale 1:1


TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

Page

10

Scale:

1:1June 2008


Legends


S = visible surface



S = 152 mm





69 84 10end cap for 67 84 07


9679 clamping lever








92 65 08

S

(mm)

Ix

(cm4)

Iy

(cm4)2.50 12.8 25.8

Steel also

available in

prepunched

designs for

the lock side!

Scale 1:1


TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

Page

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Scale:

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63 01 00 mullion / transom

Scale 1:1

53 03 08


4)

2.50 9.3 2.2

57 03 08


4)

2.00 6.7 1.8


S = 122 mm

63 01 00 mullion / transom




69 25 19T connector

69 26 17cross connector

Legends


S = visible surface







TROCAL AluFusion AD

System

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Register

2.1

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63 22 00 floating mullion profile


S = 87 mm




69 17 10floating mullionend capinner for cover67 69 07

69 19 10floating mullionend capouter for cover67 69 07

Legends


S = visible surface

Scale 1:1

69 08 10floating mullionend capinner for cover67 76 07


S = 74 mm


TROCAL AluFusion AD

System

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Register

2.1

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Scale:

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Legends


S = visible surface



S = 106 mm




69 05 10floating mullion end capfor use with thresholdprofile

69 06 10 floating mullionend cap

Scale 1:1

52 06 08


4)

1.251.50

1.3

1.6

0.2

0.3


TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

Page

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Scale:

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53 11 00 Georgian bar profile


S = 80 mm





53 11 08


4)

1.50 2.0 0.5






59 22 19T connectorset

aluminium strip forcovering theGeorgian bar

Aluminium strip notincluded in the TROCALdelivery programme!

Legends


S = visible surface


S = 41 mm

Scale 1:1


TROCAL AluFusion AD

System

AluFusion AD

Register

2.1

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Scale:

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June 2008





53 15 08

S

(mm)

Ix

(cm4)

Iy

(cm4)

1.50 4.9 4.1






59 23 19T connectorset

aluminium strip forcovering theGeorgian bar

Aluminium strip notincluded in the TROCALdelivery programme!

Legends


S = visible surface

69 46 17Georgian bar con-nector


S = 80 mm




S = 41 mm


TROCAL AluFusion AD

System

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Register

2.1

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Scale:

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57 31 07 threshold

Scale 1:1

57 31 07 threshold profile

57 45 07weather bar

E. = 124 mm

S = 20 mm

59 45 10end cap

50 44 00gasket

69 13 10threshold connectorfor 61 01 00

69 14 10 threshold connectorfor 61 02 00

69 15 10threshold connectorfor 63 01 00

69 52 10rebate pad set


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System

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Register

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Scale:

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57 40 07 threshold profile

57 42 07weather bar

E = 130.5 mm

S = 89 mm

59 42 10end cap

50 52 00gasket

95 38 00groove panellingprofile

57 40 07 threshold

Scale 1:1

01 59 00PVC panel for outer frame:

61 02 00 = 45 x 30 ... 75 mm61 01 00 = 27 x 30 ... 75 mm

alternative block strip30 x 50 x 1000 mm

69 35 10rigid foam board,6 x 38.5 x 62 mm,white, single-sidedself-adhesive

Profile overviewAdditional profiles

TROCAL AluFusion AD

System

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Register

2.2

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2.2 Additional profiles

54 03 30*

54 01 30*steel 97 66 08

54 04 30*steel 97 66 08

54 05 36

94 55 36

94 12 00

54 11 00 54 12 00

94 19 3694 14 36

91 23 08 0.2

Steel Ix cm4

976608s = 2.0s = 3.0

5.67.7

Steel Ix cm4

91 01 08s = 1.25s = 1.5

1.26 1.46

Steel Ix cm4

52 06 08 1.6

Steel Ix cm4

54 36 06 base single column profile

*The aluminium covers for the

extension profiles are not part of

the TROCAL delivery programme.

53 11 08 2.0

Steel Ix cm4

54 12 00


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System

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Register

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Scale:

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54 08 00

94 39 40*

94 40 40

54 20 00*90 corner coupling

54 26 00*135 corner coupling

94 92 00*steel tube 100 x 40 mm

(commercial product)91 07 08 5.2

Steel Ix cm4

Coupling profiles

*The aluminium covers for the coup-

ling profiles are not part of the

TROCAL delivery programme.

54 26 08 3.5

Steel Ix cm4

94 01 08 8.7

Steel Ix cm4 94 03 08 22.4

Steel Ix cm4 94 01 08 8.7

Steel Ix cm4

57 96 07

67 89 07anodised surface 112 mm

visible surface 34 mm

99 67 88Clamping screw

54 21 00*

94 03 08 22.4

Steel Ix cm4


TROCAL AluFusion AD

System

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Register

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Page

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Scale:

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58 60 07aluminium Georgian baranodised surface 70 mm










98 60 00

PVC Georgian bar

98 61 00

PVC Georgian bar

98 62 00

PVC Georgian bar

98 63 00

PVC Georgian bar

98 64 00

PVC Georgian bar

Georgian bar profiles

self-adhesive on one side

Profile combinationsDeductions

TROCAL AluFusion AD

System

AluFusion AD

Register

3.1

Page

1Scale

nicht Scalegerecht

June 2008


3.1 Deductions

How to determine deductions

Determining the trims and deductions requires the values listed in the tables onthe following pages 3.1 313.

Bear in mind that the deductions are based on their respective intersec-tions.

Example

a double-sashed window with fixed centre mullionframes external measurements FEM = 2000 x 1200 mm (W x H)

1. for sash, to the frame see Table on page 3.1 32. for sash, to the mullion see Table on page 3.1 93. for glazing, to the sash see Table on page 3.1 10

frames external measurements = FEM

pane size

sash rebate size = SRS

sashs external measurements = SEM

Example FEM = 2000; X = 1000; a = 40; b = 13

SEM = 1000 (40 + 13) = 947

Deductions

Determining the sashs external measurements (width) SEM on anysash size

SEM = X or Y (a + b)

Determining the pane size

pane size = SEM 132

a = 4061 01 00

b = 13

63 01 00

read off on page3.1 3 (Table)

read off on page3.1 7 (Table)

pane size

sash rebate size = SRS

sashs external measurements = SEM


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System

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Register

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June 2008


We recommend using your hands on the welded outer frame to

measure out the trims for all aluminium covers. Owing to the differing

coefficients of linear thermal expansion for aluminium and PVC production

tolerances can be as high as -0.5 mm per side when the aluminium cover is

trimmed (see Fig 1).

Note on trimming aluminium covers

Determining the trims and deductions requires the values listed in the tables

on the following pages 3.1 313.

1. Straight-edged trim in smooth design 2. Straight-edged trim in milled design

Before milling the

straight-edged trim first

add an extra 2.3 mm to

the value listed in the

table for the respective

intersection between

outer and mullion cov-

ers.

sash cover horizontal

outer frame cover horizontal

sash c

over

vert

ical

ou

ter

fra

me

co

ve

r ve

rtic

al

Fig 1 Production tolerance

See t

able

for

str

aig

ht-

edged a

lum

iniu

m

cover

trim

s f

or

oute

r fr

am

e

See table for aluminium

cover trim for sash


TROCAL AluFusion AD

System

AluFusion AD

Register

3.1

Page

3

Scale

1:1June 2008


FEM width

FE

M h

eig

ht

FEM

Deductions Frame profiles

The specified deductions are basedon their respective intersections only

Deductions in mm for(based on framesexternal measurement = FEM)

61 01 00 61 02 00

sashs external measurement (SEM) 40 55

sash rebate size (SRS) 60 75


TROCAL AluFusion AD

System

AluFusion AD

Register

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Scale

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FEM width

FE

M h

eig

ht

FE

M

Deductions Frame profiles



61 01 00 61 02 00

fixed glass pane 53 68

steel (frame) 47 62

transom/mullion 48 68

steel (transom/mullion) 62 77

aluminium cover frame, horizontal +1.3 +1.3

aluminium cover, frame, vertical 64.3 79.3

aluminium cover transom/mullion 65.4 80.4


TROCAL AluFusion AD

System

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Register

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5

Scale

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FEM width

FE

M h

eig

ht

Deductions Frame profiles Thresholds



61 01 00 61 02 00 57 40 07 57 31 07

sashs external measurement (SEM) 38 53 8 10

sash rebate size (SRS) 60 75 30 32

transom / mullion / glazing bead 48 63 18 20

steel (transom/ mullion) 62 77 20 22

57 42 07

57 40 07

The specified deductions apply only to the residential door sash 62 25 00!

alternatively

threshold 57 31 07

weather bar: 57 42 07


TROCAL AluFusion AD

System

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Register

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Scale

1:1June 2008


FEM width

FE

M h

eig

ht




61 01 00 61 02 00 57 31 07

sashs external measurement (SEM) 38 53 8

sash rebate size (SRS) 60 75 30

transom / mullion / glazing bead 48 63 20

steel (transom/ mullion) 62 77 22

57 45 07

57 31 07

The specified deductions apply only to the residential door sash 62 25 00!


TROCAL AluFusion AD

System

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Register

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Scale

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FEM width

FE

M h

eig

ht




61 01 00 61 02 00 57 31 07

sashs external measurement (SEM) 40 55 10

sash rebate size (SRS) 60 75 30

transom / mullion / glazing bead 48 63 20

steel (transom/ mullion) 62 77 22

57 45 07

57 31 07

The specified deductions apply only to the balcony door sash 62 22 00!


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Deductions Threshold profiles



57 40 07 57 31 07

frame 18 20

steel (frame) 100 57

transom / mullion 18 20

steel (transom/mullion) 20 22

aluminium cover, frame, vertical 17.9 22.5

aluminium cover mullion 18.9 22.5

FE

M

FE

M

FE

M

FEM width

FE

M h

eig

ht


TROCAL AluFusion AD

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Scale

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distance between axes

FE

M h

eig

ht

distance between axes

FE

M h

eig

ht

62 05 00;

62 22 00 62 25 00

Deductions Transom profiles


Deductions in mm for (based on profiles centre axis)

63 01 00


sash rebate size (SRS) 33

fixed glass pane 26

transom/mullion 21

steel (transom/mullion) 35

aluminium cover transom 38.6



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SEM width

SE

M h

eig

ht

Deductions Sash profiles


Deductions in mm for(based on sashs external measurementSEM)

62 05 00


pane/steel size 66

aluminium cover 678107, horizontal 63.8

aluminium cover 678107, vertical 38.2

aluminium cover 678007, horizontal 61



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62 22 00


pane/steel size 89

aluminium cover 67 85 07 horizontal 43

aluminium cover 67 85 07 vertical 84.7

SEM width

SE

M h

eig

ht

67 85 07


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62 22 00


pane/steel size 89

aluminium cover 67 86 07 horizontal 43


SEM width

SE

M h

eig

ht

67 86 07


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13

Scale

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SEM width

SE

M h

eig

ht




62 25 00


pane/steel size 115

aluminium cover 67 82 07 horizontal 110.7


67 82 07


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Scale

1:1June 2008


SEM width

SE

M h

eig

ht




62 25 00


pane/steel size 115



67 83 07


TROCAL AluFusion AD

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Register

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Scale

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SEM width

SE

M h

eig

ht

67 84 07




62 25 00


pane/steel size 115




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FEM width

FE

M h

eig

ht

X Y

Sash deductions Frame profiles

The specified deductionsare based only on their respective frameintersections in conjunctionwith the floating mullion profile 63 22 00

Deductions in mm for61 01 00 61 02 00

sashs external measurement (SEM) X 34 X 49

sash rebate size (SRS) X 74 X 89

trim for floating mullion profle = SEM (2 x 40 mm)

aluminium cover 67 76 07 (67 69 07 planned) = SEM (2 x 40 mm)

67 76 07

67 69 07


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Scale

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FEM width

FE

M h

eig

ht

X Y

Sash deductions Frame profiles

The specified deductionsare based only on their respective frameintersections in conjunctionwith the floating mullion profile 63 24 00


sashs external measurement (SEM) X 45 X 60

sash rebate size (SRS) X 85 X 100

trim for floating mullion profle = SEM (2 x 39 mm)

aluminium cover 677607 = SEM (2 x 37 mm)

steel for floating mullion = SEM (2 x 39 mm)

62 05 00

or

62 22 00


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Register

3.1

Page

18

Scale

1:1June 2008


Sash deductions Frame profiles Floating mullion profile trim

The specified deductionsare based only on their respective frame intersec-tions in conjunctionwith the floating mullion profile 63 24 00


sashs external measurement 62 22 00 (SEM) X 45 X 60

sash rebate size 62 22 00 (SRS) X 85 X 100

sashs external measurement 62 25 00 (SEM) X 41 X 56

sash rebate size 62 25 00 (SRS) X 85 X 100 sash 62 22 00 sash 62 25 00

Floating mullion profile 62 24 00 trim SEM 61 mm SEM 65 mm

Aluminium cover 677607 trim SEM 57 mm SEM 61 mm

Steel 52 06 08 trim SEM 61 mm SEM 65 mm

FEM width

FE

M h

eig

ht

X

62 22 00 62 25 00


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Page

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Scale

1:1June 2008


Sash deductions Sash

The listed deductions apply to therespective intersections only

Deductions in mm for(based on the sashsexternal measurements = SEM)

62 05 00

Georgian bar 53 11 00 / 53 16 00 56

Steel 63

aluminium cover 67 90 07 64

metal strip 2 x 25 mm or 2 x 53 mm 64.9

Sash deductionsGeorgian bar pro-files


Deductions in mm for(based on the profilescentre axis)

53 11 00 53 16 00

Georgian bar 53 11 00 / 53 16 00 9 23

Steel 19 33

aluminium cover 67 90 07 20.3 34.3

metal strip 2 x 25 mm or 2 x 53 mm 21 35

Cutting angle for metal strip

67 90 07 67 80 07


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System

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Register

3.1

Page

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Scale

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62 05 00

Georgian bar 53 11 00 / 53 16 00 56

Steel 63

aluminium cover 67 91 07 70.9


Sash deductionsGeorgian barprofiles



53 11 00 53 16 00

Georgian bar 53 11 00 / 53 16 00 9 23

Steel 19 33

aluminium cover 67 91 07 26 40

metal strip 2 x 25 mm or 2 x 53 mm 26.7 40.7


67 91 07 67 81 07


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System

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Page

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Scale

1:1June 2008





62 22 00

Georgian bar 53 11 00 / 53 16 00 79

Steel 86






53 11 00 53 16 00

Georgian bar 53 11 00 / 53 16 00 9 23

Steel 19 33




67 90 07 67 85 07


TROCAL AluFusion AD

System

AluFusion AD

Register

3.1

Page

22

Scale

1:1June 2008





62 22 00

Georgian bar 53 11 00 / 53 16 00 79

Steel 86






53 11 00 53 16 00

Georgian bar 53 11 00 / 53 16 00 9 23

Steel 19 33




67 91 07 67 86 07


TROCAL AluFusion AD

System

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Register

3.1

Page

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Scale

1:1June 2008





62 25 00

Georgian bar 53 11 00 / 53 16 00 105

Steel 113






53 11 00 53 16 00

Georgian bar 53 11 00 / 53 16 00 9 23

Steel 19 33




67 90 07 67 83 07 or

67 82 07


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Page

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Scale

1:1June 2008





62 25 00

Georgian bar 53 11 00 / 53 16 00 105

Steel 113






53 11 00 53 16 00

Georgian bar 53 11 00 / 53 16 00 9 23

Steel 19 33




67 91 07 67 84 07

Profile combinationsSectional drawings

TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

1

Scale

1:2June 2008


framealuminiumcover

steel

sashaluminiumcover

61 01 0067 70 07

52 06 08

62 05 4067 80 07

1.6

Ix (cm4)

framealuminiumcover

steel

sashaluminiumcover

61 01 0067 70 07

52 06 08

62 05 4067 81 07

1.6

Ix (cm4)

3.2 Sectional drawings


TROCAL AluFusion AD

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Register

3.2

Page

2

Scale

1:2June 2008


framealuminiumcover

steel

sashaluminiumcover

61 02 0067 71 07

52 06 08

62 05 4067 80 07

1.6

Ix (cm4)

framealuminiumcover

steel

sashaluminiumcover

61 02 0067 71 07

52 06 08

62 05 4067 81 07

1.6

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

3

Scale

1:2June 2008


framealuminiumcover

steel

sashaluminiumcover

61 01 0067 70 07

52 06 08

62 22 4067 85 07

1.6

Ix (cm4)

framealuminiumcover

steel

sashaluminiumcover

61 01 0067 70 07

52 06 08

62 22 4067 86 07

1.6

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

4

Scale

1:2June 2008


framealuminiumcover

steel

sashaluminiumcover

61 02 0067 71 07

52 06 08

62 22 4067 85 07

1.6

Ix (cm4)

framealuminiumcover

steel

sashaluminiumcover

61 02 0067 71 07

52 06 08

62 22 4067 86 07

1.6

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

5

Scale

1:2June 2008


transomaluminiumcover

steel

sashaluminiumcover

63 01 0067 75 07

53 03 08

62 05 4067 80 07

9.3

Ix (cm4)


steel

sashaluminiumcover

63 01 0067 75 07

53 03 08

62 05 4067 81 07

9.3

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

6

Scale

1:2June 2008


framealuminiumcover

steel

sashaluminiumcover

63 01 0067 75 07

53 03 08

62 22 4067 85 07

9.3

Ix (cm4)

framealuminiumcover

steel

sashaluminiumcover

63 01 0067 75 07

53 03 08

62 22 4067 86 07

9.3

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

7

Scale

1:2June 2008



steel

sashaluminiumcover

63 01 0067 75 07

53 03 08

62 05 4067 80 07

9.3

Ix (cm4)


steel

sashaluminiumcover

63 01 0067 75 07

53 03 08

62 05 4067 81 07

9.3

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

8

Scale

1:2June 2008


framealuminiumcover

steel

sashaluminiumcover

63 01 0067 75 07

53 03 08

62 22 4067 85 07

9.3

Ix (cm4)

framealuminium cover

steel

sashaluminium cover

63 01 0067 75 07

53 03 08

62 22 4067 86 07

9.3

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

9

Scale

1:2June 2008


floatingmullionaluminiumcover

sashaluminiumcover

63 22 00

67 76 07

62 05 4067 80 07

Ix (cm4)


sashaluminiumcover

63 22 00

67 76 07

62 05 4067 81 07

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

10

Scale

1:2June 2008



sashaluminiumcover

63 22 00

67 69 07

62 05 4067 80 07

Ix (cm4)


sashaluminiumcover

63 22 00

67 69 07

62 05 4067 81 07

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

11

Scale

1:2June 2008



sashaluminiumcover

63 22 00

67 69 07

62 22 4067 85 07

Ix (cm4)


sashaluminiumcover

63 22 00

67 69 07

62 22 4067 86 07

Ix (cm4)


TROCAL AluFusion AD

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Register

3.2

Page

12

Scale

1:2June 2008



steel

sashaluminiumcover

63 24 00

67 77 07

52 06 08

62 05 4067 80 07

1.6

Ix (cm4)


steel

sashaluminiumcover

63 24 00

67 77 07

52 06 08

62 05 4067 81 07

1.6

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

13

Scale

1:2June 2008



steel

sashaluminiumcover

63 24 00

67 77 07

52 06 08

62 22 4067 85 07

1.6

Ix (cm4)

floating mullionaluminium cover

steel

sashaluminium cover

63 24 0067 77 07

52 06 08

62 22 4067 86 07

1.6

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

14

Scale

1:2June 2008


Georgianbaraluminiumcover

steel

53 11 40

67 90 07

53 11 08

2.0

Ix (cm4)


steel

53 16 40

67 90 07

53 15 08

4.9

Ix (cm4)


TROCAL AluFusion AD

System

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Register

3.2

Page

15

Scale

1:2June 2008



steel

53 11 40

67 91 07

53 11 08

2.0

Ix (cm4)


steel

53 16 40

67 91 07

53 15 08 4.9

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

16

Scale

1:2June 2008


sashaluminiumcover

threshold

weather bar

62 22 4067 85 07

57 40 07

57 42 07

Ix (cm4)

sashaluminiumcover

threshold

weather bar

62 22 4067 85 07

57 31 07

57 45 07

Ix (cm4)

Side entrance doors


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

17

Scale

1:2June 2008


sashaluminiumcover

threshold

weather bar

62 22 4067 86 07

57 40 07

57 42 07

Ix (cm4)

sashaluminiumcover

threshold

weather bar

62 22 4067 86 07

57 31 07

57 45 07

Ix (cm4)


TROCAL AluFusion AD

System

AluFusion AD

Register

3.2

Page

18

Scale

1:2June 2008


sashaluminiumcoveror

threshold

weather bar

62 25 4067 83 07

67 82 07

57 40 07

57 42 07

Ix (cm4)


threshold

weather bar

62 25 4067 82 07

67 83 07

57 31 07

57 45 07

Ix (cm4)

Residential doors


TROCAL AluFusion AD

System

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Register

3.2

Page

19

Scale

1:2June 2008


sashaluminiumcover

threshold

weather bar

62 25 4067 84 07

57 40 07

57 42 07

Ix (cm4)

sashaluminiumcover

threshold

weather bar

62 25 4067 84 07

57 31 07

57 45 07

Ix (cm4)


TROCAL AluFusion AD

System

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Register

3.2

Page

20

Scale

1:2June 2008


framealuminiumcover

steel


61 01 0067 70 07

51 03 08

62 25 4067 83 07

67 82 07

2.6

Ix (cm4)

framealuminiumcover

steel

sashaluminiumcover

61 01 0067 70 07

51 03 08

62 25 4067 84 07

2.6

Ix (cm4)


TROCAL AluFusion AD

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Register

3.2

Page

21

Scale

1:2June 2008


framealuminiumcover

steel


61 02 0067 71 07

57 04 08

62 25 4067 83 07

67 82 07

4.5

Ix (cm4)

framealuminiumcover

steel

sashaluminiumcover

61 02 0067 71 07

57 04 08

62 25 4067 84 07

4.5

Ix (cm4)


TROCAL AluFusion AD

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Register

3.2

Page

22

Scale

1:2June 2008



steel

sashaluminiumcover

63 01 0067 75 07

53 03 08

62 25 4067 84 07

9.3

Ix (cm4)


steel


63 01 0067 75 07

53 03 08

62 25 4067 83 07

67 82 07

9.3

Ix (cm4)


TROCAL AluFusion AD

System

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Register

3.2

Page

23

Scale

1:2June 2008


transomaluminium cover

steel

sashaluminium cover

63 01 0067 75 07

53 03 08

62 25 4067 84 07

9.3

Ix (cm4)


steel


63 01 0067 75 07

53 03 08

62 25 4067 83 07

67 82 07

9.3

Ix (cm4)


TROCAL AluFusion AD

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Register

3.2

Page

24

Scale

1:2June 2008



steel


63 24 00

67 77 07

52 06 08

62 25 4067 83 07

67 82 07

1.6

Ix (cm4)

floating mullionaluminium cover

steel

sashaluminium cover

63 24 0067 77 07

52 06 08

62 25 4067 84 07

1.6

Ix (cm4)

Profile combinationsElement coupling profiles

TROCAL AluFusion AD

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Register

3.3

Page

1

Scale

1:2June 2008


3.3 Element coupling profiles

Coupling profile 2

Profile Steel Ix (cm4)

61 01 0061 01 0054 26 00*

51 03 0851 03 0854 26 08

2.602.603.50

design value 8.70

Coupling profile 1


61 01 0061 01 0054 20 00*

51 03 0851 03 0891 07 08

2.602.605.20

design value 10.40

* The aluminium sheets for covering the coupling profiles are not part of the TROCAL delivery programme.


TROCAL AluFusion AD

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Register

3.3

Page

2

Scale

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Coupling profile 3


61 01 0061 01 0094 92 00*

51 03 0851 03 08steel tube

2.602.60

96.10

design value 101.3



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System

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Register

3.3

Page

3

Scale

1:2June 2008


Coupling profile 4


61 01 0061 01 0094 39 40*

51 03 0851 03 0894 01 08

2.602.608.70

design value 13.90

Coupling profile 5


61 01 0061 01 0094 40 40*

51 03 0851 03 0894 03 08

2.602.60

22.40

design value 27.60



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Register

3.3

Page

4

Scale

1:2June 2008


Coupling profile 6


61 01 0061 01 0054 08 00

51 03 0851 03 0894 01 08

2.602.608.70

design value 13.90

Coupling profile 7


61 01 0061 01 0054 21 00*

51 03 0851 03 0894 03 08

2.602.60

22.40

design value 27.60



TROCAL AluFusion AD

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Register

3.3

Page

5

Scale

1:2June 2008


* The aluminium sheets for covering the extension profiles are not part of the TROCAL delivery programme.

54 01 30 extension profile97 66 08 steelaluminium sheet* 63 x 1.5 mm

54 05 30 extension profile53 11 08 steel

54 03 30 extension profile91 23 08 steelaluminium sheet* 33 x 1.5 mm

54 04 30 extension profile97 66 08 steelaluminium sheet* 103 x 1.5 mm Extension profiles can be combined and and used for false edges.

Extensions

TROCAL AluFusion AD

Register

4

June 2008


System

AluFusion AD

Register 4Contents

4.1General processing instructions

Incoming materials ---------------------------------------------------------------------------------------- p 1

Trims ---------------------------------------------------------------------------------------------------------- pp 24

Milling --------------------------------------------------------------------------------------------------------- p 5

Drilling -------------------------------------------------------------------------------------------------------- p 5

Reinforcing instructions ---------------------------------------------------------------------------------- p 6

Welding ------------------------------------------------------------------------------------------------------- p 7

Cleaning corners ------------------------------------------------------------------------------------------- p 8

Fitting mullions and transoms -------------------------------------------------------------------------- p 9

Gaskets ------------------------------------------------------------------------------------------------------ p 9

Processing instructions for weldable gaskets ------------------------------------------------------ pp 10-14

Hardware ------------------------------------------------------------------------------------------------- p 15

Adhesive joints --------------------------------------------------------------------------------------------- pp 16-17

Cleaning profile surfaces -------------------------------------------------------------------------------- p 17

Warranty ----------------------------------------------------------------------------------------------------- p 17

Drainage ----------------------------------------------------------------------------------------------------- pp 18-23

Mechanical connections

(mullions/transoms and Georgian bars) ------------------------------------------------------------- pp 24-34

Processing stick-on Georgian bars ------------------------------------------------------------------- pp 35-37

Processing extension profiles -------------------------------------------------------------------------- p 38

Production of element coupling profiles ------------------------------------------------------------- pp 39-45

4.2 Processing aluminium covers

Machines ---------------------------------------------------------------------------------------------------- p 1General aluminium cover trims ------------------------------------------------------------------------ p 1General aluminium cover milled and punched contours ---------------------------------------- p 2Milling the aluminium cover 67 80 07 and 67 81 07 --------------------------------------------- p 3Milling and drilling the aluminium cover 67 85 07 and 67 86 07 ------------------------------ p 45Milling and drilling the aluminium cover 67 82 07 and 67 84 07 ------------------------------ p 6-8Milling and drilling the aluminium cover 67 90 07 and 67 91 07 ------------------------------ p 9Sealing ------------------------------------------------------------------------------------------------------- p 10Installing aluminium covers ----------------------------------------------------------------------------- pp 1113

4.3 Window system InnoNova_70.M5

Processing floating mullion profile 63 22 00 with aluminium cover 67 76 07 -------------- p 1Processing floating mullion profile 63 22 00 with aluminium cover 67 69 07 -------------- p 2Processing floating mullion profile 63 24 00 with aluminium cover 67 77 07 -------------- p 3

4.4 TROCAL AirMatic ventilation window

4.5 Residential and side entrance door

General information --------------------------------------------------------------------------------------- pp 12Weldable corner connectors ---------------------------------------------------------------------------- p 3Floating mullion profile on the residential door 62 25 00 --------------------------------------- p 4Threshold connection ------------------------------------------------------------------------------------ p 5

Threshold 57 31 07 -------------------------------------------------------------------------------- pp 6-9 Threshold 57 40 07 -------------------------------------------------------------------------------- pp 10-12

Weather bar overview ------------------------------------------------------------------------------------ p 13 57 42 07 with threshold 57 40 07 -------------------------------------------------------------- pp 14-15 57 45 07 with threshold 57 31 07 -------------------------------------------------------------- p 16

Hardware ---------------------------------------------------------------------------------------------------- p 17Prepunched steel reinforcement 92 65 08 and 52 23 08 --------------------------------------- p 18

ProductionGeneral processing instructions

TROCAL AluFusion AD

Register

4.1

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1Scale

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June 2008


1. Incoming materials

Window profiles are delivered as single lengths or in tied packages or cassettesdepending on the quantity ordered. The quantity delivered in a cassette can betaken from the respective applicable price list.

To avoid later detriment to your production (e.g. as a result of missing profiles)you should check directly on receiving your profiles

that the delivery note is complete and

that the packaging or cassettes show no signs of damage.

1.1 Unloading

When the goods are delivered in cassettes the corresponding loaders must beavailable, e.g. end loaders, sideloaders, travelling crane, etc., with a minimumload bearing capacity of 2.5 t.

The profiles must not be subjected to any unloading methods that can causeextreme torsion, deflection, or scratching.

1.2 Storage

All profiles must be placed in storage where they cannot be subjected toexcessive deformation.

Floor and wall shelves must be provided with stable and level plank or steelplate bases.

White profiles must not be stored out of doors. The profiles must be protectedagainst soiling.

You must make sure when processing the profiles that they exhibit an intrinsictemperature 15 C.

PVC window profiles heat up by about 1 C per hour when exposed to anambient temperature of about 1820 C (workshop temperature).

Accordingly, you must observe a minimum preliminary storage time beforeyou start processing. And this, of course, must be observed when the works-hop temperature is lowered over night in the winter.

Please also note the guideline 2207, Part 5 from the DVS (German WeldersAssociation) and the checklist.

Storing steel reinforcements

It is imperative that steel reinforcements are stored in closed rooms if white rustis to be prevented from forming.

If storage must be out of doors the reinforcements must be covered with rainproof,well ventilated tarpaulins.

Please compare the publication Lagerung und Transport on storage andtransport issued by the German Galvanisers Association (DeutscherVerzinkerei Verband e.V., Breite Str. 69, 40213 Dsseldorf).

4.1 General processing instructions


TROCAL AluFusion AD

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4.1

Page

2Scale

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AluFusion AD

June 2008


2. Trimming

Both single (docking) and double mitre saws are suitable for trimming rigidPVC-u profiles.

2.1 Machine-based defaults

Our experience has shown that the best results are obtained with flat trape-zoidal toothed saw blades tipped with carbide.

Tooth pitch approx 13 mm(e.g. 450 mm = 110 teeth, 500 mm = 120 teeth)

Cutting speed approx 6070 m/s

Feed The saw units feed must yield a clean cut surface.

IMPORTANT Blunt saw blades and excess feed rates cause chipping andlower the quality of the cut.

Profile trims must take into account welding burn-off on the welding machi-ne.

Most commercial welding machines are preconfigured for a welding burn-offof 6 mm, but this can vary from machine to machine.

To safeguard adherence to exact frame measurements you should verify theactual burn-off values and, if necessary, configure these to a standard value (6mm).

Likewise a single mitre saw in conjunction with a double stop allows you tocut first the frame and then the sash without having to adjust the stop.

On the other hand, double mitre saws, when they are not computer-control-led, can be advanced e.g. with spacers from the set frames external mea-surements to the sashs measurements.

Thin-walled additional profiles (glazing and spacing beads, etc.) require afine-toothed saw blade with 34 mm tooth pitch.

See Register 3.1 for the trims.

2.2. Conditions for a quality trim

You must make sure when removing profiles from cassettes and shelves thattheir visible surfaces are not damaged or scratched.

Temperature of the profiles = 15 C (observe preliminary storage for obtai-ning the right profile temperature)

Saw unit angle set to precisely 45; max deviation 0.5; saw blade angle 90

Adherence to the machine-based defaults

Trim suitable for the chamber size

The window can function properly when, for example, the specified chambersize of 12 +1 mm is observed.

reference surfaces

for the hardware

chamber


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June 2008


The profiles must therefore be trimmed to their respective chamber size inaccord-

ance with the saw-related values in the following table.

2.3 Trim checks

The trim must be checked at both the start of production and after every profilechange.

Trimmed profiles should be stored with the cut surface facing down and pro-cessed within forty-eight hours. Longer storage times can lead to soiling onthe cut surface and therefore deterioration of the weld quality.

When sawing make sure that there is no soiling on the profiles, and in parti-cular the profiles cut surfaces.

Soiling and other residue on the profiles cut surfaces prove detrimentalto the weld quality and must be removed completely before the weldingprocess!

Saw unit frombehind, pivoting

range 45/90/45

frame and sash:bedding below

Saw unit fromabove or below,pivoting range

45/90/45

frame and sash:bedding below

saw unit 45 pivo-ted outwards

saw unit 45 pivotedinwards

saw unit 45 pivo-ted outwards

saw unit 45 pivotedinwards


TROCAL AluFusion AD

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4.1

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4Scale

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June 2008


2.4 Angled windows

Min point angle

The smallest possible point angle is 70 (Fig 3). This can be obtained withoutadditional work on the outer and sash frames and with retained:

1. chamber size = 12 + 1 mm2. distance of hardware hinge = 11/20 mm from the inside edge of the outer

frame

.

Processing the aluminium cover

The aluminium cover is mitred in the non-90 corners.

deduction aluminium cover 67 80 07 = SEM 20.9 mmdeduction aluminium cover 67 81 07 = SEM 22.9 mm

NOTEDepending on the sash covers position and lining the trim length may have tobe corrected. Every blind must be measured exactly if there are to be no majordiscrepancies.

The aluminium cover must be installed in the order shown in Figs 1 and 2.

Additional measures

If elements with particularly acute angles are required (max 45) the companyBKV provides special installation hinges (see Fig 4). Please note the installa-tion instructions from the hinge manufacturer.

GLUSKE-BKV GmbHHatzfelder Str. 16116342281 Wuppertaltel +49 (0)202 27057-0fax +49 (0)202 27057-250

Fig 1

Fig 2

Fig 3 Fig 4


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June 2008


3. Milling

High-speed milling units as used on the timber and aluminium sectors are alsosuitable for machining PVC-u window profiles. You must use milling heads witha large number of teeth and a good chip clearance.

4. Drilling

All PVC-u panels can be machined with (DIN 1412) 30 twist drills usually applied tometal materials. The point angle can be as high as 110, but the lip clearanceangle should not be less than 1216. The cutting speed and the feed are afunction of the drilling depth and are inversely proportional to the thickness ofthe workpiece. Drilled holes exceeding 20 mm in diameter require two-flute cut-ters with pilot; drilled holes exceeding 40 mm in diameter are machined with cir-cle cutters (e.g. hollow drills).


TROCAL AluFusion AD

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4.1

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6Scale

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June 2008


5. Reinforcing instructions

5.1 General

PVC-u main profiles (frames, sashes, transoms/mullions) must be reinforced inaccordance with the instructions (see Register 6.2 for the sash size diagram).

5.2 White profiles

5.2.1 Outer frames

Outer frames must be reinforced when they are larger than 2 m and whenthe fasteners are spaced greater than 700 mm apart on the body shell. Onsashes weighing up to 80 kg screws unions for load-bearing hardware partsare allowed through two PVC walls (this applies only to Class A RAL profi-les under EN 12608). In the case of sashes weighing over 80 kg the outerframe must be reinforced and there must be at least two screw unionsthrough the steel at the corner and stay arm bearings.

Mechanical screw unions to the mullion/transom must be shimmed withsteel in the frame (Fig 2) or the corresponding mounting sleeves 59 4488/59 45 88 must be used (Fig 1).

Register 1.1 System attributes lists the reinforcing steels for the main pro-files.

5.2.2 Sashes

The dimensioning diagram in Register 6.2 applies to sashes.

5.2.3 Mullions/transoms

Mullion/transom profiles must always be reinforced with steel.

5.3 Steel trim

5.3.1 Sashes and frames

Min distance from the mitre 5 mm (see Fig 3).

Max distance from the mitre 60 mm (see Fig 4).

5.3.2 Mullions/transoms

The distance between the mullions reinforcement and the outer frame reba-te is 10 mm. This means that the rebate angles can be screwed in the steelfor the cross connection.

5.4 General fastenings

5.4.1 Fasteners

approved: corrosion-protected, watertight rivets or self-drilling screwsrecommended: self-tapping countersunk head screwsforbidden: nail fastenings

5.4.2 Fastener spacing

between the screws/rivets max 300 mm from the end of the steel reinforcement max 30 mm

Fig 4

Fig 3

Fig 2

Fig 1


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Abkhlzeit vor dem Verputzen mindestens 45 sec.

(jedoch nicht lnger als 30 min.) keine beschleunigte Abkhlung

(z. B. durch Druckluft)

Schweien mit Schweieckverbindern Schweispiegeltemperatur 235 C Anschmelzzeit 60 sec. Umstellzeit, maximal 2 sec. Fgezeit, mindestens 25 sec. Abkhlzeit, mindestens 60 sec.

VERPUTZEN

Kerben vermeiden Nuttiefe maximal 0,3 mm abgerundetes Inneneckmesser Ausbohren der Dichtungsaufnahmenuten

auf die notwendige Tiefe beschrnken

RICHTLINIE zum Schweien von PVC-Fensterprofilen

Hinweis: Die in den Richtlinien genannten Parameterangaben stellen Empfehlungen dar, die jedoch in Abhngigkeit der jeweiligenMaschineneinrichtung variieren knnen.

VORAUSSETZUNGEN

Temperatur der Profile mind. 15 CTemperaturaufnahme ca. 1 C pro Std.(z. B. 10 C im Auenlager =^ 25 Std.Lagerung bei mindestens 15 CRaumtemperatur)

Fgeteile magerecht maximale Winkelabweichung 0,5 Fgeflchen frei von Schmutz, Fett,

Handschwei, Spnen, Feuchtigkeitund Schutzfolie

SCHWEISSEN

Schweispiegeltemperatur 235 245 Cberprfung mit Megert amSchweispiegel

Oberflchen der Schweifolie frei von Rckstnden und Beschdigungen

Schweibeilagen passend zum Profiltyp

Standard Arbeitsdrcke Spanndruck ca. 6 bar Angleichdruck 2,5 3,0 bar Fgedruck 5 - 6 bar

Schweiwulstbegrenzung 2 0,2 mm 1) Messertemperatur 45 50 C

Schweizeiten Anschmelzzeit 40 50 sec. Umstellzeit, maximal 2 sec. Fgezeit, mindestens 25 sec.

1) Eine Schweiwulstbegrenzung von 0,2 mm ist ebenfalls mglich. Um die geforderten Schweieckfestigkeitswerte zuerreichen, ist auf die Einhaltung der vorgeschriebenenMaschinenparameter sorgfltig zu achten. Eine regelmigeKontrolle der Schweieckfestigkeiten wird empfohlen.

Einfluss der Anschmelzzeit auf die Eckfestigkeit bei einer Schweispiegeltemperatur von 240 C

Eck

fest

igke

it [

N]

Anschmelzzeit [sec.]

empfohlener Bereich

Fig 1 Welding bed for the sash

6. Welding

The optimal weld must observe the specifications in the PVC-u profile weldinginstructions given below.

These instructions present a highly compressed description of the key weldingparameters, etc.

In addition you must also take into account the following guideline DVS 2207,Part 25, on welding PVC-u window profiles.

The instructions from the manufacturer of the welding machine must be observed.

NOTEThe profiles placed in the welding machine must be retained by the holding fix-ture and beds so that they can neither move nor deform during the weldingprocess. You must ensure that the requisite beds are used for each profile. (Fig 1)

6.1 Cleaning the welding electrode

There must be no damage to either lined or coated welding electrodes. So thatthere is no detriment to the weld during follow-up operations all residue suchas sawdust that may adhere to the electrode during welding must be removedwith linen cloths, crepe paper, or other synthetic-free fabrics. Only oily soilingshould be removed with solvents.


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7. Cleaning frames and sashes

Weld beads on profile surfaces are removed primarily on automated cleaningmachines. In this case a cutter draws a visible groove in the profile over theweld bead.

Follow-up work on welds

1) Do not accelerate cooling (e.g. with compressed air).

2) The welded profile corners may not be processed until at least one minutehas passed. Processing earlier proves detrimental to the corner strength.Also, the groove bottom is at risk of collapsing.

So that grooves can be processed with the minimum of effort work shouldhave finished after thirty minutes at the latest.

3) Grooves are processed ideally with so-called negative cutters.

Groove width 3 mm

Max groove depth 0.3 mm

Note

Drilled holes that are too deep or too large have the following effects:

1) reduced strength of corners

2) Under hard driving rain (e.g. Groups BC) water in this section is pressedunder the gasket to the inside.

7.1 Processing corners

The corners at the weather seal and glazing grooves are processed with a drillof 8 mm (Fig 1)

The strength is reduced by the following:

notching in the inside corner (e.g. from mechanical chisel)

groove too deep

wrong drilling position and gasket receiver grooves bored too deeply (seeFig 1)

Do not use any cleaning or polishing agents that dissolve PVC.

Fig 1


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8. Fitting mullions and transoms

8.1 Mechanical connections

Special T connector sets with seal plates are available for mechanical connec-tions (T and cross connections).

A mechanical connection involves milling contours at both ends of themullion/transom profiles so that they match the frames.

8.2 Welding in

The outer profile chamber must be vented when colour mullion/transom profilesare welded.

a) V-welding in transoms/mullions

9. Gaskets

Prefabricated gasket profiles are used for sealing between the profile stop orleg on the sash and frame and the profile leg and glazing.

Installation is facilitated when the gasket profiles are subjected to a slight silico-ne treatment.

These gaskets form part of the system test. Like all of our products theyare subject to QA.

Processing

9.1 Weather seals 10 10 00, 50 05 00

The internal sash weather seal is rolled into the profile gasket receiver aroundthe sash (gasket 50 05 00). Length allowance 2%. The outer frame weatherseal 10 10 00 must not be rolled in all around, but in separate vertical andhorizontal pieces. The gasket joins must be bonded at the corners with adhesi-ve C007 (low viscosity).

9.2 Glazing gaskets 10 02 00, 10 03 00, 10 04 00, 10 08 30, 10 11 30

Glazing gaskets are inserted in the gasket receiver groove running around theprofiles corners. So that the gasket profile can present visually appealing cor-ners the gaskets must be laid loosely around the corners (see Fig 1). Theirstraight ends must then be connected in the top transverse area and glued inthe gasket profile cross section.

Fig 1

wrong right


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9.3 Processing instructions for weldable gaskets

9.3.1 Material

Weldable window gaskets are coextruded in the profiles at the production site.There is then no need to roll in EPDM gaskets on ready-welded and cleaned ele-ments.

The weldable gaskets are manufactured from a PVC-compatible material so thatsawing sections do not have to be sorted.

9.3.2 Transport/storage

Do not store gaskets where they can deform. Soiling must be prevented!

9.3.3 Processing

A decisive factor affecting the windows quality is the care taken in processing theprofiles. The applicability of the basic processing instructions remains unaffec-ted.

A list of the corresponding deviations and other instructions is given in the follo-wing.

9.3.4 Trimming

The profiles are trimmed on the same commercially available equipment as areused for profiles without rolled-in gaskets.

Beds and guide rails must be designed to provide adequate space for the gasket.The gasket must not deform permanently during the sawing process. After trim-ming, the gaskets trimmed edge should be in alignment with the profiles trim-med edge and be free of gasket residue.

The quality of the cut is affected by: the saw blade used, the circumferential and feed speeds for trimming, the saws state of wear and tear, and the direction of the cut (matched to the profile) Note the gaskets contact points on the machining centre.

Please consult the manufacturer of your machine.

Fig 1 Observing the functional mea-surements on weldable gaskets

Saw unit from behind,pivoting range

45/90/45

saw unit 45 pivotedoutwards

Saw unit from aboveor below, pivotingrange 45/90/45

saw unit 45 pivotedoutwards


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9.3.5 Welding

This takes place on commercially available welding machines, but there must beno changes to the parameters for processing profiles without rolled-in gasket.This also applies to the burn-off and the welding bead limit on normal PVC surfa-ces. Make sure when placing the profiles on the machine that the gasket is notdeformed or damaged.

The market offers various beds that support the profile in the Euro grooveor at the leg. Please consult the manufacturer of your machine.

Correctly laid and positioned welding beds are crucial if the window is to functionproperly.

Weather seal for the sash

The bedding must be adjusted accordingly to the gasket geometry. The bedsmust be fitted with limiter cutters (Fig 1) at the weather seal to restrict its move-ment completely (Fig 2).

Fig 1 Beds with limiter cutters

Fig 2 Optimal zero configuration ofthe limiter cutters

limiter cutter


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