en cintralux alu 25 mm€¦ · before the barrel vault can be mounted, the customer must provide a...

BARREL VAULTS

Cintralux® alu 25 mmMounting instructions fixed parts for bevelled curb

EN

Art.N° 62821

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SafetyTake the necessary and required safety precautions, such as safety nets and lifelines when installing from the outside, safety goggles, gloves, hard hat, etc.Do not step on the glass.

Falling from height

• When using ladders to go on the roof: - Ladder in good condition? - Set up correctly at an angle of 75°? - Secured below and on top against moving? - Don’t take heavy material with you on the ladder (3-point contact rule)! If possible, use a crane to lift the material.• Do not lift material over the roof edge; use a crane to put the material on the roof.• Roof zone: make sure the part of the roof where the skylight/barrel vault will be installed is safe enough, e.g. secure the edge (support system in the roof gutter that supports against the outer wall of the building, with suitable A B C categorie depending on the roof pitch) or use a scaffold so no one can fall off the roof. If the roof is not safe enough, always use a harness with lifeline (adapted to the fall height), attached to a suitable attachment point.• Make sure the roof is stable and does not have dangerous openings or insufficient secure parts (e.g. corrugated sheets, …). Take the necessary measures if this is not the case: strengthen, use suitable safety nets below the danger zones, …• Before making the roof opening for the skylight/barrel vault: make sure there are safety nets conform to the current legislation. The nets must be attached firmly and sufficiently to the building.• When using an aerial work platform: always wear and secure your harness (mandatory)! Leaving the cage is forbidden. • Never walk backwards on a roof, always walk forwards.• Make sure there’s enough light in the working zone.

Low-hanging obstacles and falling loads

• Forbidden to walk under or within a radius of 1 m of a hanging or lifted load.• Demarcate the danger zone below the skylight/barrel vault, in the building as well as on the outside near the outer walls (in case material slides off the roof). If the zone is demarcated, people cannot be hit by any falling loads. It’s prohibited to enter these danger zones during construction.

Crushing hazard

• All working tools are in good condition, provided with a valid CE label and all necessary safety regulations. These cannot be removed.• People who use these working tools are educated for this purpose. Protections are always present on all working tools. They are in good condition and need to be set correctly.

Tripping/falling

• Safety is key and it begins with order and tidiness. Clean everything immediately, leave nothing lying around. • Trash needs to be sorted. • Be cautious with electric cables (danger of tripping/falling). Never walk backwards! • Make sure there’s enough light in the working zone.

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Sharp objects

• Make sure your fingers/hands are not pinched and watch out for cuts while handling skylights or barrel vaults.• Be careful where you put your hands during the installation.• Wearing cut-resistant gloves is mandatory.

Ergonomics

• Always lift loads correctly: bend your knees, move your feet instead of forcing your spine, lift as close to your body as possible. • Parts of more than 25 kg must be lifted with at least 2 persons.

Personal protective equipment

• Work clothes, safety shoes and helmet are mandatory for everyone.

• Lifeline and harness are mandatory if the edge is not secured enough or if there are no safety nets below the roof opening. They are also necessary when using an aerial working platform.

• Use gloves when handling skylight or barrel vault parts.

• BSafety glasses and hearing protection are mandatory when using saws / grinders.

Always perform a Last Minute Risc Analysis!If in doubt: STOP! Do not take unnecessary risks. Ask your supervisor if needed.


SAFETY p. 2

PRIOR INSPECTION p. 5

OVERVIEW OF PROFILES AND ACCESSORIES p. 7

OUTLINE DRAWING OF CINTRALUX ALUMINIUM25 MM FIXED PARTS - BEVELLED CURB p. 8

ASSEMBLY SEQUENCE OF FIXED PARTSCINTRALUX ALUMINIUM 25 MM -BEVELLED CURB p. 8

ASSEMBLY OF CINTRALUX ALUMINIUM 25 MMFIXED PARTS - BEVELLED CURB p. 9

MAINTENANCE p. 18

SNOW AND WIND LOAD p. 18

WARNINGS p. 19

SAFETY DURING ASSEMBLY p. 19

PHYSICAL PROPERTIES MULTI-LAYERED SHEETS p. 19

Table of contents

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Warnings and safetySee p. 19 of these instructions.

Prior inspectiona. CurbBefore the barrel vault can be mounted, the customer must provide a sufficiently strong curb that must retain its shape (if necessary, reinforced with tie beams) and with roof covering. To guarantee stability, a calculation must be made by an architect or engineering office. The maximum roof pitch is 10°. Before getting started with mounting, check whether the following specifications have been met:

• Material: wood / galvanized steel min. thickness of 3 mm (*) If the curb is in concrete, a wooden batten of at least 48 x 60 mm must be firmly anchored into the concrete with countersunk and appropriate screws in advance. The wooden batten must also be covered with roof covering. The agreed dimensions must be strictly observed. • Height above finished roof: min. 200 mm • Min. finished thickness: 65 mm • Max. finished thickness: 100 mm • The top flange and the curb must share the same thickness. Insulation may not protrude or be thinner than the top flange. • The upper flanges on each of the 4 sides must be on the same plane! • Curb construction must be unobstructed on all sides: neither of the two curbs may go further at the corner of the longitudinal side and on the end side of the curb. • Curb top flange: The curb must be flat or bevelled, depending on span B. Make the curb at the right angle α:

(**) horizontal force per running metre, at 1,500 N/m Bevelled curb:

(*) to be calculated depending on the lateral forces

For a bevelled curb, Aluflex, the curbs on the short sides are executed horizontally.

It’s also possible to follow the roof pitch (up to max 10°).

Span B Radius R Alpha Horizontal Sagitta (mm) (mm) α force H ratio(angle of

(**)bevelled curb)

1500 4000 11° ± 5947 1 / 21,1

2000 4000 14° ± 5905 1 / 15,7

2500 4000 18° ± 5850 1 / 12,5

3000 4000 22° ± 5781 1 / 10,3

3500 4000 26° ± 5698 1 / 8,7

4000 4000 30° ± 5598 1 / 7,5

4500 4000 34° ± 5480 1 / 6,5

5000 5000 30° ± 6998 1 / 7,5

5500 5000 33° ± 6882 1 / 6,7

6000 5000 37° ± 6750 1 / 6

6300 5000 39° ± 6662 1 / 5,6

min. 65max. 100

min

. 200

min. 3

Span includingroof cladding

Roof opening

(*)


• Durability: must be able to withstand the horizontal and vertical loads. See Eurocodes and our technical sheet to determine the maximum force on the curb. Consult your architect or engineering office. • Deformation: maximum 5 mm at the maximum horizontal load on the curb. Ensure that there are enough anchors for this provided on top of the curb. Consult your architect or engineering office.

Skylux does not guarantee curb stability as this is the responsibility of the client.

b. DimensionsThe barrel vault is made to customer specifications. It’s for this reason that the curb’s overall length and width (roof covering included) must perfectly conform with the dimensions ordered at all points of the barrel vault. Look for the narrowest and broadest spot* and measure the minimum and maximum overall width.

Permissible tolerances with respect to the size ordered:

Width: Min: -2 cm Max: +1 cm Length: ± 0,05 % (± 5 cm for a length of 100 m) The barrel vault could possibly still be shortened in length on site, but try to avoid this.

Check the straightness* (±1 cm/5 m), parallelism* (±1 cm/5 m) and squareness (± 1°).

Check the agreed correct measurements of the curb in advance (overall sizes - including roof covering). Also check whether the curbs run parallel in a row of two, verify the squareness and see whether the top is flat and smooth. Clean it in advance, if necessary, and remove sawdust, irregularities, etc.

* Tighten a rope on both sides of the curb (or use lasers). Find the average position of the curb edge to tighten the rope. This rope will also be used later to mount the lateral profiles nicely aligned with each other.

Important: should one of these specifications fail to be met, then mounting must not take place. Should you nevertheless assemble the unit, it may have an adverse effect on several different parameters (stability, air and water tightness, etc.), thus rendering any guarantee null and void.

c. Glazing and arches- The glazing panels are only clamped to allow the expansion and contraction as a function of fluctuations in temperature. The system is designed to render any silicone or rubber seals between the aluminium and glazing redundant (and even strongly discouraged).- All profiles and glazing panels (with the exception of the end piece retainer sheets) are custom-made, pre-bent, pre-drilled and screw thread tapped.- Be careful with the exposed UV-protected top side of the sheets (glazing).- As a last step, do not forget to remove the protective film from the glazing sheets.

d. SealingInstall the roof cladding according to the manufacturer’s specifications. The curb must be clad up to the daylight size. If the barrel vault is obstructed, meaning that it is adjacent to one or more walls, the connection must be vertical and flat. This can be done by means of a lead flashing. Before assembling: clean, remove sawdust, irregularities, etc.

A max + 1 cmmin - 2 cm

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Overview of profiles and accessoriesProfiles

LP725 Bottom profile end piece+ foam sealant 8 x 10 mm

LP625 Lateral profile for bevelled curb

LP525 Bottom arch

LP025 Finishing profile

LP502 Top arch

LP512 Side top arch

LP726 End piece retainer profile

VPGDGL Arch stabiliser

Accessories

46576 Bracket for bevelled curb

47785 Bracket for bevelled curb left

47786 Bracket for bevelled curb right

36187 Screw with neoprene sealØ 6.5 x 50 mm

15441 Hexagon-end piece tapping boltM8 x 60

SPC25X6 PC 25 mm

46573 End cap

47471 End cap on end piece

46580 Lateral profile connector

47475 Corner sheet

22433 Self-tapping screw4.2 x 16 mm

14416 BB25 tape


Outline drawing of Cintralux aluminium 25 mm fixed parts - bevelled curb

Assembly sequence of fixed parts Cintralux aluminium 25 mm - bevelled curb 1. Bottom profile end piece 2. Lateral profile 3. Bracket 4. Bottom arch 5. Arch stabilisers 6. Multi-walled PC panel 25 mm

7. Top arches 8. Multi-walled PC end piece retainer sheet 25 mm 9. End piece retainer profile 10. Side top arch 11. Corner sheets 12. Checking arch tension

1

2

3

4

6

7510

98

11

Bevelled curb(not supplied)

Roof cladding(not supplied)

Aluminiumlateral profile

Roof opening =daylight opening

Span including roof cladding

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Assembly of Cintralux aluminium 25 mmfixed parts - bevelled curb1. Bottom profile end piece

First position the two bottom profile end pieces LP725 with foam sealant 8 x 10 mm onto the ends of the barrel vault curb and only then the first bevelled curb lateral profile LP625.

Align profile LP725 with rope or a laser using the long side of the finished curb.

Screw the bottom profile end piece LP725 onto the curb with the screws supplied (Ø 6,5 x 50 mm with neoprene seal), with a spacing of 500 mm. For this, use the screw line provided in the bottom profile end piece LP725.

Important: always use the right screws depending on the type of curb (metal screws for a metal curb, wood screws for wood, etc.).

Measure the curb width. If this corresponds with the ordered size, 1 cm play will be provided between the curb and the bottom profile end piece.

Aligning:

2. Lateral profile

Position the lateral profiles for bevelled curb LP625 at the location of the long sides. Lay all lateral profiles in one line on the long side (use a rope for this).

Aligning:

Align the first lateral profile LP625 up to the U-shape of the bottom profile end piece LP725. Make sure that the lateral profile LP625 just meets the end piece retainer sheet.

Roof cladding

Screw

LP725Bottom profile end piece

500

Align with the ends of the finished curb

LP725Bottom profileend piece

LP625Lateral profile for flat curb

Align(with play ± 1 cm)

LP625Lateral profile for flat curb + foam sealant 15 x 15 mm

Screw Ø 6,5 x 50 mm

Small profiles overlap

Screw with neoprene seal Ø 6,5 x 50 mm

LP725Bottom profile end piece + foam sealant 8 x 10 mm

Finished curb at the end of the barrel vault

Finished curb on the long side of the barrel vault


Aligning:

Align the vertical edge of the lateral profile of bevelled curb LP625 with the outside of the finished long side of the curb.

Screw the lateral profile bevelled curb LP625 onto the curb with the screws supplied (Ø 6,5 x 50 mm with neoprene seal) in the holes provided, each time with two brackets and with a spacing of max. 500 mm. For this, use the screw line provided in the lateral profile LP625.

Important: at the location of the filler panels, the distance between the brackets will be less (than where full sheet widths are to come).

Several lateral profiles are linked together by means of connector 46580, which is already clamped in the lateral profiles.

The connector also ensures a play of 5 mm (± 2 mm) between the lateral profiles.Seal the seams between the lateral profiles LP625 so water dripping onto the lateral profile cannot seep inside.

Seal the corners (where lateral profile LP625 andbottom profile end piece LP725 come together).

After that, mount the lateral profiles LP625 in the same way on the other side of the long side of the curb.Important: ensure that the lateral profiles LP625 lie perfectly two by two in parallel and are connected to each other at the correct distance to obtain an equal daylight opening everywhere.

LP625Lateral profile for bevelled curb

Screw Ø 6.5 x 50 mm LP725Bottom profile end piece + foam sealant 8 x 10 mm

5 mm

46580Front lateral profile connector

500

± 100

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3. Bracket

Place the bracket for bevelled curb 46576 on lateral profile LP625 and screw it tight in the pre-drilled holes with the two screws supplied (Ø 6.5 x 50 mm with neoprene seal 36187).

Important: always use the right screws depending on the type of curb (metal screws for a metal curb, wood screws for wood, etc.).

4. Bottom arch

Place the pre-bent bottom arch LP525 at the location of bracket 46576 and tighten using the bolts supplied M8 x 60 mm. Each bottom arch LP525 is fixed like this to the two ends of both lateral profiles LP625 by means of brackets 46576. Also mount the bottom arches to the end of the barrel vault, at the location of the end pieces, on the special brackets left and right.

ScrewØ 6,5 x 50 mm

46576 bracketfor flat curb

ScrewØ 6,5 x 50 mm


LP525Bottom arch

Bolt M8 x 60

ScrewØ 6,5 x 50 mm

47785bracket for bevelled curb

Align left side of bracket withthe side of lateral profile LP625 LP625Lateral profile

LP525Bottom arch

Bolt M8 x 60

46576Bracket for

bevelled curb

Important: the four corners of the barrel vault will be fitted with the special brackets for bevelled curbs 47785 and 47786, for the left-hand side and the right-hand side respectively. These brackets will be aligned with the side without holes with respect to the end of lateral profile LP625.


5. Arch stabiliser

Place the arch stabilisers VPGDGL between the bottom arches LP525 and hook them behind the screw.The shortest arch stabilisers are placed at the filler panels.

For narrow barrel vaults with up to a 5 m span: Always place an arch stabiliser VPGDGL at the locationof the first two sheets; seen from the end pieces. In thisway, the barrel vault will have a total of eight arch holders.

6. Multi-walled polycarbonate panel 25 mm

Remove the protective film from both sides of PC panel SPC25X6, just before assembly and place the multi-walled 25 mm PC panel with the UV side facing upwards.There are three types of PC panels 25 mm X6:- full panel widths (1050 mm), cut to size- narrower panel widths (< 1050 mm), cut to size filler panels)- end piece retainer sheets, cut to size exactly and accurately (in accordance with the barrel vault arc of circle) see page 12 “End piece retainer sheet”

First push the PC panel 25 mm (with the UV side facing outwards) in the finishing profile LP025. Do this at both ends of the panel. Centre the finishing profile with respect to the panel.

For wider barrel vaults with a span > 5 m: Always place an arch stabiliser VPGDGL between all bottom arches LP525; and do this on both sides of the barrel vault.

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Take hold of this panel with the finishing profile LP025 and CLIP the feet over the lateral profile LP625, between the bottom arches LP525. Bend the panel over the bottom arches LP525 and also clip the other side of the panel with the finishing profile LP025 to the other lateral profile LP625.

Clips

Full panel widths (1050 mm) are always used, with the exception of the outer edges of the barrel vault towards the end pieces; where filler panels (sawn panel widths < 1050 mm) are used.

PC 25 mmUV side facing upwards!

LP025Finishing profile

Filler panel PC 25 mm UV side facing upwards!


LP625Lateral profile for flat curb

CLIPS

PC 25 mm



LP625Lateral profile

CLIPS


7. Top arches

Place the top arches LP502 on top of the PC panels; at the location of the bottom arches. Secure the top arches LP502 by means of the end cap 46573 and the bolts M8 x 60 mm 15441 to the brackets 46576.Do this at both ends of top arch LP502.Pull this top arch until the aluminium top arch fits snugly against the multi-walled polycarbonate panel.Do not fasten too tightly!

Wait a moment with placing the side top arches LP512, which will come at the ends of the barrel vaults.

8. End piece retainer sheet

Place the multi-walled PC end piece retainer sheet 25 mm in the bottom profile end piece LP725 and make sure that the UV side of the panel is facing the outside of the barrel vault. (The end piece retainer sheet is longer than the bottom profile end piece and comes up against the drip channel at the bottom of the lateral profile LP625.)

LP502Top arch

BoltM8 x 60

46573End cap

PC 25 mm end piece retainer sheet with UV side facing outwards


LP502Top arch

46573End cap

46576Bracket

BoltM8 x 60

Filler panel (< 1050 mm)

Full panel width (1050 mm)

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Mark off the saw line on the PC end piece retainer sheet 25 mm. The saw line of the rounding is 3 mm under the top of the bottom arch LP525. Also mark off the tips of the bottom profile end piece LP725 on the 25 mm PC end piece retainer sheet.

Remove the PC end piece retainer sheet 25 mm once more, and saw it off at the saw line.

PC 25 mm end pieceretainer sheet with

UV side facing outwards

Mark off the saw line PC 25 mm end piece

retainer sheet

Top of bottom arch LP525

3 mm


PC 25 mm End piece retainer sheet

Saw on themarked line

PC end piece retainer sheet

Bottom arch LP525


Remove the protective film from the PC end piece retainer sheet.Blow the sawdust out of the grooves and tape up the sawed edges with the supplied BB25 tape.

Place the sawed panel back into the bottom profile end piece LP725.

Do this in the same way for the other end of the barrel vault.

9. End piece retainer profile

Now place the end piece retainer profile LP726 on top of the sawn off PC end piece retainer sheet.

Do this in the same way for the other end of the barrel vault.

Sawn PC 25 mm end piece retainer sheet


LP726End piece retainer profileSawn PC 25 mm

end pieceretainer sheet

Sawn PC 25 mm end piece retainer sheet

LP726End piece retainer profile

LP502Bottom arch


BB25 tape

BB25 tape

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10. Side top arch

Place the side top arches LP512 on top of the bottom arch LP525 at the location of the end piece. Secure the side top arch LP512 by using the end cap of end piece 47471 LT825 on the ends of the arch and a bolt M8 x 60 mm 15441. The end cap of end piece 47471 fits over the bracket 47785 (left) or 47786 (right). Tighten the bolts.

Do this in the same way for the other end of the barrel vault.(Depending on the assembly on one or the other end of the barrel vault, the left or the right assembly hole in the end cap on end piece 47471 is used.)

LP512Side top arch

47785Bracket for bevelled curb

LP525Bottom arch

PC 25 mmFiller panel

LP726End piece

retainer profile 47471End cap on end piece

BoltM8 x 60 mm

LP512Side top arch

M8 x 60 mm bolt

47471End cap on end piece

47471End cap on

end piece

LP512Side top arch

BoltM8 x 60 mm


11. Corner sheets

Finish the four corners of the barrel vault with the corner sheets 47475. Screw the corner sheet 47475 tight with the three screws supplied 4.2 x 16 mm 22433.

12. Checking arch tension

Check that the top arches LP502 and side top arches LP512 are tensioned evenly at all points across the sheets.Gently tighten the M8 x 60 mm bolts where needed.

MaintenanceThe client must perform annual maintenance on the opening parts of the Cintramax and on the fixed parts of the barrel vault. At minimum, this maintenance includes cleaning of the sheets with water and a light PH-neutral soap. All fastenings must be checked and loose or damaged parts of the Cintramax must immediately be fixed or replaced with original parts as described in the Cintralux ETA.

At least once a year the condensation drains (in the lateral profile, etc.) need to be cleared and the inside of the lateral profile cleaned.

Snow and wind loadThe barrel vaults are designed for normal wind and snow loads. For specific locations (seaside or very high buildings > 12 m), this should always be specially calculated.

47475Corner sheet

ScrewØ 4,2 x 16 mm

47475Corner sheet

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WarningsInstallers: installation should be performed by trained technicians with sufficient knowledge of and experience in the installation of barrel vaults.

Fixing materials: use suitable fixing material depending on the surface and the load. If in doubt, contact the screw supplier or a specialised engineering firm. We supply fixing material that is suitable for most metal or wooden surfaces, but this needs to be checked before starting the installation. Skylux is not responsible for the fixing materials used

Compatibility: only use polycarbonate-friendly materials. Avoid using silicone, polyurethane foam, detergents, paints, varnishes, timber protectants, lubricants, insecticides, etc. A lead sheet may not come into contact with the multi-layered sheets.

Covering: only cover the barrel vault (e.g. heat-deflecting effect) with canvas that does not contain softening agents. It is not recommended to cover acrylic or polycarbonate with a coating or paint. In this case our guarantee will no longer apply. It is in your interest that the manufacturer of the coating or paint provides guarantees on compatibility with acrylic and polycarbonate.

Dust: in the event that there are still certain works to be carried out that entail the release of dust particles (such as grinding, drilling, plaster work, etc.), then the opening under the barrel vault must be hermetically sealed, for example with a PVC film. The dust can accumulate on, in, or between the plastic sheets. The grooves of the multi-layered sheets are taped shut. When sawing multi-layered sheets at the project site, all grooves must be carefully blown out and taped shut with suitable tape. Before assembly, double check that the grooves are properly taped and correct as necessary. Ensure that the tape has not been damaged during assembly. There is no warranty for dust inclusion.

UV side and scratches: always mount the multi-layered sheets with the UV protective side facing up. This ‘sunny side’ is indicated on the protective film. Only remove the protective film just before installation to avoid scratches.

Point load: avoid point load on multi-layered sheets as this can cause permanent imprints. Never lean or walk on the multi-layered sheets.

Snow accumulation: do not mount barrel vaults in places where snow can slide from a higher structure and end up on the barrel vault.

Original parts: only use original parts and install them according to the assembly instructions.

Skylux reserves the right to modify this product or these instructions without prior notice. Changes to the assembly instructions or to the product carry no right to compensation or exchange of parts. The most recent version of these instructions can be consulted at any time at www.skylux.be.

Safety during assemblyObserve the necessary and required safety precautions, such as safety nets in the roof opening(s), fall protection, protection of the roof edge, safety shoes, protective glasses, gloves, hard hat, etc.

Physical properties multi-layered sheetsExpansion and settlement sounds: acrylic and polycarbonate sheets are plastic sheets and will expand and contract as the temperature rises and falls. The profile system allows for this. Expansion or contraction can cause settlement noises.

Condensation: acrylic and polycarbonate sheets are barely permeable to moisture. This means that condensation can form in the grooves. This usually happens at the start because large amounts of building moisture are evaporating at that time. This is a physical phenomenon which will disappear after a while. This condensation does not influence the characteristics of the plastic sheets or the guarantee.

Reflection: acrylic and polycarbonate sheets can, in some cases, depending on orientation and slope, reflect the sunlight to the inside or outside.

E_MH_Mounting_instructions_Skylux_Cintralux_Alu_25mm_fixed_parts_bevelled_curb 01/04/2020

CINTRALUX IS A REGISTERED BRAND OF SKYLUXSPINNERIJSTRAAT 100 - B-8530 STASEGEMT +32 (0)56 20 00 00 - F +32 (0)56 21 95 [email protected]

ONLY USE ORIGINAL PARTS SUPPLIED BY SKYLUX. FAILURE TO USE ORIGINAL PARTS VOIDS THE GUARANTEE.

THESE GUIDELINES ARE ONLY ADVISORY IN NATURE. THEY ONLY SERVE AS INFORMATION. INSTALLATION IS CONDUCTED UNDER THE SOLE RESPONSIBILITY OF THE CUSTOMER.

THE DoP IS ALSO AVAILABLE ON THE WEBSITE WWW.CINTRALUX.COMEN 14963

en cintralux alu 25 mm€¦ · before the barrel vault can be mounted, the customer must provide a...

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